Alternator Temperature rise

Key Points
Scope
Generator Categories
Insulation Classes
Generator Designs
Temperature Rise Testing
Derations
Longevity Testing
Applications & Other Considerations
Introduction
Whenever a wire carries electrical current, its temperature will increase due to the resistance of the wire.
One important factor of this temperature rise is the influence it has on the insulation system of an
electrical machine, such as an alternator. The hotter the wire, the shorter the life expectancy of the
insulation, and of course the machine itself. This article will explain some standards and considerations
regarding alternator temperature rise.
Scope
The standard for designing generators relied on by the electrical generation industry is National Electrical
Manufacturers Association (NEMA) Standard MG1, which encompasses the entire machine, and includes
requirements for alternator temperature rise. (Other standards and definitions will be addressed in future
articles in this series.)
Generator Categories
The MG1 standard defines two duty cycles: continuous, meaning 24 hours a day, 7 days a week under full
load conditions, and standby, an emergency power source designed to back up a continuous source. While
the standby category doesn't have any designated hour limits, the accepted standard of operation is much
less per year.

Figure 1
Insulation Classes
MG1 recognizes four classes of electrical insulation materials used in alternators A, B, F, and H. Each
of these has different characteristics, but the common accepted feature is that they will have an expected
minimum life of 30,000 hours under continuous operating conditions (actual insulation life would need to
be determined in the end product). The primary difference is the maximum allowable temperature at
which the alternator windings can operate with these types of insulation, as shown in Table 1.
Table 1 - Maximum Operating Temperature Continuous

Since standby duty requires less operating hours than continuous use, MG1 allows the standby windings
to operate at a temperature up to 25 C warmer, as shown in Table 2.
Table 2 Maximum Operating Temperature Standby

The additional operating temperature allows alternators of these types to generate more kilowatts,
justifying the higher standby ratings found on most gensets.
Per UL 2200, Generac uses a Class H insulation system while designating its alternators to operate at a
continuous temperature rating of 125C, thus reducing thermal stress and building in a temperature
margin that prolongs alternator life.
These maximum temperatures are actually made up of two parts the ambient temperature of the
environment and the heat, or temperature rise, created by the alternator windings.
MG1 uses 40C as its standard for ambient temperature.

Subtracting 40C from the maximum operating temperature gives us the temperature rise allowed for the
heat generated by the resistance of the wire in the windings and other losses in the alternator, as shown in
Table 3.
Table 3 Maximum Temperature Rise (40 C ambient)

Generator Design
Generator manufacturers have standard designs for alternators based on a number of physical and
operating criteria. Some of the physical attributes that control the voltage and kilowatt rating of a design
are: the size and material of the steel laminations, the length of the lamination stack, and the amount of
copper wire. The frequency is controlled by the RPM of the rotating magnetic field. DC Current is
supplied to create the magnetic field in the rotor through various designs categorized as brush-type,
brushless or permanent magnet type. All these items, and the amount of cooling air driven through the
alternator, affect the unit's output and temperature behavior.
Temperature Rise Testing
Once a prototype alternator is constructed, it is tested to verify the design. One of the tests is to determine
the temperature rise of the windings. There are two methods to obtain this data:
1) embed thermocouples into the windings during the winding process and measure this temperature
directly or, 2) measure the resistance of the wire and calculate the temperature.
At first glance, method 1 may seem the most accurate. In actuality, it requires a number of thermocouples
to get a good picture of what is happening throughout the alternator.
The thermocouples themselves may cause some distortion, impacting temperature measurements. On the
other hand, the resistance of copper wire per degree of temperature variance is a very consistent number.
By accurately controlling all of the variables in a lab test (ambient temperature, load, frequency, etc.), the
unit can be brought up to a stable, full load operating temperature. After stopping and disassembling
enough to attach instrument leads, recording equipment can take a number of readings over a known span
of time and accurately construct an equation to extrapolate the true operating temperature of the winding.
Derations
NEMA does not allow any deviation from its maximum temperature constraints. If the ambient
temperature is above their 40C standard, the temperature rise must be reduced by the same number of
degrees. This holds the maximum allowable operating temperature constant.

Temperature rise is also influenced by altitude. The thinner air at higher altitudes has a decreased capacity
to cool the alternator. NEMA's standard is 1000 meters (3,300 feet) before it requires a deration factor on
the temperature rise, which amounts to 1% for every 100 meters above the 1000 meters.
Longevity Testing
The temperature class of an insulation system is typically determined using the test methods outlined in
Underwriters Laboratory standard UL 1446 (Systems of Insulating Materials General). The thermal
aging test requires representative samples to be subjected to a series of test cycles to withstand heat aging,
cold shock, mechanical stress, and moisture exposure. An electrical stress test is performed at the end of
each cycle to determine if the sample is capable of continuing to cycle.

Figure 2
These tests are performed on the samples and are only intended for determination of the thermal class of
the insulation system. It is important to note that the thermal ratings determined are for a complete system
of insulating components, reflecting how the individual materials interact with each other. This helps
build confidence that, when used properly, the group of materials in a UL recognized component
electrical insulation system will help produce a quality product.
Applications & Other Considerations
Another thing to consider is that the temperature class of the insulation system established above is for a
continuous duty application. NEMA MG1 recognizes the reduced amount of time a standby duty
alternator runs (typically less than 200 hours per year). Typically, the allowable temperature rating is
25C above the continuous duty temperature rating. Operating the alternator insulation at the higher
temperatures associated with a standby rating may shorten the insulation life by a factor of between 4 and
8. However, since standby units only run occasionally and don't amass long hours of operation, their
alternators will still provide many years of service that are well within those parameters.

