User's guide and maintenance manual

LEROY SOMER

ALTERNATOR

43-2 & 44-2

SHUNT & AREP & PMG

3434.en/g
33522059401_4_1
06/2007
 3434 en - 06.2007 / g

198
124
207
120

44.2 coupling

gi v en
o b e
n u a l i s t s er
ma du
T hi s o t he e n
t

1
28
37
4
15
30
33
320
325
322
324
323
P

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
Installation and maintenance
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS

This manual concerns the alternator which We wish to draw your attention to the contents
you have just purchased. of this maintenance manual. By following
certain important points during installation,
The latest addition to a whole new generation use and servicing of your alternator, you can
of alternators, this range benefits from the look forward to many years of trouble-free
experience of the world’s leading operation.
manufacturer, using advanced technology and
incorporating strict quality control.

SAFETY MEASURES WARNING SYMBOLS

Before using your machine for the first time, it is important to A set of self-adhesive stickers depicting the various warning
read the whole of this installation and maintenance manual. symbols is included with this maintenance manual. They
should be positioned as shown in the drawing below once the
All necessary operations and interventions on this machine machine has been fully installed.
must be performed by a qualified technician.

Our technical support service will be pleased to provide any

additional information you may require.

The various operations described in this manual are

accompanied by recommendations or symbols to alert the
user to potential risk of accident. It is vital that you understand
and take notice of the different warning symbols used.

CAUTION

Warning symbol for an operation capable of damaging or

destroying the machine or surrounding equipment.

Warning symbol for general danger to personnel.

Warning symbol for electrical danger to personnel.

Copyright 2004: MOTEURS LEROY-SOMER

Note: LEROY-SOMER reserves the right to modify the
This document is the property of:
characteristics of its products at any time in order to
MOTEURS LEROY-SOMER
incorporate the latest technological developments. The
It may not be reproduced in any form without prior
information contained in this document may therefore be
authorization.
changed without notice.
All brands and models have been registered and patents
applied for.

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 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
CONTENTS

1 - RECEIPT 4 - SERVICING - MAINTENANCE

1.1 - Standards and safety measures ....................4 4.1 - Safety measures ......................................... 10

1.2 - Inspection.......................................................4 4.2 - Regular maintenance.................................. 10

1.3 - Identification...................................................4 4.3 - Fault detection ............................................ 10

1.4 - Storage ..........................................................4 4.4 - Mechanical defects ..................................... 11

4.5 - Electrical faults............................................ 11

2 - TECHNICAL CHARACTERISTICS 4.6 - Dismantling, reassembly............................. 13

2.1 - Electrical characteristics ................................5 4.7 - Installation and maintenance of the PMG ... 14

2.2 - Mechanical characteristics.............................5 4.8 - Table of characteristics ............................... 15

3 - INSTALLATION - COMMISSIONING
5 - SPARE PARTS
3.1 - Assembly .......................................................6
5.1 - First maintenance parts .............................. 17
3.2 - Inspection prior to first use.............................6
5.2 - Bearing designations .................................. 17
3.3 - Terminal connection diagrams.......................7
5.3 - Technical support service ........................... 17
3.4 - Commissioning ..............................................9
5.4 - Exploded view, parts list ............................. 18
3.5 - Settings ..........................................................9

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
RECEIPT

1 - RECEIPT 1.3 - Identification

The alternator is identified by means of a nameplate glued to
1.1 - Standards and safety measures the frame.
Make sure that the nameplate on the machine conforms to
Our alternators comply with most international standards and your order.
are compatible with: The machine name is defined according to various criteria
- the recommendations of the (see below).
International Electrotechnical Commission Example of description: LSA 43.2 M45 J6/4
IEC 34-1, (EN 60034) • LSA: Name used in the PARTNER range
- the recommendations of the • M: Marine
International Standards Organisation ISO 8528 • C: Cogeneration
- the European Community directive 89/336/EEC on • T: Telecommunications
Electromagnetic Compatibility (EMC) • 43.2: Machine type
- the European Community directives • M45: Model
73/23/EEC and 93/68/EEC (Low Voltage Directive) • J: Excitation system (C: AREP/J: SHUNT or PMG/
They are CE marked with regard to the LVD (Low Voltage E: COMPOUND)
Directive) in their role as a machine component. A declaration • 6/4: Winding number/number of poles
of incorporation can be supplied on request.
Before using your generator for the first time, read carefully Nameplate
the contents of this installation and maintenance manual, So that you can identify your machine quickly and accurately,
supplied with the machine. All operations performed on the we suggest you fill in its specifications on the nameplate
generator should be undertaken by qualified personnel below.
trained in the commissioning, servicing and maintenance of
electrical and mechanical components. This maintenance
manual should be retained for the whole of the machine's life 1.4 - Storage
and be handed over with the contractual file. Prior to commissioning, machines should not be stored in
The various operations described in this manual are humid conditions: at relative humidity levels greater than
accompanied by recommendations or symbols to alert the 90%, the machine insulation can drop very rapidly, to just
user to potential risks of accidents. It is vital that you above zero at around 100%. The state of the anti-rust
understand and take notice of the different warning symbols protection on unpainted parts should be monitored.
used. For storage over an extended period, the machine can be
placed in a sealed enclosure (heatshrunk plastic for example)
1.2 - Inspection with dehydrating sachets inside, away from significant and
frequent variations in temperature to avoid the risk of
On receipt of your alternator, check that it has not suffered condensation during storage.
any damage in transit. If there are obvious signs of knocks, If the area is affected by vibration, try to reduce the effect of
contact the transporter (you may able to claim on their these vibrations by placing the generator on a damper
insurance) and after a visual check, turn the machine by hand support (rubber disc or similar) and turn the rotor a fraction of
to detect any malfunction. a turn once a fortnight to avoid marking the bearing rings.

