ELECTRICS

Alternators

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Before You Start
The information included in this document is intended for experienced
personnel familiar with this type of equipment.
If there are any questions regarding the information provided or the
application of the provided information, please contact,
aftersales@powerscreen.com.
Operation and maintenance of the machine must be done in accordance with
the instructions in the operation manual for the machine.

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 STAY SAFE !

Electricity can kill

Isolate and lock out all supplies before

commencing work.

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 Switch Off, Tag out and Lockout Procedure

PRIOR TO CARRYING OUT MAINTENANCE OR ADJUSTMENT THE

FOLLOWING PROCEDURE MUST BE FOLLOWED: -
Ensure the plant is empty prior to shut down
Disengage each machine component (e.g. conveyors etc.) using the control
levers.
Turning off all machine components at once causes a pressure spike in the
hydraulic circuit. A slight pause between disengaging each component can
prevent this spike taking place.
Turn components off in the order:
Feeder Conveyor
Main conveyor
Screenbox/Fines Conveyor (Oversize Conveyor on Warrior models)
RH/LH side conveyor
Switch off engine and remove ignition key. Carry the key with you.
Engage emergency stop.
Place appropriate maintenance warning sign.
Use padlock to secure isolator and prevent restart.
NEVER WORK ALONE

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Introduction to Alternators
- AC( ))/DC( ) Voltage
Although all the systems we will consider are DC
Systems it is important to point out the difference
between AC/DC

AC current and voltages vary over time between

positive and negative, and the resulting waveform
shape is a sine wave

A DC supply stays at a fixed, regular voltage all of

the time. Like the voltage in a battery. A DC supply
is required by most circuits as a fixed reference
voltage.

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Introduction to Alternators
- DC Voltage
In Powerscreen applications the required type of
Voltage is DC Volts. The reason for this is that an
electrical storage device such as a machine battery
needs a constant supply of a stable voltage level such
as 12V on the Screeners and 24V on the Crushers.

If an alternating current was supplied to a machine the

voltage would be unstable and intermittent causing the
machine batteries to charge and discharge
continuously

This would also cause any sensors and systems on the

machine that require reference voltage (approx. 5v)
such as the Can-Bus systems, to give faults as they
are not receiving the correct values.

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Introduction to Alternators
- AC Voltage In the past a form of basic electronic generator called a
dynamo was used to produce electricity, this was fed
directly to the electrical system and created a spike of DC
power that would raise with engine speed using a device
called the Commutator, which acts like a switch that
constantly changes the polarity of the output in accordance
with the position of the motor. A good example of the
dynamo is a wind-up torch.
For some smaller applications such as motorcycles, the
dynamo is still a sufficient producer of DC electricity, but for
heavy applications an alternative was required as the
dynamos components wear quickly and is not very efficient.
A progression of the dynamo was created with the
alternator. This motor produces a AC voltage which is
converted to DC voltage to be stored in the machine
battery.

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Introduction to Alternators
- 3 Phase Current
The alternating current is converted to direct
current by a device called the rectifier which we will
discuss later.
Once the conversion has taken place this will only
leave the positive voltage to be fed to the machine
battery.
The problem with this is that it would leave an
intermittent input of voltage where the voltage dips
to below the positive polarity.
For this reason the alternator is wired with 3
separate windings that provide 3 separate currents
in an equal sequence.
This provides an almost constant supply of
electrical current which is known as direct current

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Introduction to Alternators
- 3 Phase Current
The alternating current provided comes from 3 alternator windings as displayed in the schematic diagram shown below, this particular
set-up is known as a star formation and is set 120 apart to provide a constant feed of current.
From here this current is fed into the rectifier pack which is how the negative polarity is removed, leaving behind only positive current.
The rectifier pack is made up of a series of Diodes which is designated this symbol , this indicates that it is an electrical one-way
valve.

