alternators eng

A LT E R N AT O R S R A N G E

A A G

A A K

A A K c o m p a c t

A A N c o m p a c t

A A T

Alternators type AAG

Alternators type AAK

Alternators type AAK compact

Alternators type AAN compact

Alternators type AAT

A LT E R N AT O R S I S K R A

C L A S S I F I C A T I O N O F A L T E R N A T O R S

The technical performance of Iskra alternators is based on long-term relationships with the customers, their high

requirements and expectations and our own long-standing experience in development and production. We control

quality using ISO 9001 and QS-9000 standards. The entire process from customer requirement and expectation,

through development and production is planned and controlled in detail. High operating reliability is assured by

optimising the design for use in different operating conditions, together with numerous validations of different

alternators in Iskras own laboratories and on vehicles.

Alternators are air-cooled synchronous three-phase generators with claw poles and a built-in semiconductor rectifier.

A three-phase stator winding is connected to the three-phase rectifier bridge with power rectifier or Zener diodes.

The rotor coil is connected to the slip rings with brushes that conduct the excitation current. Alternators are self-

excited through excitation diodes or they are excited directly by the battery. The voltage regulator can be either

built-in or separately mounted. The negative terminal is normally connected to the chassis.

Iskra Avtoelektrika keeps abreast of all technical innovations in the field of alternators. Its staff are aware that energy

conservation in vehicles is an absolute necessity. The results are different families of alternators designed in modern

compact versions with internal fans in parallel with families of conventional design using external fans. Modern

versions of rectifiers and specific multifunction regulators are also available.

Different versions of alternators meet very high specifications in terms of resistance to salt spray, humidity, water,

mud, dust, vibrations, high and low temperatures and aggressive liquids. They are also designed to meet electromagnetic

compatibility and other international directives and standards. They are produced using ecologically sound technologies

and environmentally friendly materials.

Iskra alternators are designed to meet a wide range of engineering specifications and applications. They are used

on petrol and diesel engines in the automotive industry, on trucks, buses, tractors, construction machinery and in

other applications. Different solutions of our alternators are defined taking into account the demands of each

application and are designed for long life, maintenance free operation under extreme conditions.

s tator d iameter 108 mm

stator d iameter 125 mm




A LT E R N AT O R S 14 V, 2 8 V

A L T E R N A T O R S 2 8 V

A L T E R N A T O R S 1 4 V

Output in Amps. at 6000 RPM

100

90

80

70

60

50

40

30

20

10

0

10 20 30 40 50 60 70 80 90 100 110 120 130 140 160

Ou

tpu

t in

Am

ps.

at

18

00

RP

M

AAT

14kg

AAN compact

7.3kg

4.7kg

A A K

AAG3.5kg

AAK compact

5.3kg

Output in Amps. at 6000 RPM

100

90

80

70

60

50

40

30

20

10

0

10 20 30 40 50 60 70 80 90 100 110 120 130 140 160

Ou

tpu

t in

Am

ps.

at

18

00

RP

M

4.7kg

AAK 5.3kg

AAK compact

AAG

3.5kg

150

150

AAN compact

7.3kg

A LT E R N AT O R S A A G

A P P L I C A T I O N SLow output powers make it possible for the

alternators to be built into systems with low

electrical requirements. Small dimensions allow

installation on all types of combustion engines

used on small tractors, small agricultural

machinery, stationary engines and some other

applications.

D E S I G NThe alternator is a three-phase, 12-pole

synchronous self-excited generator with built-

in rectifier and regulator and cooled by an

external fan. Various design solutions are

available depending upon the application:

insulated, marine, dustproof and other versions.

C o o l i n gThe integral fan provides effective through coolingof the alternator. Two different fans are available,for CW and CCW direction of rotation.

R o t o rThe rotor winding fixed between the claw polesprovides excitation of the alternator through sliprings. For particularly dusty environments slip ringsand brushes are additionally protected.

R e c t i f i e rPress fit rectifier diodes or Zener diodes are mountedinto protected heat sinks. Zener diodes protect theloads on the vehicle against overvoltages from thealternator.

R e g u l a t o rThe regulator incorporating the brush holder is builtinto the alternator. The regulator is produced usingthin-film hybrid or microelectronic technology.Monofunction or multifunction is availabledepending upon the requirements of the application.The highest quality brushes ensure long life of thealternator.