ALTERNATEURS ALTERNATORS
LSA Date PUISSANCE / RATING
Made by Leroy Somer - 1 024 930/b

Tension
N Hz Voltage
V
Min-1/R.P.M. Protection Ph.
Cos Ø /P.F. Cl. ther. / Th. class Connex.
Régulateur/A.V.R.
Continue kVA
Altit. m Masse / Weight
Continuous kW
Rlt AV/D.E bearing
40C A
Rlt AR/N.D.E bearing
Graisse / Grease Secours kVA
Std by
Valeurs excit / Excit. values kW
en charge / full load 27C A
à vide / at no load

LR 0021 Conforme à C.E.I 34-1(1994). According to I.E.C 34-1(1994).

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
TECHNICAL CHARACTERISTICS

2 - TECHNICAL 2.2 - Mechanical characteristics

CHARACTERISTICS - Steel frame
- Cast iron end shields
2.1 - Electrical characteristics - Protected ball bearings, greased for life
- Mounting arrangements:
PARTNER LSA 43.2/44.2 alternators are machines without IM 1201 (MD 35) foot and flange mounted, single-bearing
sliprings or revolving field brushes, wound as "2/3 pitch", with SAE coupling disc.
12-wire; the insulation is class H and the field excitation IM 1001 (B 34) double-bearing with SAE flange and standard
system is available in either "SHUNT", "AREP" or "PMG" cylindrical shaft extension.
versions (see AVR manual). - Drip-proof machine, self-cooled
- Degree of protection: IP 23
2.1.1 - Options
2.2.1 - Mechanical options
- Stator temperature detection probes
- Space heaters - Air inlet filter
Interference suppression conforms to standard EN 55011, - Regreasable ball bearings
group 1, class B. (Europe). - IP 44 protection

2.1.2 - SHUNT system with R 250 AVR

Other version R 251 AVR for dedicated single-phase or R 448 for additional function
MAIN FIELD STATOR : 12 wires (marked T1 to T12)
Exciter
T1 T7 T2 T8 T3 T9
Armature
Varistor

5+
Field 6–
T4 T10 T5 T11 T6 T12
SERIES connection
R 250 Power supply and voltage reference

2.1.3 - AREP system with R 438 AVR

MAIN FIELD STATOR : 12 wires (marked T1 to T12)
Exciter Auxiliary windings
T1 T7 T2 T8 T3 T9
Armature
Varistor

Field
5+ 6–
T5 T11 T6 T12
Yellow

T4 T10
Green

Black
Red

PARALLEL
connection

R 438 Voltage reference

2.1.4 - PMG system with R 438 AVR

MAIN FIELD STATOR : 12 wires (marked T1 to T12)
Exciter
T1 T7 T2 T8 T3 T9
Armature
Varistor

PMG

Field
5+ 6–
T4 T10 T5 T11 T6 T12
PARALLEL
connection

R 438 Voltage reference

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
INSTALLATION

3 - INSTALLATION 3.1.2.2 - Two-bearing alternator

- Semi-flexible coupling
3.1 - Assembly Careful alignment of the machines is recommended,
checking that the concentricity and parallelism of both parts of
the coupling does not exceed 0.1 mm.

CAUTION
All mechanical handling operations must be undertaken
using approved equipment. This alternator has been balanced with a half-key.
Whilst being handled, the machine should remain
horizontal. 3.1.3 - Location
Ensure that the ambient temperature in the room where the
3.1.1 - Handling alternator is placed cannot exceed 40 °C for standard power
The generously-sized lifting rings are for handling the ratings (for temperatures > 40 °C, apply a derating
alternator alone. They must not be used to lift the genset. coefficient). Fresh air, free from damp and dust, must be able
Choose a lifting system which respects the positioning of the to circulate freely around the air intake grilles on the opposite
rings. side from the coupling. It is essential to prevent not only the
recycling of hot air from the machine or engine, but also
exhaust fumes.

