Design Performance • Available in voltages of 12 to 500 Vdc • 32 pole high frequency design provides low electrical ripple • Compact and lightweight • Direct engine mounting further enhances the compact and lightweight design • Conventional 3 phase stator lowers assembly cost • NdFeB Magnets for high efficiency • Class 220 C magnetic wire for long service life • Anodized type III process for aluminum parts • Nickel plating for steel parts • Stator is varnished Exceeding Military Standards without the Cost Polar Power 249 E. Gardena Blvd Carson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825 www.polarpower.com 8000 Series DC Alternators Telecommunications Military APU Hybrid Electric Propulsion Fast Battery Charger Hybrid Photovoltaic Solar Uninterruptible Power Systems Hydroelectric Wind Energy Advantages • High reliability and limited maintenance • High degree of corrosion resistance • No mechanical adjustments • Very light weight • High quality electrical output • Stiff voltage regulation to current demand • Up to 94% efficiency • -40° to 70° C operational range Blower Rotor Mount attaches to Flywheel Solid Rotor 3 Phase Stator Yoke attaches to SAE 5 Bell Housing Terminal Plate NdFeB 32 Magnets
Transcript
Design Performance• Available in voltages of 12 to 500 Vdc• 32 pole high frequency design provides low electrical ripple• Compact and lightweight • Direct engine mounting further enhances the compact and lightweight design• Conventional 3 phase stator lowers assembly cost• NdFeB Magnets for high efficiency• Class 220 C magnetic wire for long service life• Anodized type III process for aluminum parts• Nickel plating for steel parts• Stator is varnished
Exceeding Military Standards without the Cost
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
www.polarpower.com
8000 SeriesDC Alternators
Telecommunications Military APUHybrid Electric PropulsionFast Battery ChargerHybrid Photovoltaic Solar Uninterruptible Power SystemsHydroelectric Wind Energy
Advantages• High reliability and limited maintenance• High degree of corrosion resistance• No mechanical adjustments• Very light weight• High quality electrical output• Stiff voltage regulation to current demand• Up to 94% efficiency• -40° to 70° C operational range Blower
Rotor Mount attaches to Flywheel
Solid Rotor
3 Phase Stator
Yoke attaches to SAE 5 Bell Housing
Terminal Plate
NdFeB32 Magnets
Low Maintenance and High Reliability
1. Our unique alternator design with its large diameter and 32 poles allows you to run your engine at lower speed with lighter weight, higher efficiency, and longer engine life. 2. Each Polar Power stator lamination stack is fully bond-ed to create a stator without voids which prevents mois-ture penetration, corrosion, and swelling. After the copper winding is in place, the entire stator assembly is varnished submersed in a class H coating then baked. This seals the metal surfaces from corrosion and improves thermal perfor-mance. This also increases resistance to salt fog. The coat-ings also protect the stator windings from particle abrasion and vibration.
3. The steel magnet ring is 100% Nickel plated. The mag-nets are then bonded to the inside of the ring with high tem-perature aerospace grade epoxy. The purpose of Nickel plating the ring is to provide the surface with high degree of corrosion resistance, thereby preventing corrosion from starting in one area, migrating under the magnets, and cre-ating a bond failure. The assembled magnet ring is then ep-oxy coated to further seal the surfaces and provide a higher degree of salt fog corrosion resistance.
4. The magnets are mounted on the inside of the ring, so there are no centrifugal forces pulling against the epoxy bonds.
5. There are no electronic parts (diodes, etc.) or electrical connections inside the alternator. There is nothing to short or vibrate loose inside the alternator.
6. The alternator is almost impossible to damage electrical-ly. The outputs can be shorted for minutes without damage.
7. The alternator’s rotor is mated to the engine’s flywheel, and this mated pair is dynamically balanced to improve the engine’s bearing life.
8. Polar Power’s PMHH alternator should have an MTBF exceeding 100,000 hours, as there are no parts which rub, wear, or overheat under normal operating conditions.
Model # Power Range Width Weight Rotor Weight Yoke
8080 2-8 KW 2.8 in
7.15 cm
13.5 lb
6.14 kg
18 lb
8.19 kg
8220 8-22 KW 3.915 in
9.95 cm
20 lb
9.1 kg
26.5 lb
12.05 kg
8340 15-34 KW 4.46 in
11.35 cm
25.5 lb
11.59 kg
33 lb
15 kg
* Maximum power is rated at 3200 RPM. Weights will vary with specific configuration
and do not include controls and diodes. Fluid cooling adds 3.5 lb (1.6 kg).
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
www.polarpower.com
8000 SeriesDC Alternators
Supra Controller Features To maintain a regulated voltage, the 8000 Series alternator requires the voltage regulator to change the engine speed in response to changing loads (current). The voltage regula-tor provides thermal protection for the alternator; a sensor on the yoke can alert the operator of a high temperature condition. If no action is taken, the regulator automatically reduces the alternator’s output power so the alternator can run cooler.
The voltage regulator, through a current transducer, moni-tors the output current of the alternator. The voltage regula-tor lowers the engine speed during an over current condi-tion. This feature prevents the alternator from overheating or stalling the engine.
