ALTERNATORS

4886 en - 2011.12 / b

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LL 1500 - 4 POLES
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322 15
323 324

ALTERNATORS
Installation and maintenance
 Installation and maintenance 4886 en - 2011.12/ b

LL 1500 - 4 POLES
ALTERNATORS
This manual concerns the alternator which you have just purchased.

We wish to draw your attention to the contents of this maintenance manual.

SAFETY MEASURES WARNING SYMBOLS

Before using your machine for the first time, We wish to draw your attention to the
it is important to read the whole of this following 2 safety measures which must be
installation and maintenance manual. complied with:

All necessary operations and interventions a) During operation, do not allow anyone
on this machine must be performed by a to stand in front of the air outlet guards,
qualified technician. in case anything is ejected from them.

Our technical support service will be pleased b) Do not allow children younger than 14
to provide any additional information you to go near the air outlet guards.
may require.
A set of self-adhesive stickers depicting the
The various operations described in this various warning symbols is included with
manual are accompanied by recommenda- this maintenance manual. They should be
tions or symbols to alert the user to the positioned as shown in the drawing below
potential risk of accidents. It is vital that you once the machine has been fully installed.
understand and take notice of the different
warning symbols used.
WARNING
WARNING The alternators must not be put into
service until the machines in which they
are to be incorporated have been
Warning symbol for an operation capable declared compliant with Directives EC
of damaging or destroying the machine and plus any other directives that may be
or surrounding equipment. applicable.

Note: We reserve the right to modify the

characteristics of its products at any time in
order to incorporate the latest technological
developments. The informa-tion contained
Warning symbol for general danger to in this document may therefore be changed
personnel. without notice.

This document may not be reproduced in

any form without prior authorization.
All brands and models have been registered
and patents applied for.

Warning symbol for electrical danger to

personnel.

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LL 1500 - 4 POLES
ALTERNATORS

CONTENTS

1 - RECEIPT.............................................................................................................................4
1.1 - Standards and safety measures....................................................................................4
1.2 - Inspection......................................................................................................................4
1.3 - Identification.................................................................................................................. 4
1.4 - Storage.........................................................................................................................4
1.5 - Applications................................................................................................................... 4
1.6 - Contraindications to use................................................................................................4

2 - TECHNICAL CHARACTERISTICS.....................................................................................5
2.1 - Electrical characteristics................................................................................................5
2.2 - Mechanical characteristics............................................................................................5

3 - INSTALLATION................................................................................................................... 6
3.1 - Assembly.......................................................................................................................6
3.2 - Checks prior to first use.................................................................................................7
3.3 - Terminal connection diagrams.......................................................................................7
3.4 - Commissioning........................................................................................................... 10
3.5 - Setting up.................................................................................................................... 10

4 - SERVICING - MAINTENANCE.......................................................................................... 11
4.1 - Safety measures......................................................................................................... 11
4.2 - Routine maintenance.................................................................................................. 11
4.3 - Fault detection............................................................................................................. 11
4.4 - Mechanical defects.....................................................................................................12
4.5 - Electrical faults............................................................................................................ 12
4.6 - Dismantling, reassembly.............................................................................................14
4.7 - Installation & maintenance of the PMG.......................................................................16
4.8 - Table of characteristics................................................................................................16

5 - SPARE PARTS.................................................................................................................. 18
5.1 - First maintenance parts...............................................................................................18
5.2 - Technical support service............................................................................................18
5.3 - Exploded views, parts list and tightening torque..........................................................19

EC declaration of incorporation..........................................................................................21

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LL 1500 - 4 POLES
ALTERNATORS
1 - RECEIPT 1.4 - Storage
1.1 - Standards and safety Prior to commissioning, machines should
measures be stored :
- away from humidity (< 90%); after a long
Our alternators comply with most period of storage, check the machine
international standards. insulation (section 3.2.1). To prevent the
See the EC Declaration of Incorporation on bearings from becoming marked, do not
the last page. store in an environment with significant
vibration.
1.2 - Inspection
On receipt of your alternator, check that it 1.5 - Application
has not suffered any damage in transit. If These alternators are mainly designed to
there are obvious signs of knocks, contact produce electricity in the context of
the transporter (you may be able to claim applications involving the use of
on their insurance) and after a visual generators.
check, turn the machine by hand to detect
any malfunction. 1.6 - Contraindications to use
Use of the machine is restricted to operating
1.3 - Identification conditions (environment, speed, voltage,
The alternator is identified by means of a power, etc) compatible with the characteri-
nameplate fixed on the machine (see stics indicated on the nameplate.
drawing).
Make sure that the nameplate on the
machine conforms to your order.
1.3.1 - Nameplate
So that you can identify your machine
quickly and accurately, we suggest you
write its specifications on the nameplate
below.