3.2 - Inspection prior to first

use
3.2.1 - Electrical checks

Under no circumstances should an alternator, new or

otherwise, be operated if the insulation is less than
1 megohm for the stator and 100,000 ohms for the other
windings.
There are three possible methods for restoring the above
minimum values.
a) Dry out the machine for 24 hours in a drying oven at a
temperature of approximately 110 °C (without the AVR).
b) Blow hot air into the air inlet, having made sure that the
machine is rotating with the exciter field disconnected.
c) Run in short-circuit mode (disconnect the AVR):
- Short-circuit the three output terminals (power) using
3.1.2 - Coupling connections capable of supporting the rated current (try not to
exceed 6 A/ mm2)
3.1.2.1 - Single-bearing alternator
- Insert a clamp ammeter to monitor the current passing
Before coupling the two machines, check that both are
through the short-circuit connections
compatible by:
- Connect a 48 Volt battery in series with a rheostat of
- undertaking a torsional analysis of the transmission on both
approximately 10 ohms (50 W) to the exciter field terminals,
units
respecting the polarity
- checking the dimensions of the flywheel and its housing, the
- Open all the alternator openings fully
flange, coupling discs and offset
- Run the alternator at its rated speed, and adjust the exciter
field current using the rheostat to obtain the rated output
CAUTION current in the short-circuit connections
Note: Prolonged standstill: In order to avoid these problems,
When coupling the alternator to the prime mover, the we recommend the use of space heaters, as well as turning
holes of the coupling discs should be aligned with the over the machine from time to time. Space heaters are only
flywheel holes by cranking the engine. really effective if they are working continuously while the
Do not use the alternator fan to turn the rotor. machine is stopped.
Tighten the coupling disc screws to the recommended torque
(see section 4.6.2) and check that there is lateral play on the
crankshaft.

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
INSTALLATION

3.2.2 - Mechanical checks 3.3 - Terminal connection diagrams

Before starting the machine for the first time, check that: To modify the connection, change the position of the terminal
- the fixing bolts on the feet are tight cables. The winding code is specified on the nameplate.
- the cooling air is drawn in freely
- the protective grilles and housing are correctly in place
- the standard direction of rotation is clockwise as seen from
the shaft end (phase rotation in order 1-2-3). For anti-
clockwise rotation, swap 2 and 3.
Any intervention on the alternator terminals during
- the winding connection corresponds to the site operating
reconnection or checks should be performed with the
voltage (see section 3.3)
machine stopped.

Connection codes L.L voltage Factory connection

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

T1 T7 T12 N
3 phases 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 250 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 AR

D T1 L1(U) Winding 50 Hz 60 Hz T11

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 250 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
0 => (T3) / 380 V => (T2) T1
AR

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 250 voltage sensing: T2
M
0 => (T1) / 110 V => (T4) T12 T5
R 438 voltage sensing:
LM voltage = 1/2 LL voltage
0 => (T10) / 220 V => (T1) T1
AR

L1(U) Winding 50 Hz 60 Hz T11

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

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
INSTALLATION

Connection codes 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 250 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) AR

FOR LSA 44.2, THE COUPLING B IS NOT POSSIBLE

Connection not Winding 50 Hz 60 Hz T11 T5

G recommended
6 T10 M
1 PH 220 - 240 220 - 240
T4
T6 T1 M
T12
T7 7 250 - 260 - T9 L
T4 T3
T3
T10
T2 8 200 220 - 240 T8 L
T9 T5
L
R 250 voltage sensing: T12 T2
L T11 T8 0 => (T8) / 110 V => (T11) T7 T6
R 438 voltage sensing:
LM voltage = 1/2 LL voltage 0 => (T3) / 220 V => (T2) T1 AR

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

SERIAL CONNECTION PARALLEL CONNECTION (Not possible with LSA 44.2)
T3 T4
T1 T2 T3 T4
T1 T2

M
L L L L
Voltage 50/60 Hz Output Voltage 50/60 Hz Output
L-L L-M Link L L M L-L L-M Link 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 251 voltage sensing: 0 => (T1) / 110 V => (T2) R 251 voltage sensing: 0 => (T1) / 110 V => (T2)

3.3.1 - Exciter field connection

Series connection (shunt excitation) Parallel connection (AREP or PMG excitation)
White White
Blue Blue

– – Black – – Black

5+ 5+
6- 6-
6– 6–
+ + Red R 250 + + Red R 438

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
INSTALLATION

3.3.2 - Option connection diagram

R 791 T interference suppression kit (standard for CE marking) 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 Voltage adjustment
Blue N N by remote potentiometer
White