B r a c k e t s - B e a r i n g s - P u l l e y sBrackets, bearings and pulleys are made accordingto the customers requirements. A range of specialsealed bearings makes it possible to designalternators for specific installations, operating inthe harshest conditions whilst achieving long,maintenance free life.

E l e c t r i c a l t e r m i n a l sElectrical terminals are according to the customersrequirements.

M A I N T E C H N I C A L D A T A

AAG

14V 28V

33A - 50A 18A

108 mm

~3.5 kg without pulley

18,000 RPM

Built-in or separate

Hybrid technology

Different types according to

customers requirements

Screw and/or blade terminal

Type 6203 2RS

Type 63001

Press fit rectifier diodes or Zener diodes

Type

Nominal voltage

Nominal current

Stator diameter

Weight

Max. speed

Regulator

Pulleys and drive

end brackets

Terminals

Drive end bearings

Rear end bearing

Power diodes

Protection of the slip

rings and brushes

Ambient temperature

Protected against access by a wire

or splashing water (IP 44)

Protected against ingress of solid foreign

matter and powerful water jets (IP 56)

From - 40C to + 110C

A LT E R N AT O R S A A G

C R O S S S E C T I O N

Pos 1 Pu l l ey

Pos 2 Dr i ve end bear ing

Pos 3 Fan

Pos 4 Dr i ve end bracket

Pos 5 S ta tor

Pos 6 Rotor

Pos 7 Rear b racket

Pos 8 Snap r ing

Pos 9 Sea l ing fe l t

Pos 10 Rect i f i e r

Pos 11 Sl ip r ings

Pos 12 Termina l s B+ , W, D+

Pos 13 Capac i to r

Pos 14 Rear bear ing

Pos 15 Brush

Pos 16 Brush ho lder w i th vo l tage regu la tor

Pos 17 Rubber gasket s

C H A R A C T E R I S T I C S

C O N N E C T I O N D I A G R A MREGULATOR

D+ B+ B- W D-

DF D+

G

1

2

3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

123 mm

o 10

8 m

m

20

15

10

5

0

U=const.=27VTo=23C5C

I(A)

n(RPM)

0 1000 2000 3000 4000 5000 6000 7000

18A


n(RPM)

0 1000 2000 3000 4000 5000 6000 7000

60

45

30

15

0

I(A)

50A

35A33A

14V 33A

14V 35A

14V 50A

n (RPM)

1150

1250

1250

I (A) at

1800 RPM

15

13

20

I (A) at

6000 RPM

32

35

48

28V 18A

n (RPM)

1200

I (A) at

1800 RPM

8

I (A) at

6000 RPM

18

A LT E R N AT O R S A A K

A P P L I C A T I O N SHigh output power alternators to satisfy the

needs for electrical energy in a wide range

of applications:

for cars

for commercial vehicles

for heavy-duty applications

for special applications

D E S I G NThe alternator is a three-phase 12-pole

synchronous self-excited generator with built-

in rectifier and regulator and cooled by an

external fan. Depending upon the purpose

of the installation, various versions can be

supplied: insulated, marine and other versions

according to special requirements.

C o o l i n gAn integral fan provides effective through coolingof the alternator. Two different fans are useddepending upon the required direction of rotation.

R o t o rWith regard to the requirements of the installationand the operating conditions, different protectionlevels are provided for the slip rings and brushcompartment.

R e c t i f i e rA three-phase bridge circuit with power rectifierdiodes and excitation diodes provides D.C. outputcurrents and excitation of the alternator. It is possibleto use Zener power diodes to protect loads on thevehicle against alternator overvoltages.

R e g u l a t o rRegulator with brush holder is fitted to the alternator.They are made in thin-film hybrid or microelectronictechnology. With regard to the requirementsof the application they may be monofunctionor multifunction. The highest quality brushes ensurelong life of the alternator.

B r a c k e t s - B e a r i n g s - P u l l e y sBrackets, bearings and pulleys are made accordingto the customers requirements. A range of specialsealed bearings makes it possible to designalternators for specific installations, operatingin the harshest conditions whilst achieving long,maintenance free life.