A.C. SYNCHRONOUS GENERATOR

ISO 8528-3 IEC 60034-1 & 5 NEMA MG1-32 & 33

ref:1.024.990/a

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LL 1500 - 4 POLES
ALTERNATORS
2 - TECHNICAL CHARACTERISTICS - Greasable ball bearings
- Mounting arrangement
1.1 - Electrical characteristics
The LL 1500 alternator is generator without MD 35 :
sliprings and revolving field brushes, wound single bearing with standard feet and SAE
as “2/3 pitch”; 12-wire, with class H insulation flanges/coupling discs.
and a field excitation system available in B 34 :
either “SHUNT” or “AREP” or “PMG” two-bearing with SAE flange and standard
version. cylindrical shaft extension.
In order to conform to standard EN 61000- - Drip-proof machine, self-cooled
6.3, EN 61000-6.2, the R 791 interference 2.1.1 - Mechanical options
suppression kit is needed.
- Protection against harsh environmentsh.
2.1.1 - Electrical options - Air input filter, air output labyrinth cowling.
- Stator temperature detection probes. Alternators fitted with air inlet filters should
- Space heaters. be derated by 5% (power).
To prevent excessive temperature rise
2.2 - Mechanical characteristics caused by clogged filters, it is advisable to fit
- Steel frame the stator winding with thermal sensors
- End shields in cast iron (PTC).

MAIN FIELD
STATOR : 12 wires (T1 to T12 identification)
SHUNT version

EXCITER T1 T7 T2 T8 T3 T9
Varistor

Armature
Red Black
+ Field - T4 T10 T5 T11 T6 T12

R 220
6-
5+ Voltage reference

MAIN FIELD STATOR : 12 wires (T1 to T12 identification)

AREP version Aux. windings
T1 T7 T2 T8 T3 T9
EXCITER
Varistor

Armature
White Blue
Yellow

Green

T5 T11 T6 T12
Black

+ - T4 T10
Red

Field

R 438
5+ 6-
Voltage reference

MAIN FIELD
PMG version STATOR : 6 or 12 wires (T1 to T 12 identification)

EXCITER T1 T7 T2 T8 T3 T9
Varistor

PMG

Armature
5+ 6-

Field T4 T10 T5 T11 T6 T12

R 438 Voltage reference

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LL 1500 - 4 POLES
ALTERNATORS
3 - INSTALLATION
Personnel undertaking the various
operations indicated in this section must
wear personal protective equipment
appropriate for mechanical and electri-
cal hazards.

3.1 - Assembly WARNING

After handling the machine using the
lifting ring, snap on the plastic cover
provided in the maintenance manual
wallet.
All mechanical handling operations 3.1.2 - Coupling
must be undertaken using suitable
equipment and the machine must be 3.1.2.1 - Single-bearing alternator
horizontal. Check how much the machine Before coupling the machines, check that
weighs (see 4.8.5) before choosing the they are compatible by:
lifting tool. - undertaking a torsional analysis of the
During this operation, do not allow transmission,
anyone to stand under the load. - checking the dimensions of the flywheel
and its housing, the flange, coupling discs
and offset.
3.1.1 - Handling
The generously-sized lifting rings are for
WARNING
handling the alternator alone. They must not
be used to lift the genset. The choice of When coupling the alternator to the
lifting hooks or handles should be determined prime mover, do not use the fan to turn
by the shape of these rings. Choose a lifting the alternator or rotor.
system which respects the integrity and the The holes of the coupling discs should
environment of the machine. be aligned with the flywheel holes by
cranking the engine.
Make sure the machine is securely
bedded in position during coupling.
Check that there is lateral play on the
crankshaft.
3.1.2.2 - Double-bearing alternator
- Semi-flexible coupling
Careful alignment of the machines is
recommended, checking that the lack of
concentricity and parallelism of both parts
of the coupling do not exceed 0.1 mm.
This alternator has been balanced with a
1/2 key.
3.1.3 - Location
The room where the alternator is placed
must be ventilated to ensure that the
ambient temperature cannot exceed the
data on the nameplate.

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LL 1500 - 4 POLES
ALTERNATORS
3.2 - Checks prior to first use 3.3 - Terminal connection diagrams
3.2.1 - Electrical checks To modify the connection, change the
position of the stator cables on the terminals.

Under no circumstances should an

alternator, new or otherwise, be operated
if the insulation is less than 1 megohm Any intervention on the alternator
for the stator and 100,000 ohms for the terminals during reconnection or checks
other windings. should be performed with the machine
stopped.
There are 2 possible methods for restoring
the above minimum values. Under no circumstances must the
a) Dry out the machine for 24 hours in a terminal box internal connections be
drying oven at a temperature of 110 °C subjected to any stress due to the cables
(without the regulator). connected by the user.
b) Blow hot air into the air intake, having
made sure that the machine is rotating with
the exciter field disconnected.
Note : Prolonged standstill: In order to avoid
these problems, we recommend the use of
space heaters, as well as turning over the
machine from time to time. Space heaters
are only really effective if they are working
continuously while the machine is stopped.

