An electric generator is a device that converts mechanical energy obtained from an

external source into electrical energy as the output.

The main components of an electric generator can be broadly classified as follows

(refer to illustration above):

(1) Engine
(2) Alternator
(3) Fuel System
(4) Voltage Regulator
(5) Cooling and Exhaust Systems
(6) Lubrication System
(7) Battery Charger
(8) Control Panel
(9) Main Assembly / Frame
(1) Engine
The engine is the source of the input mechanical energy to the generator. The size
of the engine is directly proportional to the maximum power output the generator
can supply. There are several factors that you need to keep in mind while assessing
the engine of your generator. The manufacturer of the engine should be consulted
to obtain full engine operation specifications and maintenance schedules.

(a) Type of Fuel Used Generator engines operate on a variety of fuels such as
diesel, gasoline, propane (in liquefied or gaseous form), or natural gas. Smaller
engines usually operate on gasoline while larger engines run on diesel, liquid
propane, propane gas, or natural gas. Certain engines can also operate on a dual
feed of both diesel and gas in a bi-fuel operation mode.

(b) Overhead Valve (OHV) Engines versus non-OHV Engines OHV engines differ
from other engines in that the intake and exhaust valves of the engine are located

in the head of the engines cylinder as opposed to being mounted on the engine
block. OHV engines have several advantages over other engines such as:

Compact design
Simpler operation mechanism
Durability
User-friendly in operations
Low noise during operations
Low emission levels

However, OHV-engines are also more expensive than other engines.

(c) Cast Iron Sleeve (CIS) in Engine Cylinder The CIS is a lining in the cylinder of
the engine. It reduces wear and tear, and ensures durability of the engine. Most
OHV-engines are equipped with CIS but it is essential to check for this feature in the
engine of a generator. The CIS is not an expensive feature but it plays an important
role in engine durability especially if you need to use your generator often or for
long durations.

(2) Alternator
The alternator, also known as the genhead, is the part of the generator that
produces the electrical output from the mechanical input supplied by the engine. It
contains an assembly of stationary and moving parts encased in a housing. The
components work together to cause relative movement between the magnetic and
electric fields, which in turn generates electricity.

(a) Stator This is the stationary component. It contains a set of electrical

conductors wound in coils over an iron core.

(b) Rotor / Armature This is the moving component that produces a rotating
magnetic field in any one of the following three ways:

(i) By induction These are known as brushless alternators and are usually used in
large generators.
(ii) By permanent magnets This is common in small alternator units.
(iii) By using an exciter An exciter is a small source of direct current (DC) that
energizes the rotor through an assembly of conducting slip rings and brushes.

The rotor generates a moving magnetic field around the stator, which induces a
voltage difference between the windings of the stator. This produces the alternating
current (AC) output of the generator.

The following are the factors that you need to keep in mind while assessing the
alternator of a generator:

(a) Metal versus Plastic Housing An all-metal design ensures durability of the
alternator. Plastic housings get deformed with time and cause the moving parts of
the alternator to be exposed. This increases wear and tear and more importantly, is
hazardous to the user.

(b) Ball Bearings versus Needle Bearings Ball bearings are preferred and last
longer.

(c) Brushless Design An alternator that does not use brushes requires less
maintenance and also produces cleaner power.

FuelTank1.jpg(3) Fuel System

The fuel tank usually has sufficient capacity to keep the generator operational for 6
to 8 hours on an average. In the case of small generator units, the fuel tank is a part

of the generators skid base or is mounted on top of the generator frame. For
commercial applications, it may be necessary to erect and install an external fuel
tank. All such installations are subject to the approval of the City Planning Division.
Click the following link for further details regarding fuel tanks for generators.

Common features of the fuel system include the following:

(a) Pipe connection from fuel tank to engine The supply line directs fuel from the
tank to the engine and the return line directs fuel from the engine to the tank.

(b) Ventilation pipe for fuel tank The fuel tank has a ventilation pipe to prevent the
build-up of pressure or vacuum during refilling and drainage of the tank. When you
refill the fuel tank, ensure metal-to-metal contact between the filler nozzle and the
fuel tank to avoid sparks.

