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Marelli Generator Review

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Marelli Motori is a global leader in the production of electric motors and generator ends (also referred to internationally as alternators). It started off over 125 years ago in Italy and now has operations in both Italy and Malaysia for manufacturing.

Marelli generators have a well-deserved reputation for durability and excellence. Most of the time, gray cast iron or spheroidal graphite cast iron shields are used, and tough structural steel or aluminum alloy fans. They range from devices with a power output of 10 kW to those with a power output of 10 MW.

About the company

The company, which has been in operation since 1891, has expanded to become a household name all over the world thanks to its innovative products and extensive sales, distribution, and service networks that span four continents.

The company's two manufacturing facilities are located in Italy and Malaysia, where its technologically advanced products are produced and exported to more than 120 countries.

Their values

They have risen to a prominent position in the modern energy industry thanks to their ability to give lasting value to our customers and partners and to increase the marketability of their products.

Commitment to quality

Their commitment to quality is evidenced by many certifications, which ensure they always provide excellent products and services while also minimizing our negative effects on the environment. Marelli Motori's products are designed to maximize performance and energy efficiency for the lowest possible environmental impact.

Product range

Providing innovative solutions backed by unrivaled application experience, their wide catalog of motors and generators is tailored to the varying requirements of their clientele.

Protecting customers

Indeed, their is a story of inventiveness and fervor, but it is also one of family and community. The prosperity of a business depends on its capability for entering new markets.

Marelli Motori's global standing was bolstered by the company's commitment to regular, sizable technological investments in the factory and the expansion of its product line to meet the demands of its new market.

Environment

Reducing environmental impact and conserving global natural resources are at the core of Marelli Motori's approach to corporate social responsibility. One important part of this strategy is including stakeholders, our supply chain, customers, and organizations like universities in environmental protection research.

Industry of Power-Related Solutions

Businesses such as Bergen Engines, Marelli Motori, and Piller Power Systems collaborate under the Langley Holdings Power Solutions Division to manufacture hybrid-renewable microgrids. Meeting current and future microgrid needs at an affordable price and with little environmental impact is the objective.

The department handles a wide range of microgrid management and deployment responsibilities, including the balancing and stabilization of renewable energy sources to ensure a constant power supply at all times.

With Marelli Motori alternators, the H2-ready combustion engines from Bergen Engines have a rapid start time, excellent efficiency even at low loads, and reduced fuel consumption.

Piller's stabilization and storage solutions make it possible to make the most of the microgrid's diverse power sources, reducing both upfront and ongoing expenses.

A versatile, reliable, and cost-effective power solution is guaranteed at all times thanks to the integrated offering.

Generators

Marelli Motori creates electric generators for use in power-and-heat applications.

Here are some examples of what they offer.

1. MJHRM

Major Fields of Use: Auxiliary Generator, Offshore, Hybrid Machine, Propulsion Generator, Shaft Generator, and Variable Speed Generator. Designed for use in the maritime sector.

Housing

Steel construction with a sturdy structure and robust welding (EN 10025 - S235 JR). The addition of side ribs gives the framework an extra strength boost.

Shield

Built using either gray cast iron (EN 1561) or spheroidal graphite cast iron (EN 1563) up to a 630 frame size.

Shaft

Constructed using carbon steel lamination (EN 10083–2 C40–TN). A shaft having a diameter of at least 290 millimetres is forged from a single piece of metal. The manufacturer checks the shaft thoroughly to make sure it is defect-free.

Cooling System

The principal fluid, water, is in motion through a water system that is external to the main system. The generator's internal air is moved by a fan mounted on the driving side of the generator's shaft.

Rotor

IEC 60034-14 specifies that a half key applied to the rotor's shaft extension achieves vibration grade A during dynamic balancing. The construction industry has produced a wide range of vibration-level structures. Which are always met by Marelli.

Bearing

Standard horizontal construction generators' bearings have a theoretical lifetime of more than 50,000 hours without radial and/or axial loads, as specified by ISO 281. On special order, L10h, a bearing's specified life duration, can go well over 100,000 hours.

ND end bearings can be insulated to prevent a current from flowing in reverse through the bearing surfaces. Insulated anti-friction bearings having a standard design.

Safety precautions

Specific marine-based materials are used. 

Epoxyvinyl, there must be at least 120 m of thickness.

Epoxivinilic refers to materials that take epoxy as their base but replace some of the original vinyl.

Polyacrylic is a polyurethane product that retains the original hydroxy acrylic resin's two components.

Certificates

A Marine Survey Certificate should be provided in addition to the equipment.

Marelli Motori is responsible for evaluating the ABS blueprint.

The shaft, housing, and exchanger have all been approved by the Marine Classification Society for use.

Overloads

For S1 continuous duty, the following excesses are allowed:

10% for 60 minutes, 15% for 10 minutes, 30% for 2, 50% for 1 minute.

These overloads should be rare, occurring no more than once per month, and should be followed by no more than one hour of normal load.

Parallel processes

Each generator with the paralleling device installed has a damper cage that is large enough to allow for operation in parallel with other generators. Upon inquiry, a power factor regulator is made available for use in parallel with the mains.

Transient operations are performed by all generators in compliance with maritime laws.

The voltage loss is within 15% when operating at 60% of the nominal load.

THD

All Class B Group 1 radio interference filters required by EN 55011 are standard on all generators.

With no load, the voltage waveform is perfectly sinusoidal, and the total harmonic distortion (THD) is less than 2%.