For long reliable life, the Diode Bridge is remote from the alternator and mounted on a large heat sink to keep cool and free of engine vibration. The Supra controller also monitors the diode bridge for an over temperature condition. The voltage regulator maintains the voltage drift to less than 1.5% during a change in ambient temperatures of 60° F over 8 hours.
Very High Quality Electrical Output Low EMI emissions are designed into the system. There are no brushes or slip rings. The 32-pole design reduces the amplitude of the voltage and current waveforms.
Light Weight Model 8000 series alternators incorporate an aluminum yoke. Additional reductions in weight can be attributed to the 32 pole design, high-energy Neodymium-Iron-Boron magnets, and the “pancake” design of the assembly.
Low Fuel Consumption The PM alternator has an efficiency of between 85% to 94% versus 45% to 70% typical of most other DC alternators.
Low Acoustic Noise Improving alternator efficiency reduces the horsepower demand on the engine, which reduces engine noise. The engine can also operate at slower speeds further reducing noise.
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
www.polarpower.com
8000 SeriesDC Alternators
Product ComparisonPolar’s 6200 verses 8000 series
6200 Series Profile• Available in one size covering the power range of 2 to 14 kW• Voltage and current regulation is independent of engine speed• Fixed speed or variable speed operation• Engine speed can be manually or automatically adjust- ed over a 1,000 RPM range to meet load requirements Very fast voltage and current regulation
8000 Series Profile• Available three sizes covering the power ranges of 1 to 34 kW• Variable speed operation over a 500 RPM range is required to maintain voltage and current regulation• Higher efficiency• Very compact and light weight• Lower cost
When to select the 6200 series over the 8000 • Engine is fixed speed• The engine needs to operate over a wide speed range
• Engine is driving other devices that take priority in speed control• Alternator is powering loads that require very fast voltage regulation• The load is less that 8 kW for all voltages except for 28.• The 28 Vdc load is less than 13 kW
When to select the 8000 series over the 6200 • Loads exceed 10 kW• Engine speed can be controlled• Small size and light weight are desired
Preferred applications for 6200• Telecommunications• Systems without batteries and sensitive loads• APU’s• Cogeneration and CHP
Preferred applications for 8000• Telecommunications• Hybrid Propulsion systems• Renewable hybrid power systems• APU’s• Battery charging applications• Rapid electric vehicle charging• Cogeneration and CHP
Model # Chart
Model # Cooling Type Nominal Voltage Speed Rotor Mount Style
808 0 = air cooled 12 A = 800 rpm 3 = 3 hole mount
822 1 = water cooled 24 B = 1200 rpm 6 = 6 hole mount
834 2 = water and air cooled 36 C = 1600 rpm 8 = 8 hole mount
48 D = 2000 rpm 1000 = 1” shaft mount
72 E = 2400 rpm 1125 = 1.125” shaft mount
96 F = 2800 rpm
120 G = 3200 rpm
144 H = 3600 rpm
240
320
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
www.polarpower.com
8000 SeriesDC Alternators
Rotor Configuration
Polar Power Inc. (hereinafter “Polar”), hereby warrants goods manufactured and sold by it to be free from defects in material and workmanship for 24 months after the date of shipment.
The warranty is limited to repair or replacement at 249 E. Gardena Blvd, Carson, CA 90248 or other point designated by Polar of such parts as they appear to Polar, upon in-spection, to be defective in material or workmanship. This warranty is extended to the first user only and no warranty is made or authorized to be made assignable on resale by the first end user.
The above warranty includes a pass-through warranty from the engine and controller manufacturers for whatever period and warranty is in effect by the manufacturer at that time. The above warranty only extends to applications and instal-lations which are approved by mutual agreement between Polar and the first end users.
To obtain performance of any obligation under this warranty, contact must be made with Polar in writing at 249 E. Garde-na Blvd, Carson, CA 90248. Submission of a claim does not obligate Polar to accept such claim in full or in part.
No bills for service, labor or other expenses that have not been previously approved and authorized by Polar will be allowed.
No goods or materials may be returned until authorized in writing by Polar and, where the return of the material is authorized, it shall be F.O.B. to whatever point Polar desig-nated within the U.S.A.
Repairs or alterations made to the goods without Polar writ-ten concurrence or the operation of the goods in excess of rated capacity will invalidate this warranty.
There is no implied warranty or condition of merchantability. There is no other warranty or condition expressed or implied, statutory or otherwise, except such as is expressly set forth herein. Neither Polar nor manufacturers will be liable for any general, consequential or incidental damages, including with-out limitation any damages for loss of use or loss of profits, for any breach of warranty or condition or for negligence; Polar’s and manufacturer’s liability and the buyer’s exclusive remedy being expressly limited to the repair or replacement of the goods sold by polar as provided herein.
Limited Warranty
8000 SeriesDC Alternators
Polar Power249 E. Gardena BlvdCarson, CA 90248 USA Tel: (310) 830 - 9153 Fax: (310) 830 - 9825