WARNING
Ensure that the alternator has the
degree of protection matching the
defined environmental conditions.
3.2.2 - Mechanical checks
Before starting the machine for the first time,
check that:
- all fixing bolts and screws are tight,
- the cooling air is drawn in freely,
- the protective grilles and housing are cor-
rectly in place,
- the standard direction of rotation is clock-
wise as seen from the shaft end (phase
rotation in order 1 - 2 - 3).
For anti-clockwise rotation, swap 2 and 3.
- the winding connection corresponds to the
site operating voltage (see section 3.3).

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LL 1500 - 4 POLES
ALTERNATORS
Connection code L.L voltage Factory connection

A
L1(U) Winding 50 Hz 60 Hz T11 T5 T6

T12 N
3 phases
T1 T7
6 190 - 208 190 - 240
T10 T4
7 220 - 230 - T9 L3(W)
T4 T10 N
T3
T12 T5
8 - 190 - 208 T8 L2(V)
T9 T2
T11 R 220 voltage sensing: T2
T6 0 => (T8) / 110 V => (T11) T7 L1(U)
L2(V) R 438 voltage sensing:
L3(W) T3 T8
0 => (T3) / 220 V => (T2) T1 NDE

L1(U) Winding 50 Hz 60 Hz T11

D T1
T12 N
3 phases T4
6 380 - 415 380 - 480 T10
T7
7 440 - 460 - T9 L3(W)
N T6 T3
T10
T12 8 - 380 - 416 T8 L2(V)
T9
T11 T5 R 220 voltage sensing: T5 T2
T3 T6 T8 T2 0 => (T8) / 110 V => (T11) T7 L1(U)
R 438 voltage sensing:
L3(W) L2(V) T4 T1
0 => (T3) / 380 V => (T2) NDE

FF
Winding 50 Hz 60 Hz T11 T4
T7 M
1 phase 6 220 - 240 220 - 240
T3
T2 T6 T8 T12
7 250 - 260 - T9 L
T3 T10
T5 T11 T9
8 200 220 - 240 T8 T6
T1 T4 T7 T10
L L R 220 voltage sensing: T2
M
0 => (T1) / 110 V => (T4) T12 T5 L
R 438 voltage sensing:
Tension LM = 1/2 tension LL
0 => (T8) / 220 V => (T11) T1
LM voltage = 1/2 LL voltage NDE

L1(U) Winding 50 Hz 60 Hz T11

F
1 phase
T12 T1 6 220 - 240 220 - 240 T6 T3
or T9 L
3 phases
T4
T7 7 250 - 260 - T9 L3(W)
T6
T5
T3 T10 8 200 220 - 240 T8 T10 L2(V)
L3(W) L2(V) R 220 voltage sensing: T4 T2
T11 T8 T5 T2
L L 0 => (T8) / 110 V => (T11) L
M T7 T12 L1(U)
Tension LM = 1/2 tension LL R 438 voltage sensing:
LM voltage = 1/2 LL voltage T1
0 => (T3) / 220 V => (T2) NDE

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LL 1500 - 4 POLES
ALTERNATORS
Connection code L.L voltage Factory connection
L1(V) Winding 50 Hz 60 Hz T11 T5
B L
L3(W)
1 phase 6 110 - 120 120
T3
or T12 T1
3 phases T6 T7
7 120 - 130 - T9
T10
L
T9 T3
T4 8 - 110 - 120 T8 T4 L2(V)
T10 T12 T2
R 220 voltage sensing:
L3(W) T5 T2 L2(V) 0 => (T8) / 110 V => (T11) T7 T6 L1(U)
L L R 438 voltage sensing:
T11 T8 T1
0 => (T3) / 110 V => (T2) NDE

4-WIRE SINGLE-PHASE - type M or M1 DEDICATED WINDING

T3 T4
T1 T2 T3 T4
PARALLEL T1 T2
SERIAL
CONNECTION
CONNECTION M
L L L L
50/60 Hz voltage Output 50/60 Hz voltage Output
L-L L-M Connect L L M L-L L-M Connect L L M
220 110 110 -
230 115 T2 - T3 T1 T4 T2 - T3 115 - T1 - T3 T1-T3 T2 - T4 -
240 120 120 - T2 - T4

R 220 voltage sensing: 0 => (T1) / 110 V => (T2) R 220 voltage sensing: 0 => (T1) / 110 V => (T2)