2. MJB

Most important uses are for emergencies, backup power, and the oil and gas industry.

Housing

Steel construction with a sturdy structure and robust welding (EN 10025 - S235 JR). The addition of side ribs gives the framework an extra strength boost.

Shield

Built using either gray cast iron (EN 1561) or spheroidal graphite cast iron (EN 1563) up to a 630 frame size.

Shaft

Constructed using carbon steel lamination (EN 10083 – 2 C40 – TN). A shaft having a diameter of at least 290 millimeters is forged from a single piece of metal. The manufacturer checks the shaft thoroughly to make sure it is defect-free.

Rotor

Prominent poles. consisting of copper wire that has been flattened. After applying a half key to the rotor's shaft extension and adjusting the vibration level to a normal vibration grade, as specified by IEC 60034-14, the rotor is considered dynamically balanced.

To begin with, there are unique vibration-level building options available.

Bearing

Anti-friction bearings are provided up to a size 800 in the frame. Sleeve bearings for frames up to 900 are provided. (may be found for smaller-sized frames).

D-end bearings come with a prelubricated inner bearing cover and grease nipple. There is a shield (2Z) around the ND-end bearing, but no way to generate pressure again.

ND end bearings can be insulated to prevent a current from flowing in reverse through the bearing surfaces.

Means of Insulation

The stator is an H-class with synthetic enamel insulation (generators with H >=800 or form wound from H >=400 must adhere to the class F standard). Class H may consider the BH technology as an alternative.

Safety precautions

Extraordinary care for oil and gas style generators. 

Poly(acrylic acid)-co(epoxy vinyl) ether. There must be at least 120 m of thickness.

Epoxy-vinyl acetate epoxy and Polyacrylic which is a polyurethane product that retains the original hydroxyl acrylic resin's two components.

Overloads

For S1 continuous duty, the following excesses are allowed:

10% for 60 minutes, 15% for 10 minutes, 30% for 2, 50% for 1 minute.

These overloads should be rare, occurring no more than once per month, and should be followed by no more than one hour of normal load.

Parallel processes

A large damper cage is standard on all generators, making them suitable for use in parallel with one another when coupled with a paralleling device. Upon inquiry, a power factor regulator is made available for use in parallel with the mains.

THD

All Class B Group 1 radio interference filters required by EN 55011 are standard on all generators.

With no load, the voltage waveform is perfectly sinusoidal, and the total harmonic distortion (THD) is less than 2%.

Standardization organization ISO 10816 has been met for vibration levels.

IEC 60034-14 governs the methods used to quantify vibration, evaluate it, and set limits on it.

3. MJHR

Most Important uses are in the cogeneration business that relies on gas and steam turbines.

Housing

Steel construction with a sturdy structure and robust welding (EN 10025 - S235 JR).

The addition of side ribs gives the framework an extra strength boost.

Shield

built using either grey cast iron (EN 1561) or spheroidal graphite cast iron (EN 1563) up to a 630 frame size.

Shaft

A shaft having a diameter of at least 290 millimeters is forged from a single piece of metal.

The manufacturer checks the shaft thoroughly to make sure it is defect-free.

A cylindrical shaft and two bearings power this generator.

Cooling System

The principal fluid, water, is in motion through a water system that is external to the system. The generator's internal air is moved by a fan mounted on the driving side of the generator's shaft.

Rotor

Windings are held in place by high-quality steel pass-through bars.

IEC 60034-14 specifies that a half key applied to the rotor's shaft extension achieves vibration grade A during dynamic balancing.

Constructions designed for lower levels of vibration are available.

Bearing

Standard horizontal construction generators' bearings have a theoretical lifetime of more than 50,000 hours without radial and/or axial loads, as specified by ISO 281. On special order, L10h, a bearing's specified life duration, can go well over 100,000 hours.

ND end bearings can be insulated to prevent a current from flowing in reverse through the bearing surfaces.

Means of Insulation

Stator is an F-class model insulated with synthetic enamel (class H option with BH technology).

In order to insulate the rotor properly, a synthetic material with an enamel coating is used.

Overloads

For S1 continuous duty, the following excesses are allowed:

10% for 60 minutes, 15% for 10 minutes, 30% for 2, 50% for 1 minute.

These overloads should be rare, occurring no more than once per month, and should be followed by no more than one hour of normal load.

Three-phase currents can short out

All generators with an overboosting mechanism installed are guaranteed to provide a short circuit current (Icc) in all three phases that is greater than three times the rated current (In): Icc > 300% In

THD

All Class B Group 1 radio interference filters required by EN 55011 are standard on all generators.

With no load, the voltage waveform is perfectly sinusoidal, and the total harmonic distortion (THD) is less than 2%.

Standardization organization ISO 10816 has been met for vibration levels.

IEC 60034-14 governs the methods used to quantify vibration, evaluate it, and set limits on it.

Optional parts

The generator and engine on the current baseframe are coupled via an insulated bearing, earthing brush, redundant rotating rectifier with 12 diodes, and elevated feet.

In frames 400–710, automatic power factor control can be supplied in an AVR.

Additional features like an excitation/overboosting PMG mounted on the generator, a sleeve bearing lubrication system, and diode failure monitoring can be added to the standard digital AVR MEC100D that comes standard with redundant AVR systems.

Final thoughts

Marelli have been established for over a hundred years in a very competitive market, which just goes to show what high quality equipment they make. 

About Tom Bell

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