Issue #WP105: Technical Information from Cummins Generator Technologies

AC Generators with 2/3rd and 5/6th

winding pitch

White Paper
Dr Jawad Al-Tayie
Chris Whitworth
Dr Andreas Biebighaeuser

Abstract
Cummins Generator Technologies has in case of parallel operation and also will
a wide range of AC generator products impact on the type of neutral grounding
covering many applications, from prime method. Paralleling generators with
power to marine, oil and gas to name different winding pitch will require careful
a few. The stator of the AC generator consideration if interconnecting star
is manufactured with either a 2/3rd points of all running generators should be
or a 5/6th winding pitch. Winding pitch necessary. Both winding pitch (2/3rd and
of AC generators has influence on the 5/6th) have some pros and cons, correct
shape of waveform (harmonic contents) selection for any proposed application
and on the level of the fundamental is the key for ensuring a cost effective
voltage. The winding pitch will have power supply solution.
an influence on neutral circulating current
I. Introduction

The stator winding pitch of a generator is a design On most sites, there is a mixture of NLLs
parameter that can be used to optimise the and ‘normal’ (non-distorting) loads such as;
generator waveform shape and minimise the lighting, heating, air-conditioning units, pump and
generator cost, because shorter pitch (lower pitch fan motors, lifts, etc. What is not always appreciated
ratios) use the generator stator less effectively and is that although many of these ‘normal’ loads
require the use of more electrical steel and copper appear to be benign with respect to harmonic
for the same kW output than higher pitch machines. distortion, many now contain variable frequency
For example: drives etc., which are harmonically distorting,
n 5/6th pitch windings suppress 5th and 7th voltage and can also be susceptible to a harmonically
harmonics but may enhance the triple harmonics distorted supply voltage waveform, as can linear
(third, ninth etc.) loads on the system.
n 2/3rd pitch windings suppress the triple
harmonics but may enhance the 5th and 7th. In addition, in the category of ‘ordinary’ load it must
In addition, 2/3rd pitch wound machines generally be considered that most buildings including modern
have lower zero sequence reactances that can equipment will almost certainly have an IT network
increase the single phase fault current. supporting PCs or terminals. Most such modules
employ switched mode power supplies, which are
When comparing generator specifications, the listed notorious for generating high neutral currents which
value for output voltage total harmonic distortion can create serious rating problems for the building
(THD%) can be similar for either a 5/6th or a 2/3rd distribution system if there is insufficient care with
pitch winding configuration. A well designed the choice of the size of neutral cables. It therefore,
generator could probably achieve very similar becomes paramount that the current waveform
voltage waveform THD% with either pitch. harmonics are considered for any generator that
may be required to support such a mixed load to
Cummins Generator Technologies considers that ensure it provides a low enough source impedance
2/3rd pitch winding is best for most electrical to ensure voltage THD% is kept acceptably
loads that require a three phase, four wire system, low. For a generator this starts by identifying the
because they may include a proportion of single generators value of subtransient reactance (X”d)
phase loads. When a generator output voltage at the site load duty point kVA, V and Hz.
with triplen harmonics (e.g. from a generator that is
not 2/3rd pitch) is used to power a load consisting The no load voltage waveform does not really tell
of single phase loads with triplen harmonics, how susceptible the generator is to NLL, it is more
the triplen harmonics from both sources will sum about stator leakage reactance, which defines this,
together in the neutral and promote high and high values are poor, therefore in marine application
therefore, potentially troublesome, neutral currents it is often pushed for low X”d in former times for
in distribution system conductors. motor starting capability, reasons nowadays also
to minimise the size of filter units.
Thyristor based and uncontrolled rectifier
converters have high harmonic currents with For balanced three-phase loads, distortion is
harmonic numbers around multiples of 6±1. It is caused by voltage drop due to the harmonic
therefore technically correct to consider that an currents in the subtransient reactance of
output voltage waveform with minimal 5th and 7th the generator. The subtransient reactance
harmonics would be best for such non-linear loads of a generator is not a function of coil pitch.
(NLLs). (IGBT[1] based converters and switched Therefore, the coil pitch does not affect waveform
mode power supplies have harmonics at much distortion. The impact of generator pitch on load
higher frequency order). generated harmonic currents is highly dependent
on the system configuration.
 II. Stamford® generators