Anti condensation heater Thermistor (PTC) temperature

130 C
103 blue
Ph1
101 150C
Ph2 black
102
Ph3 180 C
LSA 43.2, 44.2 104 red/white

3.3.3 - Connection checks 3.4 - Commissioning

Electrical installations must comply with the current The machine can only be started up and used if the
legislation in force in the country of use. installation is in accordance with the regulations and
Check that: instructions defined in this manual.
- The residual circuit-breaker complies with legislation on The machine is tested and set at the factory. When first used
protection of personnel in force in the country of use, and has with no load, make sure that the drive speed is correct and
been correctly installed on the alternator power output as stable (see the nameplate). On application of the load, the
close as possible to the alternator. (In this case, disconnect machine should achieve its rated speed and voltage;
the blue wire of the R 791 interference suppression module however, in the event of abnormal operation, the machine
linking the neutral) setting can be altered (follow the adjustment procedure: see
- Any protective devices in place have not tripped section 3.5). If the machine still operates incorrectly, the
- If there is an external AVR, the connections between the cause of the malfunction must be located (see section 4.4).
alternator and the cubicle are made in accordance with the
connection diagram
- There is no short-circuit between phase or phase-neutral 3.5 - Setting up
between the alternator output terminals and the generator set
control cabinet (part of the circuit not protected by circuit-
breakers or cubicle relays)
- The machine has been connected with the busbar
separating the terminals as shown in the terminal connection The various adjustments during tests must be made by a
diagram qualified engineer. Take care that the drive speed
specified on the nameplate is reached before
commencing adjustment. After operational testing,
replace all access panels or covers.
The AVR is used to make any adjustments to the
machine.

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

4 - SERVICING / MAINTENANCE - Ciclohexare (non toxic); inflammable

4.1 - Safety measures Cleaning of the stator, rotor, exciter and diode bridge

The insulating components and the impregnation system are

not at risk of damage from solvents (see the list of authorized
products).
Avoid letting the cleaning product run into the slots. Apply the
Servicing or troubleshooting must be carried out strictly product with a brush, sponging frequently to avoid
in accordance with instructions so as to avoid the risk of accumulation in the housing. Dry the winding with a dry cloth.
accidents and to maintain the machine in its original Let any traces evaporate before reassembling the machine.
state.
4.2.5 - Mechanical servicing

CAUTION
All such operations performed on the alternator should
be undertaken by personnel trained in the Cleaning the machine using a water spray or a
commissioning, servicing and maintenance of electrical high-pressure washer is strictly prohibited.
and mechanical components. Any problems arising from such treatment are not
Before any intervention on the machine, ensure that it cannot covered by our warranty.
be started by a manual or automatic system and that you The machine should be cleaned with a degreasing agent,
have understood the operating principles of the system. applied using a brush. Check that the degreasing agent will
not affect the paint.
Compressed air should used to remove any dust.
4.2 - Regular maintenance If filters have been added to the machine after manufacture
4.2.1 - Checks after start-up and do not have thermal protection, the service personnel
should clean the air filters periodically and systematically, as
After approximately 20 hours of operation, check that all fixing often as necessary (every day in very dusty atmospheres).
screws on the machine are still tight, plus the general state of Cleaning can be performed using water for dry dust or in a
the machine and the various electrical connections in the bath containing soap or detergent in the case of greasy dust.
installation. Petrol or chloroethylene can also be used.
After cleaning the alternator, it is essential to check the
4.2.2 - Cooling circuit winding insulation (see sections 3.2 and 4.8).
It is advisable to check that circulation of air is not reduced by
partial blocking of the air intake and outlet grilles: mud, fibre, 4.3 - Fault detection
grease, etc. If, when commissioned, the alternator does not work
normally, the source of the malfunction must be identified.
4.2.3 - Bearings To do this, check that:
The bearings are permanently greased: approximate life of - the protective devices are fitted correctly
the grease (depending on use) = 20,000 hours or 3 years. - the connections comply with the diagrams in the manuals
Monitor the temperature rise in the bearings, which must not supplied with the machine
exceed 60 °C above the ambient temperature. Should this - the speed of the unit is correct (see section 1.3)
value be exceeded, the machine must be stopped and checks Repeat the operations defined in section 3
carried out.

4.2.4 - Electrical servicing

Cleaning product for the windings

CAUTION

Do not use: trichlorethylene, perchlorethylene,

trichloroethane or any alkaline products.

Certain strictly defined pure volatile degreasing agents can be

used, such as:
- Normal petrol (without additives); inflammable
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

4.4 - Mechanical defects

Fault Action
Excessive overheating of one or both - If the bearing has turned blue or if the grease has turned black, change the
Bearing bearings (temperature > 80 °C on the bearing.
bearing retainers with or without abnormal - Bearing not properly seated.
noise) - End shields misaligned (flanges not properly fitted).
- Air flow (intake-outlet) partially clogged or hot air is being recycled from
Excessive overheating of alternator frame the alternator or engine
Temperature (more than 40 °C above the ambient - Alternator operating at too high a voltage (> 105% of Un on load)
abnormal temperature) - Alternator overloaded

- Misalignment (coupling)
Excessive vibration - Defective mounting or play in coupling
Vibration - Rotor balancing fault
Excessive vibration and humming noise - Alternator operating in single-phase mode (single-phase load or faulty contactor
coming from the machine or installation fault)
- Stator short-circuit
- System short-circuit
- Mis-paralleling
Alternator damaged by a significant impact, Possible consequences
Abnormal noise followed by humming and vibration - Broken or damaged coupling
- Broken or bent shaft end
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes or AVR