Based upon this logic, looking to extend the life of a standby alternator by specifying a unit with a lower
maximum temperature rise than NEMA allows say 105C, or even 80C may not provide any added
value to the customer.
There are, however, a number of other considerations that do require looking at the kW rating of the
alternator. High starting currents, single phase loading on three phase units, load imbalance, non-linear
loading, load sensitivity to voltage variation, and high neutral currents are just a few of the reasons to
look at upsizing the kilowatt rating of the alternator specified. These additional subjects will be covered in
future articles in this series.
Most manufacturers supply generator specification sheets listing each unit's operating ambient
temperature and the kW deration factor when elevated temperatures and / or altitudes are encountered. As
long as your peak kW load is within the rated value, adjusted for elevated temperatures and / or altitudes
as necessary, the genset under consideration will have an acceptable operating temperature.
Additional Technical References
For additional technical information, refer to NEMA MG 1 - 1998 Sections 32.6 & 32.35

Alternator Winding Temperature Rise in Generator Systems

1.0 Introduction
When a wire carries electrical current, its temperature will increase due to the resistance of the wire. The
factor that mostly influences/limits the acceptable level of temperature rise is the insulation system
employed in an alternator. So the hotter the wire, the shorter the life expectancy of the insulation and thus
the alternator.
This information sheets discusses how different applications influence temperature rise in alternator
windings and classification standards are covered by the National electrical Manufacturers Association
(NEMA).
Table 1 - Maximum Temperature Rise (40C Ambient)

Table 2 - Maximum Temperature Rise (40C Ambient)

Figure 1. Typical Windings Within a Generator Sets Alternator

2.0 Classification Standards Covered by NEMA:
(NEMA) Standard MG1, which encompasses the entire machine and includes the requirements for
alternator temperature rise. The standard operating ambient temperature in all cases is 40C (104F)
Categories. MG1 defines two duty cycles for the alternator:

Continuous Duty for operation 24-hours a day, 7- days a week, under full load conditions
Standby Duty for an emergency power source (EPS) - or standby generator set. This is designed
to operate as back-up power should the principal power source (utility) be lost or fall outside the
nominal frequency or voltage requirements

3.0 Hours Limitation for Temperature Rise:

As the standby category (NEMA MG1 22.40) has no defined hour limits, the EPS is considered to
typically run for about 200 hours or less a year considerably fewer than that for a continuous duty
application. This higher temperature rise allows more kW to be utilized and is justified by the higher
standby output ratings commonly found on most emergency generator sets. However, the insulation of a
standby unit will age thermally at about four to eight times that of a continuously rated alternator.
4.0 Insulation Classes: (See chart 1 for classification)
NEMA MG1 recognizes four classes of electrical insulation of the alternator:

A
B
F
H

Each of these categories has different characteristics, but the accepted common feature is an anticipated
minimum life expectancy of 30,000 hours. The letter signifies the maximum allowable windings
temperature allowable while the alternator is operating, if exceeded the insulation will breakdown
resulting in winding burn out.
See temperature rise Tables 1 (for Continuous Duty) and 2 (for Standby Duty) overleaf
5.0 NEMA Standby Ratings:
As standby duty results in fewer hours of operation, NEMA MG1 allows alternator windings to operate at
25C higher than for continuous duty applications. If used for continuous duty or prime power, the
standby alternators useful working life will be considerably shortened and reliability may well become
an issue.
Most manufacturers of alternators supply the market with Class H insulation, which meets most of the
normal applications and duties that are encountered. Many manufacturers will supply insulation class H
while meeting class F standby ratings with the same machine.
6.0 Application where a lower winding temperature rise is required:
There are a number of generator applications where much a lower temperature rise is required, in order to
handle the type of electrical load and duty cycle.
Prime power applications such as oil field rigs frequently run throughout the year. Heavy-duty cycles
usually specify a maximum winding temperature rise of 70C at 40C ambient. A lower temperature rise
in prime power applications increases reliability with less winding failures because the insulation was
subjected to less heat for extended periods.
7.0 Accomplishing Lower Temperature Rises:

The prime factor for a lower temperature rise in all alternators is the size and material of the steel
laminations, the length of the lamination stack and the amount of copper wire used. This, added to the
design of the amount of cooling air driven through the alternator, will affect the machines output and
temperature behavior.
A larger alternator is applied for a lower temperature rise with increased copper resulting in lower current
density.
Increased size and copper permits higher motor starting kVA and lower voltage dips on application of the
load. It also means reduced voltage distortion and overheating, due to harmonics induced by non-linear
loads The temperature class of the insulation system is typically determined using the test methods
outlined in Underwriters Laboratory standard UL 1446 (Systems of Insulating Materials General)
8.0 Checking Deterioration of Winding Insulation:
Winding insulation should be checked if the generator has been subjected to any of the following:

Been stationary for a long period without anti-condensation heaters turned on

Been subject to an intake of high volumes of water
Windings are contaminated with airborne dust and dirt, or may have become damp due to high
humidity
Windings are contaminated with airborne corrosive elements such as salt or corrosive chemicals
in the atmosphere.