(c) Overflow connection from fuel tank to the drain pipe This is required so that
any overflow during refilling of the tank does not cause spillage of the liquid on the
generator set.

(d) Fuel pump This transfers fuel from the main storage tank to the day tank. The
fuel pump is typically electrically operated.

(e) Fuel Water Separator / Fuel Filter This separates water and foreign matter from
the liquid fuel to protect other components of the generator from corrosion and
contamination.

(f) Fuel Injector This atomizes the liquid fuel and sprays the required amount of
fuel into the combustion chamber of the engine.

(4) Voltage Regulator

As the name implies, this component regulates the output voltage of the generator.
The mechanism is described below against each component that plays a part in the
cyclical process of voltage regulation.

(1) Voltage Regulator: Conversion of AC Voltage to DC Current The voltage

regulator takes up a small portion of the generators output of AC voltage and
converts it into DC current. The voltage regulator then feeds this DC current to a set
of secondary windings in the stator, known as exciter windings.

(2) Exciter Windings: Conversion of DC Current to AC Current The exciter windings

now function similar to the primary stator windings and generate a small AC
current. The exciter windings are connected to units known as rotating rectifiers.

(3) Rotating Rectifiers: Conversion of AC Current to DC Current These rectify the

AC current generated by the exciter windings and convert it to DC current. This DC
current is fed to the rotor / armature to create an electromagnetic field in addition to
the rotating magnetic field of the rotor / armature.

(4) Rotor / Armature: Conversion of DC Current to AC Voltage The rotor / armature

now induces a larger AC voltage across the windings of the stator, which the
generator now produces as a larger output AC voltage.

This cycle continues till the generator begins to produce output voltage equivalent
to its full operating capacity. As the output of the generator increases, the voltage
regulator produces less DC current. Once the generator reaches full operating
capacity, the voltage regulator attains a state of equilibrium and produces just
enough DC current to maintain the generators output at full operating level.

When you add a load to a generator, its output voltage dips a little. This prompts
the voltage regulator into action and the above cycle begins. The cycle continues till
the generator output ramps up to its original full operating capacity.

ExhaustSystem.jpg(5) Cooling & Exhaust Systems

(a) Cooling System

Continuous usage of the generator causes its various components to get heated up.
It is essential to have a cooling and ventilation system to withdraw heat produced in
the process.

Raw/fresh water is sometimes used as a coolant for generators, but these are
mostly limited to specific situations like small generators in city applications or very
large units over 2250 kW and above. Hydrogen is sometimes used as a coolant for
the stator windings of large generator units since it is more efficient at absorbing
heat than other coolants. Hydrogen removes heat from the generator and transfers
it through a heat exchanger into a secondary cooling circuit that contains demineralized water as a coolant. This is why very large generators and small power
plants often have large cooling towers next to them. For all other common
applications, both residential and industrial, a standard radiator and fan is mounted
on the generator and works as the primary cooling system.

It is essential to check the coolant levels of the generator on a daily basis. The
cooling system and raw water pump should be flushed after every 600 hours and
the heat exchanger should be cleaned after every 2,400 hours of generator
operation. The generator should be placed in an open and ventilated area that has
adequate supply of fresh air. The National Electric Code (NEC) mandates that a
minimum space of 3 feet should be allowed on all sides of the generator to ensure
free flow of cooling air.

(b) Exhaust System

Exhaust fumes emitted by a generator are just like exhaust from any other diesel or
gasonline engine and contain highly toxic chemicals that need to be properly
managed. Hence, it is essential to install an adequate exhaust system to dispose of
the exhaust gases. This point can not be emphasized enough as carbon monoxide
poisoning remains one of the most common causes for death in post hurricane
affected areas because people tend to not even think about it until its too late.

Exhaust pipes are usually made of cast iron, wrought iron, or steel. These need to
be freestanding and should not be supported by the engine of the generator.
Exhaust pipes are usually attached to the engine using flexible connectors to
minimize vibrations and prevent damage to the generators exhaust system. The
exhaust pipe terminates outdoors and leads away from doors, windows and other
openings to the house or building. You must ensure that the exhaust system of your
generator is not connected to that of any other equipment. You should also consult

the local city ordinances to determine whether your generator operation will need to
obtain an approval from the local authorities to ensure you are conforming to local
laws a protect against fines and other penalties.