4.5 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its voltage is - Lack of residual magnetism
still correct when the battery is removed.
The alternator builds up but its voltage - Check the connection of the voltage reference to the
No Connect between E- and does not reach the rated value when AVR
voltage E+ a new battery of 4 to the battery is removed. - Faulty diodes
at no load 12 volts, respecting - Armature short-circuit
on start-up the AVR polarities, for
The alternator builds up but its voltage - Faulty AVR
2 to 3 seconds
disappears when the battery is - Field windings disconnected
removed - Main field winding open circuit. Check the resistance
Check the AVR connections (AVR may be faulty)
- Field windings short-circuited
Correct speed - Rotating diodes burnt out
Voltage too low Check the drive speed - Main field winding short-circuited - Check the
resistance
Increase the drive speed
Speed too low (Do not touch the AVR voltage pot. (P2) before running
at the correct speed.)
Voltage too high Adjust AVR voltage Adjustment ineffective Faulty AVR
potentiometer
Voltage Adjust AVR stability If no effect: try normal/rapid recovery - Check the speed: possibility of cyclic irregularity
oscillations potentiometer modes (ST2) - Loose connections
- Faulty AVR
- Speed too low when on load (or LAM set too high)
Voltage between E+ and E-
Voltage correct Run at no load and check SHUNT < 20 V - AREP/PMG < 10 V - Check the speed (or LAM set too high)
at no load and the voltage between E+ Voltage between E+ and E- - Faulty rotating diodes
too low when on and E- on the AVR SHUNT > 30 V - AREP/PMG > 15 V - Short-circuit in the main field. Check the resistance
load (*) - Faulty exciter armature

(*) Caution: For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the operating terminals
Voltage Check the AVR, the surge The voltage does not return to the rated - Exciter winding open circuit
disappears suppressor, the rotating value - Faulty exciter armature
during operation diodes, and replace any - Faulty AVR
(**) defective components - Main field open circuit or short-circuited
(**) Caution: Internal protection may be activated (overload, open circuit, short-circuit)

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LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

4.5.1 - Checking the winding Assembly A: Connect a 12 V battery in series with a rheostat
of approximately 50 ohms - 300 W and a diode on both exciter
You can check the winding insulation by performing a high field wires (5+) and (6-).
voltage test. In this case, you must disconnect all AVR wires.

CAUTION ASSEMBLY A
6 – Exciter field 5 +
Damage caused to the AVR in such conditions is not
covered by our warranty. Diode 1 A Rh. 50 Ω - 300 W

4.5.2 - Checking the diode bridge

+
-
LSA 43.2 / 44.2 Diode bridge
12 V battery
Anode A C Cathode

- ~ ~ ~ - + ~ ~ ~ + Assembly B: Connect a "Variac" variable power supply and

C C C A A A a diode bridge on both exciter field wires (5+) and (6-).

Both these systems should have characteristics which are

A A A
compatible with the field excitation power of the machine (see
C C C
the nameplate).
A diode in good working condition allows the
3) Run the unit at its rated speed.
current to flow in only one direction, from anode
to cathode.
4) Gradually increase the exciter field supply current by
adjusting the rheostat or the Variac and measure the output
voltages on L1 - L2 - L3, checking the excitation voltage at no
load and at full load (see machine nameplate or ask for the
4.5.3 - Checking the windings and rotating factory test report).
diodes using separate excitation
When the output voltage is at its rated value and balanced
within 1% for the rated excitation level, the machine is in good
working order. The fault therefore comes from the AVR or its
associated wiring (ie. sensing, auxiliary windings).

ASSEMBLY B
During this procedure, make sure that the alternator is
Variac 6 – Exciter field 5+
disconnected from any external load and inspect the
terminal box to check that the connections are fully
40
50 60 +
tightened.
30

70

Diode 1 A
20

80

1) Stop the unit, disconnect and isolate the AVR wires.

10

90

2) There are two ways of creating an assembly with separate 0 100

excitation.
- DC
AC 12 V
220 V

12
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

4.6 - Dismantling, reassembly (see sections 4.6.3 - Access to connections and the
5.5.1/5.5.2)
regulation system
The terminals are accessed directly by removing the terminal
box lid [48].
To access the AVR adjustment potentiometers, the side plate
[367] should be removed.

