Kato Engineering Generators Motor Generator Sets Controls Leroy Somer North America
Kato Engineering Generators Motor Generator Sets Controls Leroy Somer North America
Kato Engineering Generators Motor Generator Sets Controls Leroy Somer North America
Kato Engineering
Generators • Motor-Generator Sets • Controls
Prime, standby, conditioning
More Power to You!
Founded in 1926, Kato
K ato Engineering (Kato) offers a complete line of precision-engineered, high
quality ac generators, motor-generator sets and controls for prime,
standby, and peak shaving power generation.
Engineering has a long
tradition of design and Kato generators supply power to tap the world’s resources; oil, gas, coal,
manufacturing excellence copper, iron ore and lumber are all extracted from the earth with the help of
and innovation: Kato generators. Kato furnishes the power to keep the world moving. Ships,
freighters, locomotives, aircraft and mass transit systems all use Kato
• Kato was an early user
of vacuum-pressure equipment. Any place where dependable, controllable electrical power is
impregnation for coil needed: hospitals, computer centers and telecommunication stations all rely on
protection. Kato generators to supply clean power.
• Kato was a pioneer in The ruggedly-constructed Kato generators survive the harshest environments,
the use of split bearings and the Kato name has become synonymous with dependable power
on rotor shafts. generation worldwide.
• Kato was an early user
of permanent magnet
and brushless excitation.
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Superior design and
manufacturing capability
Kato Engineering has a superior
staff of professionals to support
research & development, design,
manufacturing and service activities.
And, as a subsidiary of Emerson,
Kato has a broad network of human
resources, technical knowledge and
manufacturing capacity available to
augment our North Mankato, MN
manufacturing facility. All of these
assets allow us to use the latest
technology to provide a reliable
product with a competitive price.
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Rotors & Stators
Rotors
Rotor poles are punched or fabricated from high-strength steel. The pole shape
is designed to withstand mechanical stresses caused by rotational forces and
Precision-designed and
prime mover pulsations. The pole contour is optimized to generate low
skillfully manufactured
harmonics in the voltage waveform.
stators and rotors are
paramount to generator Field coils are machine wound on the poles with high temperature insulated
performance and life. copper wires. The coil end and interpolar region are blocked to prevent coil
movement and distortion. Depending upon the application, damper bars are
inserted into the pole face and brazed or welded at each end to complete the
damper/amortisseur winding. The purpose of the damper windings is to
reduce the generator harmonics and absorb torque pulsations caused by the
prime mover or an unbalanced load distribution. The damper windings also
reduce system oscillations caused during parallel operation. The complete
rotor is either vacuum-pressure impregnated before the shaft is pressed or wet
wound.
The shaft is precision machined from rolled or forged steel. The bearing
surfaces meet stringent tolerance requirements for runout and concentricity.
The rotor is dynamically balanced to meet specifications.
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Stators
Frames: Sophisticated design Form-wound windings: Insulating
software and over 75 years of tapes are precisely layered using state
experience ensure that the generator of the art equipment to ensure
frame is made with strength and maximum insulation properties and
support where needed instead of just optimum fit in the coil slot,
adding useless size and weight. Stator eliminating discharges that would
frames are welded with heavy rings shorten the generator’s operating life.
and bar steel. The frame is reinforced In the stator, coil end windings are
with welding plates between bars or braced and supported with surge
with a heavy wrapper. Heavy gauge ropes to withstand short-circuit fault
steel is formed and fastened to the conditions.
frame to provide an ample airflow
Vacuum-pressure impregnation:
path. The endrings are precisely
Entire stator assemblies are immersed
machined to support the bearing
into liquid thermosetting epoxy resin
brackets.
insulation and vacuum-pressure
Cores: Stator cores are built from impregnated. The vacuum exhausts
high-grade electrical steel air, moisture and other vapors from
laminations. Each lamination is core the windings and permits complete
plated on both sides to minimize core penetration of the epoxy resins, filling
loss and heating. Slots in the cores are voids and creating a rigid mass with
skewed to minimize harmonic optimum dielectric strength.
voltages.
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Bearings & Adaptation
Ball bearing Split roller bearing
The most popular and universally Used on large generators of low and
used bearing. Being permanently medium speed up to 1800 RPM. It is
Because bearings and lubricated or equipped with grease self aligning and can be replaced
adaptation are based upon fittings, it is suitable for low, medium without moving the generators
various factors, including or high speeds and single or two- endbracket or shaft, a feature
load carrying capacity, bearing generators. The ball bearing desirable when the generator is
speed and type of prime is lowest in cost. driven by an engine on each end.
mover, Kato Engineering Because it is self aligning, this bearing
offers several options. Spherical roller is suitable for single or two-bearing
bearing machines.