3.3.1 - Option connection diagram

R 791 interference suppression kit Voltage potentiometer
Connections A D F B F/F G
Black T1 T1 T1 T1 T1 T2
Black T2 T2 T2 T2 T9 T4 ST4
Black T3 T3 T3 T3 T3 T3 10
5
20 0
Voltage adjustment
Blue N N
40 30

90 80

0
5 70 via remote potentiometer
White
60

Space heater PTC stator sensors

130C
103 blue wire
Ph1
101
150C
Ph2 black wire
102
Ph3 180C
104 red/white wire

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LL 1500 - 4 POLES
ALTERNATORS
3.3.2- Connection checks 3.4 - Commissioning

Electrical installations must comply with The machine can only be started up and
the current legislation in force in the used if the installation is in accordance
country of use. with the regulations and instructions
Check that: defined in this manual.
- The residual circuit-breaker conforms to The machine is tested and set up at the
legislation on protection of personnel, in factory. When first used with no load, make
force in the country of use, and has been sure that the drive speed is correct and
correctly installed on the alternator power stable (see the nameplate).
output as close as possible to the alternator. On application of the load, the machine
(In this case, disconnect the wire of the should achieve its rated speed and voltage;
interference suppression module linking the however, in the event of abnormal operation,
neutral). the machine setting can be altered (follow
- Any protection devices in place have not the adjustment procedure in section 3.5). If
been tripped. the machine still operates incorrectly, the
- If there is an external AVR, the connections cause of the malfunction must be located
between the alternator and the cabinet are (see section 4.4 and 4.5).
made in accordance with the connection
diagram. 3.5 - Setting up
- There is no short-circuit phase-phase or
phase-neutral between the alternator output
terminals and the generator set control
cabinet (part of the circuit not protected by
circuitbreakers or relays in the cabinet).
- The machine should be connected with the The various adjustments during tests
busbar separating the terminals as shown in must be made by a qualified engineer.
the terminal connection diagram. Ensure that the drive speed specified on
- The alternator earth terminal inside the the nameplate is reached before
terminal box is connected to the electrical commencing adjustment.
earth circuit. After operational testing, replace all
- The alternator earth terminal on the stator access panels or covers.
mounting foot is connected to the frame. The AVR is used to make any adjustments
to the machine.

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LL 1500 - 4 POLES
ALTERNATORS
4 - SERVICING - MAINTENANCE 4.2.3 - Electrical servicing
4.1 - Safety measures Commercially-available volatile degreasing
agents can be used.
Servicing or troubleshooting must be
carried out strictly in accordance with WARNING
instructions so as to avoid the risk of
accidents and to maintain the machine in Do not use: trichlorethylene, perchlo-
its original state. rethylene, trichloroethane or any alkaline
products.

All such operations performed on the These operations must be performed at a

alternator should be undertaken by cleaning station, equipped with a
personnel trained in the commissioning, vacuum system that collects and flushes
servicing and maintenance of electrical out the products used.
and mechanical components, who must The insulating components and the
wear personal protective equipment impregnation system are not at risk of
appropriate for mechanical and electrical damage from solvents. Avoid letting the
hazards. cleaning product run into the slots.
Apply the product with a brush, sponging
Before any intervention on the machine, frequently to avoid accumulation in the
ensure that it cannot be started by a manual housing. Dry the winding with a dry cloth. Let
or automatic system and that you have any traces evaporate before reassembling
understood the operating principles of the the machine.
system. 4.2.4 - Mechanical servicing

WARNING
Warning : During and after running, the Cleaning the machine using water or a
alternator will reach temperatures hot highpressure washer is strictly prohi-
enough to cause injury, such as burns. bited. Any problems arising from such
treatment are not covered by our
4.2 - Routine maintenance warranty.
4.2.1 - Checks after start-up Degreasing: Use a brush and detergent
After approximately 20 hours of operation, (suitable for paintwork).
check that all fixing screws on the machine Dusting: Use an air gun.
are still tight, plus the general state of the If the machine is fitted with air inlet and outlet
machine and the various electrical filters, the maintenance personnel should
connections in the installation. clean them routinely at regular intervals. In
the case of dry dust, the filter can be cleaned
4.2.2 - Bearings using compressed air and/or replaced if it is
The bearings are greased for life: clogged.
approximate life of the grease (depending After cleaning the alternator, it is essential to
on use) = 20,000 hours or 3 years. Monitor check the winding insulation (see sections
the temperature rise in the bearings, which 3.2 and 4.8).
should not exceed 90°C above the ambient 4.3 - Fault detection
temperature. Should this value be exceeded, If, when commissioned, the alternator does
the alternator must be stopped and checks not work normally, the source of the
carried out. malfunction must be identified (see sections
4.4 and 4.5).