E l e c t r i c a l t e r m i n a l sElectrical terminals are according to thecustomers requirements.


Type

Nominal voltage

Nominal current

Stator diameter

Weight

Max. speed

Regulator

Pulleys and drive

end brackets

Terminals

Drive end bearings

Rear end bearing

Power diodes


rings and brushes

AAK

14V 28V

45A-80A 35A 50A

125 mm


18,000 RPM


Different types according to customers

requirements.


Type 6203 / 6303 / 6304E / 6403-2RS

Type 6201-2RS

Rectifier or Zener diodes

Protected against access by a wire or

splashing water (IP 44)

Ambient temperature



Built-in or separateMono or multifunctionHybrid or microelectronicmonochip technology

A LT E R N AT O R S A A K


C O N N E C T I O ND I A G R A M S


Pos 1 Pu l l ey


Pos 3 Fan


Pos 5 S ta tor w i th w ind ing

Pos 6 Rotor

Pos 7 Rear b racket

Pos 8 Snap r ings

Pos 9 Sea l ing fe l t

Pos 10 Rect i f i e r w i th d iodes

Pos 11 Protec t i ve cover

Pos 12 S l ip r ings

Pos 13 Termina l s B+ , D+, W

Pos 14 Capac i to r


Pos 16 Brush



B+ B-

REGULATOR

G

WD+

D+DF

D-

1

o 12

5 m

m

135 mm

2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

REGULATOR

DF

L EX

G

B+ B-

n(RPM)

0 1000 2000 3000 4000 5000 6000 7000

80

70

60

50

40

30

20

10

0

I(A)


80A

75A

65A

55A

45A

60

45

30

15

0

I(A)

n(RPM)

0 1000 2000 3000 4000 5000 6000 7000


50A

40A

35A

14V 45A

14V 55A

14V 65A

14V 75A

14V 80A

n (RPM)

1000

1100

1100

1250

1350

I (A) at

1800 RPM

28

27

30

34

29

I (A) at

6000 RPM

45

54

65

74

80

28V 35A

28V 40A

28V 50A

n (RPM)

1200

1450

1550

I (A) at

1800 RPM

15

12

5

I (A) at

6000 RPM

35

40

50

Monofunctionregulator

Multifunctionregulator

A LT E R N AT O R S A A K c o m p a c t

A P P L I C A T I O N S for passenger cars for commercial vehicles for heavy-duty applications for special applications

F e a t u r e s high specific power and efficiency small dimensions low weight low noise level higher protection against accidental contact long life operation

D E S I G NThe alternator is a three-phase, 12-polesynchronous self-excited generator with twointernal fans and built-in regulator and rectifier.The compact construction and carefully selectedmaterials assure improved technicalcharacteristics and long life, service free,operation even under the harshest conditionsof high and low temperatures, salt spray,humidity, water, dust, vibrations, aggressiveliquids.

S t a t o rThe stator has a three-phase winding on a laminatedpack. The selected design and high filling factor of thestator slots provides improved cooling, low noise andhigh output characteristics.

C o o l i n gTwo internal fans positioned on the claw poles providemore effective cooling with lower noise and higherprotection against accidental contact as well as higheroutput.

R o t o rSmaller slip rings provide higher brush durability, evenat high speeds. Encapsulated slip rings offer increaseddurability of the alternator.

R e c t i f i e rSandwich construction of the rectifier with press fitZener diodes provides the low temperatures of therectifier diodes, high resistance to vibrations andprotection of loads on the vehicle against alternatorovervoltages. The installation of the rectifier on theouter side of the rear end bracket ensures flexiblearrangement of all types of terminals.

R e g u l a t o rThe regulator together with the brush holder isassembled on the rear end bracket. Regulators usemicroelectronic technology and are mono ormultifunction. The highest quality of brushes ensurelong life of the alternator.

B r a c k e t s - B e a r i n g s - P u l l e y sBrackets, bearings and pulleys are made according tothe customers requirements. A range of special sealedbearings makes it possible to design alternators forspecific installations, operating in the harshestconditions whilst achieving long, maintenance free life.

E l e c t r i c a l t e r m i n a l sElectrical terminals are according to the requirementsof the customers.