Prime mover
connections
Single-bearing units may have either
SAE flexible disk type couplings or
forged flanged shafts for direct
connection to engine flywheels.
Generators with two bearings have
shaft extensions that are suitable for
direct coupling to prime movers.
Close-coupled SAE housing adapters
are also available with both single
and two-bearing designs.
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Excitation & Regulation
Voltage regulation
Kato Engineering offers several
voltage regulators for various
applications. Our standard K65-12B
(used for 65 Vdc field requirements) Kato’s solid state,
& K125-10B (used for 125 Vdc field encapsulated voltage
requirements) models are regulator
encapsulated for weather protection.
Their solid state analog design is UL
recognized. They have the following
specifications:
Sensing
100 to 120 V +/-10% with standard
10K ohm control, 1 phase or 3 phase,
50/60 or 400 Hz; 1 VA maximum
PMG
burden per terminal A separate permanent magnet • Provides full exciter power,
rotating exciter can be supplied in regardless of alternator voltage, for
Paralleling motor starting and is a separate
addition to the brushless exciter as an
1 A or 5 A for 6% droop maximum; voltage source for use external to
option.
10 VA maximum burden; isolated the generator set, such as a
• Reduces the effects of both
for use in either reactive droop or tachometer and relay options
conducted and radiated
cross-current method electromagnetic interference (EMI). • Provides an economical and simple
Regulation accuracy With an EMI filter, the PMG and a means of reliable, responsive and
+/- 0.5% maximum over full range Kato voltage regulator will meet the stable input power to the voltage
of generator loading and +/- 5% emissions requirements of Mil-Std- regulator
frequency variation 461C, Part 9, Class C2 • Supplies continuous power to the
• Enhances manual voltage control exciter through the voltage
Under frequency
regulation as the PMG provides a regulator to maintain up to 300%
protection breakpoints
more stable power source to the short-circuit current from the
Adjustable 45 to 65 Hz (50/60 Hz
manual control alternator during a fault condition
regulators only)
Regulator response
Less than 4 milliseconds
Field excitation
Fast voltage response time to
generator load changes with short
time constant is provided with the
Kato brushless excitation systems.
This allows the voltage regulator to
react to changes in field excitation
requirements. Three-phase high-
frequency revolving armature
excitation current is full wave
rectified through six silicon type
rectifiers mounted in heat sinks and
positioned in the air stream for
maximum heat dissipation. Diode PIV
Exciter with a PMG and
rating is at least twice the peak rotating rectifier
operating voltage normally required.
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Features & Options
Standard features
Kato’s standard generators have the
following features:
• Brushless exciter
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Testing
Before manufacturing, Kato Engineering tests its designs using
sophisticated analysis software. During manufacturing we
monitor critical processes and test or inspect components
before they move to the next step. Kato’s final test facility
includes two seismic test bases and precise control and data
acquisition systems.
• Tests on optional
components (e.g.,
RTDs, space heaters)
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Platform AC Generators
Simple but with advanced designs, Kato platform generators offer high
reliability and easy access for maintenance. Used for a variety of applications
and engine or turbine driven, they have the following specifications:
Efficiency: 88% to 97% based on power rating, operating speed and voltage.
All Kato generators have a high grade of electrical steel to yield low core losses
and provide high efficiencies. Depending upon kW rating, premium steel may
be used, resulting in even higher efficiencies. Efficiency data for specific
models will be furnished upon request.
Overload: Typical allowable overloads are 50% for 5 minutes and 10% for 2
hours during 6 hours of operation. Short-circuit cabability is at least 15 seconds
at 300%.
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Voltage balance: With balanced
loads, the voltage is held within 1.0%
between phases.
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Packaged Generators
Ratings
125° C/40° C ambient temperature rise, continuous duty, Class H
Bearings that are pre-lubricated, double shield, ball type, single row Conrad C3
fit with provisions for adding or changing grease. Minimum B-10 bearing life is
40,000 hours for single bearing units.
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Conformity
The new line of Kato generators
conforms to the applicable parts of
IEEE, NEMA, IEC and ISO standards.
The generators have CSA listing and
are suitable for submission as a
component of UL 2200 certification.
Quality Standards
The new Kato line of generators is
manufactured in a plant that is
certified to the new quality standards,
TS-16949, which includes ISO 9001.