(6) Lubricating System

Since the generator comprises moving parts in its engine, it requires lubrication to
ensure durability and smooth operations for a long period of time. The generators
engine is lubricated by oil stored in a pump. You should check the level of
lubricating oil every 8 hours of generator operation. You should also check for any
leakages of lubricant and change the lubricating oil every 500 hours of generator
operation.

(7) Battery Charger

The start function of a generator is battery-operated. The battery charger keeps the
generator battery charged by supplying it with a precise float voltage. If the float
voltage is very low, the battery will remain undercharged. If the float voltage is very
high, it will shorten the life of the battery. Battery chargers are usually made of
stainless steel to prevent corrosion. They are also fully automatic and do not require
any adjustments to be made or any settings to be changed. The DC output voltage
of the battery charger is set at 2.33 Volts per cell, which is the precise float voltage
for lead acid batteries. The battery charger has an isolated DC voltage output that
does interfere with the normal functioning of the generator.

Control-Panel-(3).jpg(8) Control Panel

This is the user interface of the generator and contains provisions for electrical
outlets and controls. The following article provides further details regarding the
generator control panel. Different manufacturers have varied features to offer in
the control panels of their units. Some of these are mentioned below.

(a) Electric start and shut-down Auto start control panels automatically start your
generator during a power outage, monitor the generator while in operation, and
automatically shut down the unit when no longer required.

(b) Engine gauges Different gauges indicate important parameters such as oil
pressure, temperature of coolant, battery voltage, engine rotation speed, and
duration of operation. Constant measurement and monitoring of these parameters
enables built-in shut down of the generator when any of these cross their respective
threshold levels.

(c) Generator gauges The control panel also has meters for the measurement of
output current and voltage, and operating frequency.

(d) Other controls Phase selector switch, frequency switch, and engine control
switch (manual mode, auto mode) among others.

(9) Main Assembly / Frame

All generators, portable or stationary, have customized housings that provide a
structural base support. The frame also allows for the generated to be earthed for
safety.

Electric motor

Electric motors defined as electromechanical devices that convert

electrical energy to mechanical energy; they are the interface
between the electrical and mechanical systems of a facility.

Electric motors are an important part of any electrical

system. They used throughout every manufacturing plant, office,
and home consuming about 64% of all electricity generated.

There are numerous ways to design a motor, thus there are

many different types of motors and each type possess different

operating characteristics (that will be listed later). Based on these

characteristics the motor can be chosen for a specified
application.

Electric machines are classified into two categories D.C. and A.C.
motors, the basic parts for each type will be different for each
type as follows:
The basic parts for AC motors are as follows:
1.
2.
3.
4.
5.
6.

Enclosure.
Stator.
Rotor.
Bearings.
Conduit Box.
Eye Bolt.

1- Enclosure
The enclosure consists of a frame (or yoke) and two end brackets
(or bearing housings).
A motor's enclosure not only holds the motor's components
together, it also protects the internal components from moisture
and containments. The degree of protection depends on the
enclosure type. In addition, the type of enclosure affects the
motor's cooling. There are two categories of enclosures as
follows:

Open Enclosure.
Totally enclosed Enclosure.

Open enclosures permit cooling air to flow through the motor. One
type of open enclosure is the open drip proof (ODP) enclosure.
This enclosure has vents that allow for air flow. Fan blades
attached to the rotor move air through the motor when the rotor
is turning. The vents are positioned so that liquids and solids
falling from above at angles up to 15 from vertical cannot enter
the interior of the motor when the motor is mounted on a
horizontal surface. When the motor is mounted on a vertical
surface, such as a wall or panel, a special cover may be needed.
ODP enclosures should be used in environments free from
contaminates.
B- Totally enclosed Enclosure
This category will include the following three types:

Totally Enclosed Non-Ventilated Enclosure.

Totally Enclosed Fan-Cooled Enclosure.