Type

Nominal voltage

Nominal current

Stator diameter

Weight

Max. speed

Regulator

Pulleys and drive

end brackets

Terminals

Drive end bearings

Rear end bearing

Power diodes


rings and brushes

AAK Compact

14V 28V

70A-120A 40A 60A

125 mm


20,000 RPM




requirements.


Type 6303, 6304E, 62304E

Type 6003

Press fit Zener diodes



Ambient temperature

Monofunction or multifunction

Microelectronic technology

A LT E R N AT O R S A A K c o m p a c t


C O N N E C T I O N D I A G R A M


Pos 1 Pu l l ey




Pos 5 Rotor

Pos 6 Rear b racket

Pos 7 Rec t i f i e r w i th d iodes

Pos 8 P rotec t i ve cover



Pos 11 Sl ip r ings

Pos 12 Brush



B+ B- WD+

D+DF

D-

REGULATOR

G

1 2 3 4 5 6 7 8

9

10

11

12

13

14

o 12

5 m

m

140 mm


60A

55A

50A

45A

40A

1000

80

70

60

50

40

30

20

10

0

I(A)

n(RPM)

0 2000 3000 4000 5000 6000 70001000

120

105

90

75

60

45

30

15

0

I(A)

n(RPM)

0 2000 3000 4000 5000 6000 7000

120A

95A

85A

80A

70A


14V 70A

14V 80A

14V 85A

14V 95A

14V 120A

n (RPM)

1000

1100

1000

1100

1400

I (A) at

1800 RPM

47

40

47

42

30

I (A) at

6000 RPM

70

80

84

94

115

28V 40A

28V 45A

28V 50A

28V 55A

28V 60A

n (RPM)

1000

1100

1200

1250

1400

I (A) at

1800 RPM

23

22

22

21

18

I (A) at

6000 RPM

40

45

50

55

60

A LT E R N AT O R S A A N c o m p a c t


Type

Nominal voltage

Nominal current

Stator diameter

Weight

Max. speed

Regulator

Pulleys and drive

end brackets

Terminals

Drive end bearings

Rear end bearings

Power diodes


rings and brushes

AAN Compact

14V 28V

100A-150A 60A 100A

142 mm


20,000 RPM




requirements.


Type 6304E, 62304E

Type 6203




Ambient temperature

A P P L I C A T I O N S for passenger cars and commercial vehicles with higher electrical demand for heavy-duty applications for special applications

F e a t u r e s high specific power and efficiency small dimensions low weight low noise level higher protection against accidental contact long life operation

D E S I G NThe alternator is a three-phase, 12-polesynchronous self-excited generator with twointernal fans and built-in regulator and rectifier.The compact construction and carefully selectedmaterials assure improved technicalcharacteristics and long life, service free,operation even under the harshest conditionsof high and low temperatures, salt spray,humidity, water, dust, vibrations, aggressiveliquids.

S t a t o rThe stator has a three-phase winding on a laminatedpack. The selected design and high filling factor of thestator slots provides improved cooling, low noise andhigh output characteristics.

C o o l i n gTwo internal fans positioned on the claw poles providemore effective cooling with lower noise and higherprotection against accidental contact as well as higheroutput.

R o t o rSmaller slip rings assure higher brush durability, evenat high speeds. Encapsulated slip rings offer increaseddurability of the alternator.

R e c t i f i e rSandwich construction of the rectifier with press fitZener diodes provides for low temperatures of therectifier diodes, high resistance to vibrations andprotection of loads on the vehicle against alternatorovervoltages. The installation of the rectifier on theouter side of the rear end bracket ensures flexiblearrangement of all types of terminals.

R e g u l a t o rThe regulator together with the brush holder isassembled on the rear end bracket. Regulators usemicroelectronic technology and are mono ormultifunction. The highest quality of brushes ensurelong life of the alternator.

B e a r i n g s - B r a c k e t s - P u l l e y sBrackets, bearings and pulleys are made according tothe customers requirements. A range of special sealedbearings makes it possible to design alternators forspecific installations, operating in the harshestconditions whilst achieving long, maintenance free life.

E l e c t r i c a l t e r m i n a l sElectrical terminals are according to the requirementsof the customers.