We recommend 2/3rd pitch on all low voltage (LV) Originally STAMFORD products were low voltage only
AC generators because, in general, these systems and these were all with 2/3rd stator winding pitch.
will need to use the neutral to service loads. For low The summing together of the triplen harmonics takes
voltage, both 50 and 60Hz, a 2/3rd pitch winding place in the distribution system the generators were
configuration will eliminate the triplen harmonic powering and although high neutral currents could
contribution from the generator and will not encourage still occur, the generator did not contribute to these
an increase in the overall triplen harmonics content and at generator winding level there was no current
of the installation. summation. Due to earthing methods in the LV power
plant business it was the correct pitch. This is still valid
For medium voltage (MV[2]) and higher voltage (HV[3]) today. An additional benefit of 2/3rd pitched windings
systems, it is acceptable to use other pitch machines, is the prevention of circulation currents through the star
since the neutrals are rarely used to directly serve points of our generators when connected in parallel.
loads and there are only low levels of triplen harmonics
as these are summed to zero in components such When the P80 machine was designed, it was decided
as delta-wound transformers, etc. to use the same pitch (2/3rd) for all LV, MV and
HV machines.
III. AvK® generators

Cummins Generator Technologies has built LV, n N

 ote that neutral point earthing and
MV and HV AvK generators for many years[4]. equipotential bonding are often confused.
For AvK generators, the stator winding pitch is Winding pitch affects neutral point bonding
dependent on the application and, in some cases, requirements only. Equipotential bonding, where
the voltage level. conductive parts of the installation are electrically
The pitch for AvK generators is: joined to avoid touch potential, etc., is required
regardless of winding pitch choice. In addition,
n 2/3 pitch for 400 V @ 50 Hz and 480 V @ 60 Hz
when generator star points are grounded it is
n 5/6 pitch for 690 V @ 60 Hz and @ 50 Hz
important that neutral current is not allowed to
n 5/6 pitch for all MV and HV circulate in the ground path as this may cause
n  tationary power plants –
S telecommunication systems issues as well as
typical voltage levels are: creating standing voltages in the ground.
400 V @ 50 Hz and 480 V @ 60 Hz => 2/3 pitch
MV and HV up to 13.8 kV => 5/6 pitch n W
 hen star points of parallel running generators
n  arine – the electrical system neutral is
M are connected together problems can arise with
unearthed/high ohmic earthed. Here earth faults circulating current if the generators are not 2/3rd
are detected but because of the safety issues pitch. However, if all generators have the same
associated with tripping essential circuits to winding pitch and rating, there is no problem
clear a single phase earth fault, an alarm is given for generators, but might be with 3rd harmonic
allowing the fault to be repaired when convenient currents in ships distribution system. Steps
in the ship’s progress and not causing a `Black must be taken to control circulating current if
Ship`, which would occur if the system would generators with different winding pitches are
be ’hard earthed‘. This is valid for LV, MV connected to the same busbar with the star
and HV. Therefore 5/6th winding pitch is used. points coupled. See section 6.
Typical voltages are:
n 690 V @ 60 Hz and @ 50 Hz
n MV and HV:
n 6.6 kV @ 60 Hz and @ 50 Hz

n 11 kV @ 60 Hz and @ 50 Hz
IV. What is winding pitch

A coil whose sides are separated by one pole pitch However the waveform of the resultant emf can
(i.e., coil span is 180º electrical) is called a full-pitch be improved by making the coil pitch less than a pole
coil. With a full-pitch coil, the emfs induced in the pitch. Such a coil is called short-pitch (or fractional
two coil sides are in phase with each other and the or partial pitched) coil. The emf induced in a
resultant emf is the arithmetic sum of individual emfs. short-pitch coil is less than that of a full pitch coil.