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LL 1500 - 4 POLES
ALTERNATORS
4.4 - Mechanical defects
Fault Action
Excessive overheating of one or both bearings
- If the bearing has turned blue or if the grease has turned black, change the bearing.
(bearing temperature 80°C above the ambient
Bearing - Bearing not fully locked (abnormal play in the bearing cage)
temperature) (With or without abnormal bearing
- End shields incorrectly aligned
noise)
- Air flow (inlet-outlet) partially clogged or hot air is being recycled from the alternator or
Excessive overheating of alternator frame
Abnormal engine
(more than 40° C above the ambient
temperature - Alternator operating at too high a voltage (> 105% of Un on load)
temperature)
- Alternator overloaded
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibrations - Rotor balancing fault (Engine - Alternator)
Excessive vibration and humming noise - Phase imbalance
coming from the machine - Stator short-circuit
- System short-circuit
- Misparalleling
Possible consequences
Abnormal Alternator damaged by a significant impact, - Broken or damaged coupling
noise followed by humming and vibration - Broken or bent shaft end
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR, surge suppressor

4.5 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its voltage
is still correct when the battery is - Lack of residual magnetism
Connect a new battery of removed.
No voltage 4 to 12 volts to terminals The alternator builds up but its voltage - Check the connection of the voltage reference to the AVR
at no load on E- and E+, respecting does not reach the rated value when - Faulty diode
start-up the polarity, for 2 to 3 the battery is removed. - Armature short-circuit
seconds The alternator builds up but its - Faulty AVR
voltage disappears when the battery - Field windings open circuit (check winding)
is removed. - Main field winding open circuit (check the resistance)
Check the AVR connections (possible AVR failure)
- Field windings short-circuited
Correct speed - Faulty rotating diodes
Voltage too - Main field winding short-circuited
Check the drive speed
low - Check the resistance
Increase the drive speed (do not touch the AVR voltage pot. (P2)
Speed too low
before running at the correct speed)
Voltage too Adjust AVR voltage
Adjustment ineffective Faulty AVR
high potentiometer
- Check the speed : possibility of cyclic irregularity
Voltage Adjust AVR stability - Loose connections
oscillations potentiometer - Faulty AVR
- Speed too low when on load (bend of the LAM set too high)
Voltage Voltage between E+ and E–
- Check the speed
correct AREP < 6V - UDC < 10V
Run at no load and check
at no load - Faulty rotating diodes
the voltage between E+
and too low Voltage between E+ and E– - Short-circuit in the main field. Check the resistance.
et E- on the AVR
when on load SHUNT < 10V - UDC < 15V - Faulty exciter armature.
(*) - Too much static
(*) Warning : During single-phase operation, check that the sensing wires from the AVR are connected to the correct output terminals.
Voltage Check the AVR, the surge - Exciter winding open circuit
disappears suppressor, the rotating The voltage does not return to the - Faulty exciter armature
during diodes, and replace any rated value. - Faulty AVR
operation defective components - Main field open circuit or short-circuited
(**) Warning : The AVR internal protection may cut in (overload lost connection, short circuit).

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LL 1500 - 4 POLES
ALTERNATORS
4.5.1 - Checking the winding series with a rheostat of approximately
You can check the winding insulation by 50 ohms - 300 W and a diode on both exciter
performing a high voltage test. In this case, field wires (5+) and (6-).
you must disconnect all AVR wires.
ASSEMBLY A 6 - Exciter field 5 +
WARNING Rh. 50Ω -300W
Diode 1A
Damage caused to the AVR in such
conditions is not covered by our
+
warranty. -

4.5.2 - Checking the diode bridge

A diode in good working order should allow 12V battery
the current to flow only in the anode-to-
cathode direction.
Assembly B: Connect a “Variac” variable
+ - power supply and a diode bridge on both
Anode Cathode
+R
exciter field wires (5+) and (6-).
IN +R Both these systems should have
characteristics which are compatible with
IN IN
the field excitation power of the machine
IN -W (see the nameplate).
-W
3) Run the unit at its rated speed.

4) Gradually increase the exciter field

current by adjusting the rheostat or the
variac and measure the output voltages on
L1 - L2 - L3, checking the excitation voltage
and current at no load (see the machine
nameplate or ask for the factory test report).
When the output voltage is at its rated value
and balanced within 1% for the rated
excitation level, the machine is in good
4.5.3 - Checking the windings and
working order. The fault therefore comes
rotating diodes using separate from the AVR or its associated wiring (ie.
excitation sensing, auxiliary windings).