Monofunction or multifunction

Microelectronic technology

A LT E R N AT O R S A A N c o m p a c t




Pos 1 Pu l l ey




Pos 5 Rotor

Pos 6 Rear b racket

Pos 7 Rec t i f i e r w i th d iodes

Pos 8 P rotec t i ve cover



Pos 11 Sl ip r ings

Pos 12 Brush



B+ B- WD+

D+DF

D-

REGULATOR

G

160

140

120

100

80

60

40

20

0

I(A)

1000

n(RPM)

0 2000 3000 4000 5000 6000 7000


150A140A

130A120A

120

105

90

75

60

45

30

15

0

I(A)

1000

n(RPM)

0 2000 3000 4000 5000 6000 7000


100A

80A

70A

28V 70A

28V 80A

28V 100A

n (RPM)

1050

1250

1250

I (A) at

1800 RPM

41

39

38

I (A) at

6000 RPM

74

85

100

14V 120A

14V 130A

14V 140A

14V 150A

n (RPM)

1050

1050

1200

1200

I (A) at

1800 RPM

78

80

72

74

I (A) at

6000 RPM

125

134

145

154

148 mm

1 2 3 4

o 14

2 m

m

5 6

13

14

12

11

9

8

10

7

A LT E R N AT O R S A AT


Type

Nominal voltage

Nominal current

Stator diameter

Weight

Max. speed

Regulator

Pulleys and drive

end brackets

Terminals

Drive end bearings

Rear end bearings

Power diodes


rings and brushes

AAT

28V

75A-140A

165 mm


Built-in or separateMonofunctionHybrid technology


requirements


Type 62306-2RS

Type NU 202




Ambient temperature

A P P L I C A T I O N SThese alternators provide very high outputpower and are designed to be built intoapplications requiring high consumption ofelectrical energy. They were all initially designedfor installation on diesel engines in buses andsome special purpose applications.

D E S I G NThe alternators are three-phase, 16-polesynchronous generators, self-excited by a rotorconsisting of claw poles using protected sliprings. They have a built-in rectifier and regulatorand are cooled by an external fan. Designsolutions and anticorrosion coatings as well asspecially chosen bearings ensure long lifewithout maintenance under normal operatingconditions. For operation in extremely hardconditions - temperature, dust, water - it isadvisable to ventilate the alternator using aspecial protection cover on the rear.

C o o l i n gThe alternator has a built-in fan with axial - radialblades that allow rotation in both directions. It isalso possible to use a low-noise fan with speciallyshaped blades.

S t a t o rA three-phase stator winding with a high fillingfactor of the slots and a special method of assemblyprovide better cooling and high output power.

R o t o rThe rotor field winding provides excitation of thealternator through slip rings. With regard to theinstallation requirements, slip rings and brushes areprotected in an enclosed environment sealed againstdust and water.

R e c t i f i e rThe rectifier stack is a three-phase bridge circuitwith built-in press fit power and excitation diodes.Press fit Zener diodes are used to protect alternatorand loads on the vehicle against overvoltages.

R e g u l a t o rThe regulator together with the brush holder is builtinto the rear end bracket of the alternator. Regulatorsare produced in thick-film hybrid technology.Monofunction versions of the regulator only areavailable.

B r a c k e t s - B e a r i n g s - P u l l e y sThe high quality specially chosen bearings providelong service free life.

E l e c t r i c a l t e r m i n a l sElectrical terminals are according to the customersrequirements.

9,000 RPM

~9.6 kg without pulley for 75A

~14.5 kg without pulley for 140A

A LT E R N AT O R S A AT

C H A R A C T E R I S T I C



Pos 1 Pu l l ey


Pos 3 Fan


Pos 5 S ta tor

Pos 6 Rotor

Pos 7 Rear b racket

Pos 8 Rec t i f i e r


Pos 10 Brush


Pos 12 Oi l sea l


Pos 14 S l ip r ings

Pos 15 Termina l s D+, B+, W

Pos 16 Capac i to r

D+DF

D-

REGULATOR

R

G

D+ C B- B+ W

o 16

5 m

m

227 mm

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

160

140

120

100

80

60

40

20

0

I(A)

1000

n(RPM)

0 2000 3000 4000 5000 6000 7000


105A95A

75A

140A

120A

28V 75A

28V 95A

28V 105A

28V 120A

28V 140A

n (RPM)