During the warranty period, this operation should only be 4.6.4 - Accessing, checking and
carried out in an LEROY-SOMER approved workshop or replacing diodes
in our factory, otherwise the warranty may be invalidated.
Whilst being handled, the machine should remain 4.6.4.1 - Dismantling
horizontal (rotor not locked when moved). - Remove the air intake grille [51]
- Remove the surge suppressor [347]
- Disconnect the 6 diodes 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)
- Replace the surge suppressor [347]
- Refit the air intake grille [51]
- Replace the terminal box lid [48]

4.6.5 - Replacing the NDE bearing on single-

bearing machines

4.6.1 - Tools required 4.6.5.1 - Dismantling

To fully dismantle the machine, we recommend using the - Remove the terminal box lid [48]
tools listed below: - Remove the air intake grille [51]
- 1 ratchet spanner + extension - Unscrew the fixing clamps on the power output cables,
- 1 torque wrench remove the connector from the exciter and the R 791 module.
- 1 set of flat spanners: 7 mm, 8 mm, 10 mm, 12 mm - Remove the 4 nuts on the tie rods
- 1 socket set: 8 mm, 10 mm, 13 mm, 16 mm, 18 mm, 21 mm, - Remove the NDE shield [36] using a puller: eg. U.32 - 350
22 mm, 24 mm (FACOM)
- 1 size 5 Allen key (eg. Facom: ET5) - Remove the ball bearing [70] using a screw puller
- 1 size 6 Allen key (eg. Facom: ET6)
- 1 size 10 Allen key (eg. Facom: ET10)
- 1 size 14 Allen key (eg. Facom: ET14)
- 1 T20 and T30 TORX bit
- 1 puller (eg. Facom: U35)
- 1 puller (eg. Facom: U32/350).

4.6.2 - Screw tightening torque

IDENTIFICATION screw Ø Torque N.m

Field terminal block screw M4 4 N.m
Field screw M6 10 N.m
4.6.5.2 - Reassembly
Diode bridge/RP M6 5 N.m
- Heat the inner slipring of a new bearing by induction or in a
Diode nut M5 4 N.m drying oven at 80 °C (do not use an oil-bath) and fit it to the
43.2 tie rod M12 57 Nm machine.
44.2 tie rod M14 90 Nm - Place the preloading wavy washer [79] in the shield and fit a
Earth screw M8 26 Nm new O ring seal [349].
Refit the NDE shield and pass the bundle of wires between
43.2 disc/shaft screw M12 110 Nm
the top bars of the shield.
44.2 disc/shaft screw M16 250 Nm - Refit the fixing clamps on the cables, the R 791 module and
44.2 turbine screw M6 5 Nm the exciter connector.
Grille screws M6 5 Nm
Cover screws M6 5 Nm
Terminal block nut M10 20 Nm

13
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

- Refit the air intake grille [51].

- Replace the terminal box lid [48].

NDE shield
Rotor
Screw rod

4.6.6 - Replacing the bearings on two-bearing 4.6.7.2 - Reassembling the main field
machines - Follow the dismantling procedure in reverse order.
Take care not to knock the windings when refitting the rotor in
the stator.
4.6.6.1 - Dismantling
- If the fan is being replaced on the 43.2, assemble the parts
- Uncouple the alternator from the prime mover.
as shown in the following diagram. Fit a tube and a threaded
- Remove the 8 assembly screws.
screw. On the 44.2 the fan is fixed by screws on the hub.
- Remove the DE shield [30].
- Remove the NDE shield (see section 4.6.5.1)
- Remove both ball bearings [60] and [70] using a puller with
a central screw.

4.6.6.2 - Reassembly
- Heat the new bearings by induction or in a drying oven at
80 °C (do not use an oil-bath) and fit them to the machine.
- Check that both the preloading wavy washer [79] and the
new O ring seal [349] have been fitted on the NDE shield [36].
Refit the NDE shield and pass the bundle of wires between
Follow the procedure for reassembling the bearings (see
the top bars of the shield.
sections 4.6.5.2 and 4.6.6.2).
- Refit the DE shield [30] and tighten the 4 fixing screws.
- Check that the machine assembly is correctly mounted and
that all screws are tightened.

4.6.7 - Accessing the main field and stator After operational testing, replace all access panels or
4.6.7.1 - Dismantling covers.
Follow the procedure for dismantling the bearings (see
sections 4.6.5.1 and 4.6.6.1)
- Remove the coupling disc (single-bearing machine) or the 4.7 - Installation and maintenance
DE end shield (two-bearing machine) and insert a tube of the
corresponding diameter on the shaft end or a support made
of the PMG
according to the following diagram. For the LSA 43.2 and LSA 44.2, the PMG reference is PMG 1.
- Rest the rotor on one of its poles, then slide it out. Use the
tube as a lever arm to assist dismantling. 4.7.1 - Mechanical characteristics
- After extraction of the rotor, be careful not to damage the
fan. If the fan is dismantled, it is essential that it is replaced for The components are:
the 43.2. - An adaptation shaft (to position the rotor on the shaft
extension)
NOTE: If intervention is required on the main field - A tie rod and nut for assembling the rotor on the shaft
(rewinding, replacement of components), the rotor - A rotor with 16 magnets
assembly must be rebalanced. - An assembly consisting of: housing + wound stator + plastic
connection sheath + plastic ferrules
- The housing closure cover (4 CBLXS M5 screws)
- 4 HM6 screws (for fixing the housing to the NDE shield)