(i) Full pitch winding

Full pitch (Figure 1) = pole centre (S) to pole centre (N), for 48 slots stator (example)
= 48/4 = 12 slots (coil span 1 – 13)

Full pitch coil

Resultant Waveform
Fundamental Harmonic
Third Harmonic
Fifth Harmonic
Seventh Harmonic

 
Main rotor Main stator
(4 pole) (48 slots)

Figure 1: Full pitch winding machine with resultant waveform of the output phase voltage

(ii) Short 5/6th winding pitch

This winding pitch equals to 5/6th of full pitch, Figure 2.
For 48 slot = 5/6th of 12 slots = 10 slots (coil span 1 – 11)

5/6th pitch coil Resultant Waveform

Fundamental Harmonic
Third Harmonic
Fifth Harmonic
Seventh Harmonic

 
 
Figure 2: Short 5/6th pitch winding machine with resultant waveform of the output phase voltage
(iii) Short 2/3rd winding pitch
This winding pitch equals to 2/3rd of full pitch, Figure 3.
For 48 slot = 2/3rd of 12 slots = 8 slots (coils span 1 - 9)

2/3rd pitch coil Resultant Waveform

Fundamental Harmonic
Third Harmonic
Fifth Harmonic
Seventh Harmonic

Figure 3: Short 2/3rd pitch winding machine with resultant waveform of the output phase voltage
V. High level Pros and Cons
of 5/6th pitch winding
(i) Pros (ii) Cons
n Increase of power density with lower costs n  ower flexibility in use - cannot be used for all
L
and weight on the generator earthing methods. Less flexible in earthing system.
n Increase of generator efficiency Hard earthed systems required 2/3 pitch, hard
earthed system is from experience an exception
n  ower iron losses for 5/6th pitch due to shorter
L
on MV/HV grids
core while same magnetic flux density
n  ther design aspects of 2/3rd and 5/6th
O
n Friction losses assumed the same
winding pitches:
n  tator copper losses about the same – core length
S
n  /3rd pitch is better regarding grid codes
2
adder but overhang length reduction for 2/3rd pitch
(due to core length increase)
add up to zero, (this however depends on core
length and pole number) n Lower Xd value
n  lightly lower rotor copper losses for 5/6th
S n Higher moment of inertia
pitch due to shorter core while about same n  /3rd pitch is better regarding motor starting
2
current density capability (lower source impedance)
n  dditional losses about the same – neglected
A n  /3rd winding pitch, shorter coil and hence
2
slightly higher losses due to damping of 5th & 7th marginally less resistance, (this is true for 4 pole
stator winding field harmonic and short core length but this is different for long
n  oss reduction is between 3% to 6% of total
L core lengths and high pole numbers)
alternator losses - depending on the load point
n In tendency a shorter and cheaper AC generator
with better efficiency
n  missions – better efficiency leads to lower fuel
E
consumption and lower emissions
n THD:
n  ine to line voltage – THD% of 5/6th pitch has
L
lower values as 3rd voltage harmonic adds
up to 0 and 5/6th pitch keeps 5th and 7th
harmonics low (IEC 60034 THD requirements
are for line to line voltage only)
n  ine to neutral voltage – 2/3rd pitch has lower
L
levels of THD% as 3rd voltage harmonic is
not existing
n  /6 winding pitch, more voltage (fundamental),
5
better efficiency, less field current, less losses
(copper and iron), Losses proportional to I2.
VI. Parallel Operation
of Generators
This section examines the parallel operation of It follows that if the site loads single phase equipment
generators of different winding pitch. Can a 2/3rd can be supported by the fully rated neutral of just
and a 5/6th pitch wound generator be connected one generator then don’t interconnect more neutrals
together for parallel operation? together if this is likely to promote unnecessary
circulating currents around the neutral conductor
The basic requirements when operating generators system. However it must be remembered that
in parallel are: waveform harmonic content, if the generator that is intended to supply neutral
excitation system able to ensure kVAr sharing current is off-line for any reason, no single phase
(droop or a static), engine able to share kW. loads can be supported and if these are connected,
During commissioning all generators must be set the system line-neutral voltages may become severely
to have same voltage droop% for a given percentage unbalanced. Consideration should be given to a
kVAr load relative to each generators designed rating. changeover arrangement to allow other machines
If they don’t have this same drooping characteristic % to become source for line-neutral current in the event
then they will not proportionally share the kVAr. of maintenance being required.