ASSEMBLY B
6 - Exciter field 5+
During this procedure, make sure that
+
the alternator is disconnected from any
50 60
40
30

external load and inspect the terminal

70

Diode 1A
20

80

box to check that the connections are

10

90

fully tightened.
0 100

- DC
1) Stop the unit, disconnect and isolate the Variac AC 12V
220V
AVR wires.
2) There are two ways of creating an
assembly with separate excitation.
Assembly A: Connect a 12 V battery in

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LL 1500 - 4 POLES
ALTERNATORS
4.6 - Dismantling, reassembly 4.6.3 - Access to connections and the
regulation system
WARNING The terminals and AVR are accessed
During the warranty period, this directly by removing the terminal box lid
operation should only be carried out in [372].
an approved workshop or in our factory, AVR is accessed directly by removing the
otherwise the warranty may be inva- terminal box lid
lidated.
Whilst being handled, the machine 4.6.4 - Accessing, checking and
should remain horizontal (rotor not replacing the diode bridge
locked in position). Check how much the
4.6.4.1 - Dismantling
alternator weighs (see section 4.8.5)
- Remove the terminal box lid [372].
before choosing the lifting method.
- Cut the fixing clamps of the exciter cables,
disconnect E+, E- from the exciter.
- Remove the 4 nuts on the tie rods.
- Remove the NDE shield [36] using a puller:
eg. U.32 - 350 (Facom).
- Unsolder the connections.
- Check the bridge using an ohmmeter or a
battery lamp (see section 4.5.2).

4.6.4.2 - Reassembly
- Replace the bridges, respecting the
polarity (see section 4.5.1).
- Resolder the connections.
- Fit a new O ring seal in the shield.
- Refit the NDE shield and pass the bundle
of wires between the top bars of the shield.
- Replace the fixing clamps on the cables.
4.6.1 - Tools required
- Replace the terminal box lid [372].
To fully dismantle the machine, we
recommend using the tools listed below:
- 1 ratchet spanner + extension
- 1 torque wrench NDE shield
- 1 set of flat spanners: 8 mm, 10 mm, 12 mm Rotor
- 1 socket set: 8, 10, 13 mm
M10 threaded rod
- 1 socket TORX bit T20, T30
- 1 puller (eg. Facom: U35, U32/350)
4.6.2 -Screw tightening torque
See section 5.3.

The screws for fixing the feet on the

housing and immobilising the stator
must not be removed (bolt of the stator
lower).

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LL 1500 - 4 POLES
ALTERNATORS
4.6.5 - Replacing the NDE bearing on 4.6.7 - Accessing the main field and
single-bearing machines stator
4.6.5.1 - Dismantling 4.6.7.1 - Dismantling
- Remove the NDE shield [36] (see section Follow the procedure for dismantling
4.6.4.1). bearings (see sections 4.6.6)
- Remove the ball bearing [70] using a screw - Remove the coupling discs (single-bearing
puller. alternator) or the DE flange (two-bearing
alternator) and insert a tube of the
corresponding diameter on the shaft end or
a support made according the following
bellow.

4.6.5.2 - Reassembly
- Heat the inner slipring of a new bearing by
induction or in a drying oven at 80 °C (do not
use an oil bath) and fit it to the alternator.
- Place the preloading wavy washer [79] in
the flange and fit a new O ring seal [349].
- Replace the NDE bracket [36] (see section
4.6.4.2).
4.6.6 - Replacing the bearings on a
- Rest the rotor on one of its poles, then slide
two-bearing alternator it out. Use the tube as a lever arm to assist
4.6.6.1 - Dismantling dismantling.
- Uncouple the alternator from the prime - After extracting the rotor, be careful not to
mover. damage the fan and place the revolving field
- Remove the 4 assembly screws. on special V-blocks.
- Remove the DE flange [30]. It is necessary to replace the fan in case of
- Remove the NDE bracket (see section disassembling.
4.6.4.1).
- Remove both bearings [60] and [70] using NOTE: If intervention is required on the
a puller. main field (rewinding, replacement of
4.6.6.2 - Reassembly components), the rotor assembly must
- Fit new bearings after heating them by be rebalanced.
induction or in a drying oven at 80 °C (do not
use an oil bath). 4.6.7.2 - Reassembly
- Check that both the preloading wavy - Follow the dismantling procedure in
washer [79] and new O ring seal have been reverse order.
fitted [349] on the NDE bracket [36]. Take care not to knock the windings when
- Replace the DE flange [30], and tighten the refitting the rotor in the stator.
4 fixing screws. If you replace the fan, respect the assembly
- Check that the whole alternator is correctly guide according the following bellow. Use a
assembled and that all screws are fully tube and a screw.
tightened.