14
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

If mounting in kit form, follow the following instructions 4.8.1 - 3-phase LSA 43.2 4 P, SHUNT excitation
(see section 5.4):
1 - Remove the PMG cover [297] and the alternator NDE Resistances at 20 °C (Ω)
shield seal. LSA 43.2 Stator L/N Rotor Field Armature
2 - Mount the PMG housing assembly [290] on the shield
S1 0,155 1,35 18,4 0,23
using the 4 HM6 screws.
3 - Put a coating of anti-vibration adhesive on the tie rod [295] S15 0,155 1,35 18,4 0,23
and fix it on the alternator shaft extension. S25 0,155 1,35 18,4 0,23
4 - Mount the magnetized rotor on the adaptation shaft, then
S35 0,128 1,41 18,4 0,23
using 2 threaded rods screwed into the rotor, slide the
assembly onto the tie rod. M45 0,105 1,57 18,4 0,23
5 - Install the cable gland washer [296]. L65 0,083 1,76 18,4 0,23
6 - Tighten the assembly with the M10 nut.
7 - Close the PMG with the cover [297]. L8 0,063 1,96 18,4 0,23
8 - Pierce the cover (Ø 21 hole) and insert the plastic sheath
and its ferrule. Field excitation current i exc (A) - 400 V - 50 Hz
9 - Connect the PMG to the AVR (see sections 2.5 and 4.7.2). "i exc": excitation current of the exciter field
LSA 43.2 no load on load
4.7.2 - Electrical connection S1 0,5 1,3
Mounting the PMG-1 on a SHUNT machine S15 0,5 1,5
(when using an R438):
- Disconnect the connection wires from the R 250 and remove S25 0,5 1,6
the AVR. S35 0,5 1,8
- Take out both the R 250 voltage reference wires, marked 2 M45 0,4 1,6
and 3, by removing them from the terminals (T8 and T11) in
which they are inserted. L65 0,4 1,6
- Use these same wires for voltage sensing on the R 438 by L8 0,4 1,6
inserting them in terminals T2 (wire 2) and T3 (wire 3).
- Fit the AVR support plate fitted with the R 438 (2 HM6 4.8.2 - 3-phase LSA 43.2 4 P, AREP excitation
screws tightened to 10 Nm).
- Connect the 3 PMG wires (14/15/16), the 2 exciter field wires Resistances at 20 °C (Ω)
(5/6) and the 2 previously mentioned voltage sensing wires
LSA 43.2 Stator Wind. Widing.
(2/3) according to the connection diagram no. 2725-02-98. L/N Rotor X1,X2 Z1,Z2 Field Armat.
- Modify the connection by replacing the single jumper on the
S1 0,155 1,35 0,32 0,52 4,6 0,23
connector located on the terminal box rear panel with 2
jumpers (see internal connection diagram). S15 0,155 1,35 0,32 0,52 4,6 0,23
Mounting the PMG-1 on an AREP machine S25 0,155 1,35 0,32 0,52 4,6 0,23
- Connect the 3 PMG wires (14/15/16), to terminals X1, X2,
S35 0,128 1,41 0,29 0,5 4,6 0,23
Z2 on the AVR. The 4 auxiliary winding wires X1.X2.Z1.Z2
should be isolated using the domino fitting supplied with the M45 0,105 1,57 0,26 0,51 4,6 0,23
kit. Both exciter field wires (5/6) and the voltage sensing wires L65 0,083 1,76 0,26 0,44 4,6 0,23
(2/3) remain in place.
L8 0,063 1,96 0,21 0,4 4,6 0,23
Electrical characteristics of the PMG
Stator phase/phase resistance 20 °C: 0.7 Ω Field excitation current i exc (A) -400 V -50 Hz
No-load voltage : 73 V "i exc": excitation current of the exciter field
LSA 43.2 no load on load
4.8 - Electrical characteristics S1 1 2,6
Table of average values: S15 1 3
Alternator - 2 and 4 poles - 50 Hz/60 Hz - Winding n° 6 and M S25 1 3,2
or M1 connected in dedicated single-phase. (400 V for the
excitation values). S35 1 3,6
The voltage and current values are given for no-load M45 0,8 3,2
operation and operation at rated load with separate field
L65 0,8 3,2
excitation. All values are given at ± 10% (for exact values,
consult the test report) and are subject to change without prior L8 0,8 3,2
warning. For 60 Hz machines, the resistance values are the
same and the excitation current "i exc" is approximately 5 to
10% weaker.