Explosion-Proof Enclosure.
a- Totally Enclosed Non-Ventilated Enclosure (TENV)
In some applications, the air surrounding the motor contains
corrosive or harmful elements which can damage the internal
parts of a motor. A totally enclosed non-ventilated (TENV) motor
enclosure limits the flow of air into the motor, but is not airtight.
However, a seal at the point where the shaft passes through the
housing prevents water, dust, and other foreign matter from
entering the motor along the shaft.
Most TENV motors are fractional horsepower. However, integral
horsepower TENV motors are used for special applications. The
absence of ventilating openings means that all the heat from
inside the motor must dissipate through the enclosure by
conduction. These larger horsepower TENV motors have an

enclosure that is heavily ribbed to help dissipate heat more

quickly. TENV motors can be used indoors or outdoors.
b- Totally Enclosed Fan-Cooled Enclosure (TEFC)
A totally enclosed fan-cooled (TEFC) motor is similar to a TENV
motor, but has an external fan mounted opposite the drive end of
the motor. The fan blows air over the motor's exterior for
additional cooling. The fan is covered by a shroud to prevent
anyone from touching it. TEFC motors can be used in dirty, moist,
or mildly corrosive environments.

c- Explosion-Proof Enclosure (XP)

Hazardous duty applications are commonly found in chemical

processing, mining, foundry, pulp and paper, waste management,
and petrochemical industries. In these applications, motors have
to comply with the strictest safety standards for the protection of
life, machines and the environment. This often requires use of
explosion proof (XP) motors.
An XP motor is similar in appearance to a TEFC motor,
however, most XP enclosures are cast iron.
Division I locations normally have hazardous materials
present in the atmosphere.
Division II locations may have hazardous material present in
the atmosphere under abnormal conditions.
Locations defined as hazardous, are further defined by the
class and group of hazard. For example,
- Class I, Groups A through D have gases or vapors present.
- Class II, Groups E, F, and G have flammable dust, such as coke or

grain dust.
- Class III is not divided into groups. This class involves ignitable
fibers and lint.

2- Stator
The motor stator consists of two main parts:
A- Stator Core
The stator is the stationary part of the motor's electromagnetic
circuit. The stator is electrical circuit that performs as
electromagnet. The stator core is made up of many thin metal
sheets, called laminations. Laminations are used to reduce energy
losses that would result if a solid core were used.
B- Stator (Windings)
Stator laminations are stacked together forming a hollow cylinder.
Coils of insulated wire are inserted into slots of the stator core.
When the assembled motor is in operation, the stator windings are
connected directly to the power source. Each grouping of coils,
together with the steel core it surrounds, becomes an
electromagnet when current is applied. Electromagnetism is the
basic principle behind motor operation.

3- Rotor
The rotor is the rotating part of the motor's electromagnetic
circuit. Magnetic field from the stator induces an opposing
magnetic field onto the rotor causing the rotor to push away

from the stator field.

There are a lot of rotor types like Squirrel cage rotor and wound
rotor, they will be explained later.

4- Bearings
Bearings, mounted on the shaft, support the rotor and allow it to
turn. Not all bearings are suitable for every application; a
universal, all-purpose bearing does not exist. The choice of
bearing arrangement is based on the following qualities:
Load carrying capacity in the axial and radial direction.
Overspeed and duration.
Rotating speed.
Bearing life.
The size of the bearing to be used is initially selected on the basis
of its load carrying capacity, in relation to the load to be carried,
and the requirements regarding its life and reliability.
Other factors must also be taken into consideration, such as
operating temperature, dirty and dusty environmental conditions,
and vibration and shocks affecting bearings in running and resting
conditions.
Bearings Types:
There are many types of bearings on the market, each with
different characteristics and different uses, these types are as
follows:
A- Deep groove ball bearings

Deep groove ball bearings are the most common type of bearing,
and can handle both radial and thrust loads. Due to their lowfrictional torque, they are suitable for high speeds.
In a ball bearing, the load is transmitted from the outer race to
the ball and from the ball to the inner race.
Since the ball is a sphere, it only contacts the inner and outer race
at a very small point, which helps it to spin very smoothly. This
also means that there is not very much contact area holding the
load, so if the bearing is overloaded, the balls can deform, ruining
the bearing.