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LL 1500 - 4 POLES
ALTERNATORS

Field excitation current i exc (A)

400V - 50 Hz
“i exc”: excitation current of the exciter field
LL 1500 No load At rated load
B 0.54 1.76
D 0.54 1.88
F 0.55 1.81
J 0.56 1.85
Follow the procedure for reassembling the L 0.56 1.84
bearings (see section 4.6.6). N 0.57 1.87
P 0.57 1.83
4.7 - Installation and maintenance of
the PMG 4.8.2 - Three-phase: 4-pole, AREP
For the LL 1500, the PMG reference is excitation
PMG 0. See the PMG maintenance manual,
ref: 4853. Resistances at 20 °C (Ω)

4.8 - Table of characteristics LL 1500 L/N stator Rotor Field coil Armature
Table of average values: B 0.28 0.60 7.35 0.19
Alternator - 4 pole - 50 Hz/60 Hz - Winding D 0.26 0.62 7.35 0.19
no. 6 and M or M1 connected in dedicated F 0.22 0.67 7.35 0.19
single-phase (400 V for the excitation J 0.16 0.78 7.35 0.19
L 0.135 0.84 7.35 0.19
values).
N 0.115 0.87 7.35 0.19
The voltage and current values are given for
P 0.095 0.95 7.35 0.19
no-load operation and operation at rated
load with separate field excitation. All values
are given to ± 10% (for exact values, consult Resistance of auxiliary windings at
the test report) and are subject to change 20 °C (Ω)
without prior warning. For 60 Hz operation, LL 1500 X1, X2 auxil. wdgs Z1, Z2 auxil. wdgs
the resistance values are the same and the B 0.403 0.454
excitation current “i exc” is approximately 5 D 0.398 0.475
to 10% weaker. F 0.402 0.517
4.8.1 - Three-phase: 4-pole, SHUNT J 0.335 0.458
excitation L 0.307 0.426
Resistances at 20 °C (Ω) N 0.319 0.447
P 0.313 0.433
LL 1500 L/N stator Rotor Field coil Armature
B 0.28 0.60 17.6 0.19
D 0.26 0.62 17.6 0.19
F 0.22 0.67 17.6 0.19
J 0.16 0.78 17.6 0.19
L 0.135 0.84 17.6 0.19
N 0.115 0.87 17.6 0.19
P 0.095 0.95 17.6 0.19

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LL 1500 - 4 POLES
ALTERNATORS
Field excitation current i exc (A) 4.8.4 - Dedicated single-phase M1:
400V - 50 Hz 4-pole, SHUNT excitation - 60 Hz
“i exc”: excitation current of the exciter field
Resistances at 20 °C (Ω)
LL 1500 No load At rated load LL 1500 L/N stator Rotor Field coil Armature
B 0.84 2.60 B 0.105 0.6 17.6 0.19
D 0.84 2.70 D 0.095 0.62 17.6 0.19
F 0.84 2.80 F 0.075 0.67 17.6 0.19
J 0.86 2.85 J 0.060 0.78 17.6 0.19
L 0.86 2.85 L 0.052 0.84 17.6 0.19
N 0.87 2.86 N 0.043 0.87 17.6 0.19
P 0.87 2.90 P 0.036 0.95 17.6 0.19

4.8.3 - Dedicated single-phase M: Field excitation current i exc (A)

4-pole, SHUNT excitation - 50 Hz 240V - 60 Hz (M1 winding)
“i exc”: excitation current of the exciter field
Resistances at 20 °C (Ω)
LL 1500 No load At rated load
LL 1500 L/N stator Rotor Field coil Armature
B 0.52 1.29
B 0.145 0.6 17.6 0.19
D 0.51 1.33
D 0.130 0.62 17.6 0.19
F 0.52 1.27
F 0.107 0.67 17.6 0.19
J 0.44 1.19
J 0.076 0.78 17.6 0.19
L 0.43 1.18
L 0.068 0.84 17.6 0.19
N 0.47 1.30
N 0.057 0.87 17.6 0.19
P 0.49 1.25
P 0.047 0.95 17.6 0.19

Field excitation current i exc (A) 4.8.5 - Table of weights

230V - 50 Hz (M winding) (values given for information only)
“i exc”: excitation current of the exciter field
LL 1500 Total weight (kg) Rotor (kg)
LL 1500 No load At rated load B 125 47
B 0.55 1.31 D 130 49
D 0.52 1.31 F 140 53
F 0.51 1.22 J 165 63
J 0.48 1.16 L 180 69
L 0.46 1.15 N 185 72
N 0.50 1.21 P 215 75
P 0.50 1.29

After operational testing, it is essential to

replace all access panels or covers.