This was the first generator
manufacturing plant to achieve this
certification. Random-wound stators are standard on Kato’s packaged generator line on models below 600 V.
Options
• Digital voltage regulator with
VAR/PF control
• Cross-current compensation
paralleling
• EMI filter
• Space heaters
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Traction Alternators
For every application, Kato Engineering’s design objectives for traction
alternators are to be both mechanically and electrically compatible. The
mechanical design ensures structural integrity, minimum vibration, maximum
Built smaller and lighter, bearing life, a proper fit and accessibility for service. Electrically, the design
Kato’s traction alternators must ensure the required power is available for the specified load
help reduce vehicle payload. requirements.
But rugged construction and
superior insulation ensure
they can handle bumpy, Locomotive applications
grimy conditions as well For new or rebuilt 1500 to 3000 hp, 700 to 1250 Vdc and up to 4800 Idc
as the thermal cycling caused
locomotives used in switchyard and short road-haul applications.
by the constant acceleration
and deceleration mine A typical locomotive package consists of a traction alternator and a dual
haul trucks and locomotives auxiliary alternator. The dual auxiliary alternator includes two components:
must endure.
• A 188 kVA, 1.83 V/Hz 2400 or 1800 RPM companion for ac loads, such as
electric air compressor, radiator cooling fans and cab accessories
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Off-highway
truck applications
For ac drive mine trucks in the 260 to
Off-highway truck
400-ton range. traction alternator
Driven by Detroit Diesel 4000 series
16V-4000 or 20V-4000 engines or
Cummins QSK60 and QSK78 series
engines in the 2700 hp to 3600 hp
range, they have the following
specifications:
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Motor-Generator Sets &
High-Frequency Generators
Motor-generator sets
Precision applications
Motor-generator (MG) sets provide line conditioning and load isolation for
around the world, including
computers and other sophisticated electrical systems. They can also perform
laboratory testing, aircraft
frequency conversion. Long life, minimum maintenance costs, low harmonics,
ground support, line
conditioning on ships high overload capacities and many other features make motor-generator sets a
and shore power depend clear choice over solid-state systems.
on the superiority of Kato With input of 50 or 60 Hz, output frequencies of 50, 60, or 400 Hz are available
motor-generator sets and as standard. For custom designed systems, fixed frequency outputs from 25 Hz
high-frequency generators.
to 1200 Hz may be selected, or we can provide continuously variable frequency
using a VFD on the motor. Power capacities range from 10 kVA to 20,000 kVA
and up, depending upon system requirements.
Motor-generator
set with a
unit-mounted
panel
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High-frequency
generators
Kato Engineering offers a complete
line of high frequency (400 Hz)
generators. These units provide
economical power for grounded
aircraft’s navigational equipment,
ground power and military support
products.
Phase: 3
Power factor: 0.8
Voltage range: 115/200, 120/208,
240/416, 277/480
Totally-enclosed
motor-generator set
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Special Cooling &
Protection
Totally enclosed air-to-air cooled (CACA/TEAAC)
In addition to our standard Air-heat exchanger cooled generators are available from 500 kW to 10 MW.
open dripproof enclosure, CACA generators are typically used in dusty, salt-laden or corrosive
used where there is an environments.
abundance of clean air, Kato These units are equipped with one or two internal fans to direct the enclosed
Engineering offers a variety
air up and through an array of stainless steel tubes, which are mounted on top
of cooling and protection
of the generator. Air from a second external fan is directed through an outer
options for gritty, moist or
sheet metal enclosure to cool the tubes, and air is then exhausted on the
explosive environments.
opposite side of the generator.
The units are equipped with one or two internal fans. Air is forced up and
through a large air-to-water radiator within the generator enclosure. Air is
continually re-circulated with the heat created from the generator being
displaced by cool water from the radiator coils. The radiator consists of an
inner tube of 90-10 copper-nickel for corrosion resistance and an optional outer
tube to detect water leakage. A separate system to pump a continuous supply
of cooling water throughout the radiator must be supplied.
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Weather-protected II unit and
Weather-protected II air flow diagram
For generators that must be under an
open sky, Kato Engineering offers
weather-protected II enclosures, built
to NEMA standards.
Air filters
For dusty, gritty applications,
Kato Engineering offers air-filtered
generators. Filters on these machines
remove over 78% of the particles with
diameters over 5 microns.
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Parts and Service
W e at Kato Engineering know how important
your power needs are. That is why we have
experienced factory field service personnel on call
24 hours a day, every day of the year.