Section 4 showed the harmonic content of generators However, if the scheme’s protection philosophy
with 2/3rd and 5/6th winding pitch. It therefore is such that all star points must be interconnected,
follows that if a 2/3rd pitch is paralleled to a 5/6th then 5/6th generators need neutral reactors and then
pitch winding there will be differences in the harmonic measurements have to be made as to the extent of
‘structure’ of the voltage waveform. These differences the circulating currents to ensure that the generator
and they are electrical ‘potential differences’, will result stator windings are not overloaded and that the
in circulating currents between the two generators, site distribution systems neutral cables are rated
in sympathy with whichever waveform - at that instant accordingly. Once generators have to supply real load
- has the highest ‘electrical pressure’. (active and reactive) the degree of circulating current
changes (reduces).
The actual level of circulating current is a complex
issue, it will depend on the interconnecting/distribution Many generators of 2/3rd, or 5/6th pitch, are used
system impedances and will also be very susceptible for embedded/co-generation applications with local
to the characteristics of the connected site load being mains/utility systems. In most cases such generators
supported by the generators. do not have their star points interconnected to
the mains neutral or earth connection. In such an
Interconnecting generators stator winding star points application the pitch factor is not an important issue.
will also change the characteristics of the circulating Also methods to restrict the circulating current in
currents, both between the generators and the level the common neutral may be implemented in case
of neutral current within the supplied distribution of dissimilar pitched generators are parallel together.
system. However, if the star points of dissimilar winding Standard reactors may be used for this purpose
pitch generators are not interconnected, then there however consideration must be given to the single
is no circulating current, but the generators may not phase fault level in the system.
exactly share reactive load proportionally and if the
neutrals of some generators are not connected to When dealing with generators operating in parallel
the system neutral, consideration must be given to with a mains supply, then understand the protection
whether the site single phase loads can be supported philosophy of the mains network and ensure that the
by the generating sets with their neutrals connected, bonding of any generator star points to earth will not
allowing for any possible maintenance conditions. provide a parallel path for fault current outside the
Therefore, consider if the site load can be correctly protections systems monitored fault-path.
supported and the site’s electrical protection system
will still function correctly, without the two ‘dissimilar’
generators having their star points interconnected.
VII. Star Points Connection
and Equipotential Bonding
It is important to understand the differences between There should only be minimal circulating currents
neutral star point reference earthing and equipotential between generators when their star points be
bonding. The latter applies no matter what the winding connected together regardless of their applications,
pitch or neutral configuration and is an electrical safety voltage level and winding pitch. Connecting generators
consideration. The former is an electrical system with similar winding pitch will limit the circulating
design function that may have safety implications current. Connecting generators with similar pitch is
if not performed correctly. In addition, when generator not always possible especially when expanding a site
neutrals are grounded it is important that neutral that has existing older generators. Adding a reactor
current is not allowed to circulate in the ground path in the common neutral limits the circulating current.
as this may cause telecommunication systems issues The neutral circulating current can be attenuated by
as well as creating standing voltages in the ground. implementing current limiting impedance (reactor)
as shown in Figure 6.
There are many configurations of the neutral star point
connection to earth. Figure 4 highlights some of these Neutral current limiting reactor would also substantially
methods. The method of star point connection to earth reduce the single phase fault level in the system.
depends on type of applications, voltage level and A fault level that is too low can be a serious safety
generator winding pitch. concern since it can prevent over current protection
from operating and lead to serious damages and
For paralleling generators with similar winding pitch, fire hazards.
their star neutral points can be interconnected.
Depending on their winding pitch and voltage level, Figure 7 shows that a multi winding reactor can be
their star may be connected to earth directly or via used to reduce the neutral circuiting current and also
current limiting impedance (reactor). Figures 5 to 7 to provide a path for the single phase fault current.
illustrate some of the neutral and earth connection
methods of parallel generators. This should not be confused with neutral earthing
resistors where generator neutrals are normally
In some applications, an unreferenced system is connected together (with or without attenuating
employed and the generator neutral points are not reactors) and the common point is grounded via
connected together. In this case, there will be no a resistor with the purpose of attenuating ground
path for the circulating current to flow. Also there fault current. Not often is each generator individually
will be no path for single phase fault currents so grounded through impedance to earth as this set up
ground fault detection system must be utilised for too many parallel paths and so difficult to get circuit
such installations as stated in the requirements of the breakers to trip.
electrical code. Figure 5 shows three wire system with
ungrounded neutral.