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LL 1500 - 4 POLES
ALTERNATORS
5 - SPARE PARTS 5.2 - Technical support service
5.1 - First maintenance parts Our technical support service will be pleased
Emergency repair kits are available as an to provide any additional information you
option. may require.
They contain the following items: When ordering spare parts, you should
Emergency kit SHUNT ALT 423 KS 001 indicate the complete machine type, its
serial number and the information given on
AVR R 220 -
the nameplate.
Diode bridge assembly -
Emergency kit AREP ALT 423 KS 002 Address your enquiry to your usual contact.
AVR R 438 - Part numbers should be identified from the
Diode bridge assembly - exploded views and their description from
Single-bearing kit ALT 423 KB 001 the parts list.
Our extensive network of service centres
Non drive end bearing - can dispatch the necessary parts without
«O» ring - delay.
Preloading (wavy)
- To ensure correct operation and the safety
washer
of our machines, we recommend the use of
Double-bearing kit ALT 423 KB 002 original manufacturer spare parts.
In the event of failure to comply with this
Non drive end bearing -
advice, the manufacturer cannot be held
Drive end bearing - responsible for any damage.
«O» ring -
Preloading (wavy)
-
washer

After operational testing, it is essential to

replace all access panels or covers.

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LL 1500 - 4 POLES
ALTERNATORS
5.3 - Exploded view, parts list and tightening torque
5.3.1 - Single bearing, AREP or SHUNT

53
36
90
383

378

382

91 79
349
70
100 37
28
1
3434
372

373

384

377

381
49

376
40

33
30
15
322
324
323

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LL 1500 - 4 POLES
ALTERNATORS

Screw Torque Screw Torque

Ref. Qty Description Ref. Qty Description
Ø N.m Ø N.m
1 1 Stator assembly - - 322 1 Coupling disc - -
4 1 Rotor assembly - - 323 6 Fixing screw M10 66
15 1 Fan M5 4 324 1 Clamping washer - -
28 1 Earth terminal - - 343 2 Direct diode assembly M5 4
30 1 DE flange - - 349 1 O ring seal - -
33 1 Air outlet grille M5 4 372 1 Top cover + insulation - -
36 1 N.D.E. bracket - - 373 1 Cowling - -
37 4 Tie rod M10 34 376 1 Terminal block - -
Crescent on casing
40 1 Plastic cover - - 377 1 - -
side
Crescent on shield
49 - Terminal box screw M5 3.6 ±0.4 378 1 - -
side
53 1 Plug - - 381 1 Seal on casing side - -
70 1 NDE bearing - - 382 1 Seal on shield side - -
Preloading wavy Right-hand cowling
79 1 - - 383 1 - -
washer support
Left-hand cowling
90 1 Wound exciter field - - 384 1 - -
support
91 4 Field fixing screw M6 10 410 1 DE shield - -
100 1 Exciter armature - - 411 12 Fixing screw M10 40

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LL 1500 - 4 POLES
ALTERNATORS

Electric Power Generation Division

Declaration of CE compliance and incorporation (1/2)

This Declaration applies to the generators designed to be incorporated into machines complying with the
Machinery Directive Nr 2006/42/CE dated 17 May 2006.

MOTEURS LEROY-SOMER MLS HOLICE STLO.SRO MOTEURS LEROY-SOMER

Boulevard Marcellin Leroy SLADKOVSKEHO 43 1, rue de la Burelle
16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517
France Czech Republic 45800 St Jean de Braye
France

Declares hereby that the electric generators of the ranges “PARTNER”, Industrial and Professional, as well as
their derivatives, manufactured by Leroy Somer or on Leroy Somer's behalf, comply with the following
International Standards and Directive :

- EN and IEC 60034 -1 and 60034 -5

- ISO 8528 – 3 “ Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets ”
- Low Voltage Directive Nr 2006/95/CE dated 12 December 2006.

Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Directives :

- Machinery Directive Nr 2006/42/CE dated 17 May 2006

- EMC Directive Nr 2004/108/CE dated 15 December 2004, as intrinsic levels of emissions and
immunity are concerned

WARNING :

The here above mentioned generators should not be commissioned until the corresponding Gen-Sets have
been declared in compliance with the Directives Nr 2006/42/CE et 2004/108/CE, as well as with the other
relevant Directives.

Leroy Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant information on
the generator.

Technical Managers
P Betge – J.Begué



4840 en – 2011.08 / a

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LL 1500 - 4 POLES
ALTERNATORS

Electric Power Generation Division

Declaration of CE compliance and incorporation (2/2)

The declaration here above, page ½, applies for the generators which serial numbers are above the following
list, according to the part of the range they are belonging :

LL / LC 1000 : 244650
LL / LC 1100 : 261869
LL / LC 1500 : 269124
LL / LC 2000 : 244394
LL / LC 3000 : 244402
LL / LC 5000 : 244334
LL / LC 6100 : 244381
LL / LC 7000 : 244381
LL 8200 / 1400 : 244838
LL 9100 / 1600 : 603294/004
LL 9200 : 603653

4840 en – 08.2011 / a

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LL 1500 - 4 POLES
ALTERNATORS

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