B- Cylindrical roller bearings

These roller bearings are used in applications where they must hold heavy radial loads. In the
roller bearing, the roller is a cylinder, so the contact between the inner and outer race is not
a point but a line. This spreads the load out over a larger area, allowing the bearing to handle
much greater radial loads than a ball bearing.
However, this type of bearing is not designed to handle much thrust loading.

C- Angular contact ball bearings

Angular Contact ball bearings have raceways in the inner and

outer rings which are displaced with respect to each other in the
direction of the bearing axis. This means that they are suitable for
the accommodation of combined loads such as simultaneously
acting radial and axial loads in vertical machines.

D- Spherical roller thrust bearing

In Spherical Roller thrust bearings, the load is transmitted from

one raceway to the other at an angle to the bearing axis. They are
suitable for the accommodation of high axial loads in addition to
simultaneously acting small radial loads. Spherical roller thrust
bearings are also self-aligning.

E- Sleeve Bearings
Sleeve bearings have no moving parts, they rely on a thin film of
oil to reduce friction and allow the motor shaft to turn freely. This
film of oil is critical to the life of a sleeve bearing.
When properly lubricated, there is actually no physical contact
between the bearing and the shaft. If for some reason the oil film
breaks down, metal-to-metal contact between the shaft and the
bearing will cause the bearing to wear very quickly and soon fail
Sleeve bearings are often chosen because of their relatively quiet
operation and lower cost compared to ball bearings.
Sleeve bearings can be divided to:
a- Flange mounted sleeve bearings are used for machines with a
shaft height of up to 1120mm. Machines with bearings of this type
are quick and easy to align. The air gap between stator and rotor
comes from the factory already adjusted, and does not need any
further adjustment on site during installation.
b- Foot mounted sleeve bearings are mounted on a pedestal. The
pedestal can either be integrated in the stator frame, or can be
mounted separately. If it is integrated with the stator frame it is
easy and fast to align.

5- Conduit Box
Point of connection of electrical power to the motors stator
windings.
6- Eye Bolt
Used to lift heavy motors with a hoist or crane to prevent motor
damage.
2- DC Motor Basic Parts:
The basic parts for DC motors are as follows:
1- Stator
The stator carries the field winding and Poles. The stator together
with the rotor constitutes the magnetic circuit or core of the
machine. It is a hollow cylinder.
2- Rotor
It carries the armature winding. The armature is the load carrying
member. The rotor is cylindrical in shape.
3- Armature Winding
This winding rotates in the magnetic field set up at the stationary
winding (Field winding). It is the load carrying member mounted
on the rotor. An armature winding is a continuous winding; that is,
it has no beginning or end. It is composed of a number of coils in
series.

4- Field Winding
This is an exciting system which may be an electrical winding or a
permanent magnet and which is located on the stator.
Note: DC Motors are generally classified by how their Armature &
Field windings are connected to their DC power supply.
5- Commutator
The coils on the armature are terminated and interconnected
through the commutator which comprised of a number of bars or
commutator segments which are insulated from each other. The
commutator rotates with the rotor and serves to rectify the
induced voltage and the current in the armature both of which are
A.C.
6- Brushes
These are conducting carbon graphite spring loaded to ride on the
commutator and act as interface between the external circuit and
the armature winding.
7- Poles
The field winding is placed in poles, the number of which is
determined by the voltage and current ratings of the machine.
8- Slot/Teeth
For mechanical support, protection from abrasion, and further
electrical insulation, non-conducting slot liners are often wedged

between the coils and the slot walls. The magnetic material
between the slots is called teeth.
9- Motor Housing
The motor housing supports the iron core, the brushes and the
bearings.

In the next Topic, I will explain the Electrical Motors types. So,
please keep following.
Note: these topics about Motors in this course EE-1: Beginner's
electrical design course is an introduction only for beginners to
know general basic information about Motors and Pumps as a type
of Power loads. But in other levels of our electrical design courses,
we will show and explain in detail the Motor and Pumps Loads
calculations.