Enclosure/Chassis/
Exposed Conductive
Enclosure/Chassis/
Surfaces
Exposed conductive
Surfaces

PH A PH A
PH B PH B
PH C PH C
Bonding Neutral
Earth

Figure 4a: No star point connection Bonding

(there is always a reference earth point connection) Earth
Figure 4b: Solid star point connection
(unrestricted fault current)
 PH A PH A
Impedance Switching
PH B PH B
Device
PH C PH C Switching
Impedance Device
Neutral Neutral

Bonding Bonding
Earth Earth

Figure 4c: Star point connection via impedance Figure 4d: Neutral star point connection via switching device
(restricted fault current)

2/3 pitch 5/6 pitch

PH A
PH B
PH C

Bonding
Earth
Figure 5: Neutral connection of similar and dissimilar winding pitch generators
(no connection between dissimilar pitch generators, neutral not connected to earth)

2/3 pitch Reactor 5/6 pitch

PH A
PH B
PH C

Bonding
Earth
Figure 6: Neutral connection of similar and dissimilar winding pitch generators
(connection via inductive reactor of dissimilar pitch generators, neutral not connected to earth)

2/3 pitch Reactor 5/6 pitch

PH A
PH B
PH C
Neutral

Bonding
Earth
Figure 7: Neutral connection of similar and dissimilar winding pitch generators
(connection via multi core reactor of dissimilar pitch generators)
Conclusion

The winding pitch of AC generators has influence Usually MV and HV generators are connected to
on the shape of waveform (harmonic contents) and delta/star transformers and this is an important
on the level of the fundamental voltage. advantage of the 5/6th winding pitch for MV and HV
machines as the transformer will act as barrier for the
2/3rd winding pitch is mainly used with three-phase triplen harmonics.
four wire low voltage generators due to the fact that
the load is directly connected to the generator without Paralleling generators with different winding pitch will
a transformer and most likely that single phase and require careful consideration if interconnecting star
non-linear loads are present. points of all running generators should be necessary.
Circulating 3rd harmonics current in the system
5/6th winding pitch machines are more suitable for neutral cables must be considered at project outset,
three-phase three wire MV and HV systems as the and steps taken to control.
load will not be directly connected and hence the
triplen harmonics are not present as third harmonics Both the 2/3rd and 5/6th winding pitch have benefits.
will sum to zero in the line to line voltages. 5/6th pitch Correct selection for the proposed application
is suitable for application where the neural point is is the key for ensuring a cost effective power
not connected to earth solidly. Directly connected supply scheme.
single phase loads are not present in most MV or
HV systems.

5/6th winding pitch reduces the quantity of active

materials and it is a smart way to increase the Appendix
fundamental generated voltage within stator.
Historically 5/6th pitch was preferred with NLLs Kp (winding pitch) = Sin (VP/2)
to reduce the harmonics in the load currents. = 0.866 for 2/3
However recent developments in IGBT technologies = 0.966 for 5/6 for fundamental frequency.
have negated the need for 5/6th with NLL
Where:
as harmonics occur as much higher frequencies.
V is Harmonic, 1, 3, 5, 7, ...
The 2/3 pitch winding does have a low zero sequence P is Angle, for 2/3 = 120, 5/6 = 150
reactance and while at low voltage, the advantages
associated with distributed neutral outweigh the
disadvantages, at MV/HV this is not the case and the Footnote
low reactance causes higher than necessary ground
[1] IGBT: Insulated Gate Bipolar Transistor
fault currents which cause greater stress on machine
windings, cables and load components. [2] Cummins Generator Technologies designation
for MV is 1kV up to 4.16kV
The fact that a 2/3rd pitch generator has a low [3] Cummins Generator Technologies designation
pitch factor for the triplen harmonics does not for HV is 6kV up to 15kV
mean that it will perform any better in paralleling [4] We do understand that in electrical power
operations. In fact, a 2/3 pitch generator has very distribution, the term medium voltage (MV) covers
low zero sequence reactance and therefore, has less the range from 1kV up to 62kV (in some areas
impedance to reduce the flow of circulating neutral up to 72.5kV).
current. Circulating currents can result with any
winding pitch.
 Cummins Generator Technologies Ltd
Barnack Road, Stamford
Lincolnshire, PE9 2NB, UK

Tel: +44 (0) 1780 484000

Fax: +44 (0) 1780 484100
email: info@cumminsgeneratortechnologies.com

www.cumminsgeneratortechnologies.com
Copyright © 2013 Cummins Generator Technologies. All rights reserved.
Cummins and the Cummins logo are registered trade marks of Cummins Inc.
STAMFORD and AvK are registered trade marks of Cummins Generator Technologies Ltd.
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