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Introduction to Alternators
This device is used to block negative current in the alternator circuit. The device itself can be seen as an electrical one way valve
- Diodes
known as a semi-conductor.
A semi-conductor is made up of conductors and insulators, in particular an anode and a cathode.
These will allow current to flow through the device in 1 direction, but not the other, this is why it is used in the rectifier pack
(pictured below), as it allows positive current through, but it blocks the negative returning.

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Introduction to Alternators
- Voltage Regulator
The next device the alternator uses is the Voltage regulator pack (pictured below) this also uses a form of diode to regulate how much voltage the alternator produces.
If this were not used the voltage would continue to increase to the point of blowing fuses and relays or even permanently damaging the machine battery.
This is regulated by a diode called a Zener or Avalanche diode. This works the same way as a diode in that current can only travel in one direction but the Zener diode
increases its draw of current when it passes a pre-set voltage, which will in turn reduce the output voltage. (In accordance with Ohms Law)
In our machines it would be set to approx. 28.4v in crushers and approx. 14.5v on the screeners.

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Introduction to Alternators
- The Alternator Components
The alternator is made up of the following components:-
1. Casing This is the outer body of the alternator usually made of a magnesium alloy or more commonly aluminium alloy.
2. Rectifier pack (shown on page 10) this converts AC voltage to DC voltage.
3. The Rotor (see page 13)
4. The Stator (see page 14)
5. The Slip rings (see page 13)
6. The Bearings which allow the Rotor to turn freely, powered by the pulley.
7. The Pulley, this is driven by the engine crankshaft via V-Belt/s
8. Threaded bolt holes, for stripping/repair/overhaul of the unit.
9. Voltage regulator (shown on page 11)

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Introduction to Alternators
The basic element of the rotor consists of iron as the core and copper winding over this core. As implied by its name,

- The Rotor the rotor rotates, driven by a belt connected to the crankshaft pulley.
The rotor is made up of field coil windings to which current is supplied via copper brushes to the slip rings (1) mounted
on the rotor shaft (this has the effect of making the rotor into an electromagnet) this system has to be used as hard
wiring cannot be used due to the rotation of the rotor.
To produce alternating poles (North & South) on the rotor, there are two claw-shaped pole pieces surround the
windings (2) as you can see in this picture. This ensures that the rotation of the rotor will produce an alternating
current in the windings of the stator, which is the next component we will discuss.

(1)

(2)

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 Introduction to Alternators
- The Stator
The stator basically consists of three groups of windings.
The core over which the above three windings are wound is made up of laminated iron strips which results
better magnetic concentration and thus the torque.
Each group is positioned at a slightly different angle to the preceding one, which gives rise to three
intersecting AC sine phases which are 120 degrees apart from each other.
Together, the three phases constitutes the AC output from the alternator. Inclusion of three phases provides
better current response and as on page 8, a more consistent supplied voltage to charge the machine battery.

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 Introduction to Alternators
- Testing The Alternator Output To test the alternator performance, connect voltmeter to alternator terminals (positive & negative) and the ammeter to alternators positive
output cable, per the picture below.
Multi-Meter Make sure ammeter is at least 6 inches (15 cm) away from alternator to eliminate the possibility of incorrect readings due to interference.
Machine Battery Make sure voltage is present at the alternators output terminals. Start engine and run it at operating RPM.
Check that all machine loads are turned off and reading on ammeter is less than 20 amps. If ammeter reading is greater than 20 amps
double check that all machine loads are turned off and that batteries are fully charged.
Record voltage on voltmeter. The reading should be between 13.8 & 14.4v for a 12v system (Powerscreen Screeners), 27.8 & 28.4v for a
24v system (Powerscreen Crushers).
If the voltage is not within these ranges and the regulator can not be adjusted, then alternator is defective.

Alternator

Amp Clamp
(This is a device used
Starter Motor
for measuring current
= Negative flow without breaking
= Positive into the circuit)

Remember when using multi-meters - always test 15

for current in series & voltage in parallel.
Questions?

Thank You For Listening.

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