1000

950

900

1020

1080

I (A) at

1800 RPM

50

60

70

78

90

I (A) at

6000 RPM

75

95

105

120

140

A LT E R N AT O R S product requirements form

1 . C U S T O M E R

Company:

Address: Country:

Responsible person:

Phone: Fax: E-mail:

P R O J E C T

Name: inquiry new project modification

Brief description:

Quantity in next years: 1st 2nd 3rd 4th 5th

A P P L I C A T I O N

cars trucks buses agriculture road industry railway marine

other applications

E N G I N E D A T A

petrol diesel 2/4 stroke No. of valves

No. of cylinders Compression Displacement Ltr.

Rated output kW Min. speed RPM Max. speed RPM

P R E D E C E S S O R / E Q U I V A L E N T T Y P E O F A L T E R N A T O R

Supplier Type Mark

Drawing Release number

E L E C T R I C A L R E Q U I R E M E N T S

Voltage V Current A (1800 min-1) A (6000 min-1)

Power kW Isolated ground NO YES

Electrical connections

B+ type of terminal D+ type of terminal

W type of terminal B- type of terminal

Other connection - terminals

Regulator voltage Ur = V

Regulator: monofunction multifunction

Description of function

2 . E N G I N E D A T A

3 . A L T E R N A T O R R E Q U I R E M E N T S

A LT E R N AT O R S product requirements form

M E C H A N I C A L R E Q U I R E M E N T S F O R A L T E R N A T O R

Direction of alt. rotation: clockwise counterclockwise both directions

Ratio between engine and alternator: 1:

Type of driving belt/ pulley:

one groove, belt width mm angle

two groove, belt width mm dimension between belt angle

poly V belt, number of grooves dimension between grooves angle

Diameter of the pulley mm Belt line dimension

Type of pulley bearing

D E S I G N R E Q U I R E M E N T S

Max. diameter: mm Max. length: mm Max. weight: kg

Please draw direction,position of cables,

terminals (back side view)

Type of installation

Other design requirements:

Grade of protection according IP (DIN 40050): IP

Environmental conditions: salt spray high temperature low temperature

humidity others

Mounting requirements: (to specify/sketch) or enclose drawing

Special requirements:

Customer test specification No.:

Safety standards:

Other standards:

Vehicle test or bench test (duration/conditions/number of samples):

Date: Signature:

I S K R A S U B S I D I A R I E S

BYELARUSIskRa, O.o.o.Ul . Gorkog 89230015 GrodnoTe l . : +375 152 313 533Fax : +375 152 317 953E-mai l : i sk ra@mai l .g rodno.by

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GREAT BRITAINIskra UK, Ltd.Red landsUl l swater Crescent , Cou lsdonSurrey CR5 2HTTe l : +44 208 668 7141Fax : +44 208 668 3108E-mai l : sa les@iskra-agency .co .uk

IRANIskra Autoelectr ic I ran, J .V.C.No.28, Eas t Mi rdamad AvenueTehran 15469-34311Te l : +98 21 226 2371 4Fax : +98 21 226 2376E-mai l : tuba.e@mai l .dc i . co . i r

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SPAINIskra Autoelectr ique SpainCal le L lobatona No. 6-DVi l l adecans08840 Barce lonaTe l : +34 936 474 083Fax : +34 936 474 084

USAIskra AE, Inc .10 Corb in Dr ive , Su i te 4Dar ien , CT- 06820Te l : +1 800 474 1996 +1 203 655 2884Fax : +1 203 655 1965E-mai l : I sk raAE@aol .com

REPRESENTATIVE OFFICE RUSSIAIskra Avtoelektr ikaProspect Kosmonavtov , 27-199141075 Koro lyev , Moscow reg ionTe l : +7 095 502 82 04Fax : +7 095 502 82 04E-mai l : i sk ra_ae@nt l . ruwww. i skra-ae . ru

SLOVENIA

Iskra Avtoelektr ika d. d.

5290 flempeter pr i Gor ic i

Po l je 15, S loven ia

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Publisher: Iskra Avtoelektrika d. d. Design: Lazar Matja, Kompas Design Photos: Zavadlav-Pavi Print: ukGraf, Postojna March 2002 722.704.187

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