15
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SERVICING / MAINTENANCE

4.8.3 - Dedicated single-phase LSA 43.2: 4.8.5 - 3-phase LSA 44.2: 4-pole, AREP
4-pole, SHUNT excitation (60 Hz only) excitation
Resistances at 20 °C (Ω) Resistances at 20 °C (Ω)
LSA 43.2 Stator L/N Rotor Field Armature LSA 44.2 Stator Wind. Wind.
L/N Rotor Field Armat.
X1,X2 Z1,Z2
S1 0,058 1,35 13,9 0,23
VS3 0,046 2,51 0,3 0,5 4,9 0,5
S25 0,058 1,35 13,9 0,23
VS45 0,046 2,51 0,3 0,5 4,9 0,5
S35 0,046 1,41 13,9 0,23
S7 0,036 2,91 0,21 0,32 4,9 0,5
M45 0,037 1,57 13,9 0,23
S75 0,036 2,91 0,21 0,32 4,9 0,5
L65 0,027 1,76 13,9 0,23
M95 0,024 3,32 0,17 0,28 4,9 0,5
L8 0,019 1,96 13,9 0,23
L12 0,019 3,66 0,16 0,21 4,9 0,5
Field excitation current i exc (A) -240 V -60 Hz
"i exc": excitation current of the exciter field Field excitation current i exc (A) -400 V -50 Hz
"i exc": excitation current of the exciter field
LSA 43.2 no load on load
LSA 44.2 no load on load
S1 0,59 1,44
VS3 1 3,6
S25 0,59 1,68
VS45 1 4,2
S35 0,66 1,65
S7 1 3,8
M45 0,61 1,48
S75 1 4,2
L65 0,62 1,48
M95 1,2 4
L8 0,74 1,46
L12 1 3,8

4.8.4 - 3-phase LSA 44.2: 4-pole, SHUNT

excitation 4.8.6 - Dedicated single-phase LSA 44.2:
4-pole, SHUNT excitation (60 Hz only)
Resistances at 20 °C (Ω)
Resistances at 20 °C (Ω)
LSA 44.2 Stator L/N Rotor Field Armature
LSA 44.2 Stator L/N Rotor Field Armature
VS3 0,046 2,51 18,4 0,5
VS3 0,0194 2,51 18,4 0,5
VS45 0,046 2,51 18,4 0,5
VS45 0,0194 2,51 18,4 0,5
S7 0,036 2,91 18,4 0,5
S7 0,0140 2,91 18,4 0,5
S75 0,036 2,91 18,4 0,5
M95 0,0088 3,32 18,4 0,5
M95 0,024 3,32 18,4 0,5
L12 0,019 3,66 18,4 0,5 Field excitation current i exc (A) -240 V -60 Hz
"i exc": excitation current of the exciter field
Field excitation current i exc (A) - 400 V - 50 Hz
LSA 44.2 no load on load
"i exc": excitation current of the exciter field
VS3 0,44 1,18
LSA 44.2 no load on load
VS45 0,44 1,25
VS3 0,5 1,8
S7 0,43 1,2
VS45 0,5 2,1
M95 0,55 1,28
S7 0,5 1,9
S75 0,5 2,1
M95 0,6 2
L12 0,6 1,9

16
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SPARE PARTS

5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an option.
They contain the following items:

Ref. Designation Qty LSA 43.2/44.2 - SHUNT Code

R 250 AEM 110 RE 019
198 AVR 1
R 251 AEM 110 RE 021
343 Diode bridge assembly 1 LSA 432 9 03/04 ESC 040 MD 003
347 Surge suppressor 1 LSA 432 1 13 CII 111 PM 002
AVR fuse 1 250 V - 8 A/slow-blow

Ref. Designation Qty LSA 43.2/44.2 - AREP 4 P Code

198 AVR 1 R 438 AEM 110 RE 003
343 Diode bridge assembly 1 LSA 432 9 03/04 ESC 040 MD 003
347 Surge suppressor 1 LSA 432 1 13 CII 111 PM 002
AVR fuse 2 250 V - 8 A/fast-blow

5.2 - Bearing designations

Ref. Designation Qty LSA 43.2 Code LSA 44.2 Code
60 Bearing on shaft extension end 1 6312 2RS/C3 RLT060TS030 6315 2RS/C3 RLT075TS030
70 Bearing on exciter end 1 6307 2RS/C3 RLT080RB002 6309 2RS/C3 RLT100RB005

5.3 - Technical support service

Our technical support service will be pleased to provide any
additional information you may require. CAUTION
When ordering spare parts, you should indicate the
complete machine type, its serial number and the
information given on the nameplate. Part numbers should be identified from the exploded
views and their description from the parts list.
Address your enquiry to your usual contact. Our extensive network of service centres can dispatch
the necessary parts without delay.
To ensure correct operation and the safety of our
machines, we recommend the use of original
manufacturer spare parts.
In the event of failure to comply with this advice, the
manufacturer cannot be held responsible for any
damage.

17
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SPARE PARTS

5.4 - Exploded views, parts list

5.4.1 - Single-bearing LSA 43.2/44.2
49 217
320
15 47
16
325 48 59
36
41

347

198
124
207
120

44.2 coupling

51
90
91
79
349
70
100
107
343

1
28
37
4
15
30 297
33 296
320 295
325 294
322 293
324 292
323 291
PMG option 290

N° Nbr Description N° Nbr Description

1 1 Stator assembly 120 1 Terminal block support (AREP)
4 1 Rotor assembly 124 1 Terminal block
15 1 Fan 198 1 Voltage regulator (AVR)
16 6 Fixing screws (44.2 only) 207 1 AVR damper seal
28 1 Earth terminal 217 1 Terminal block
30 1 DE shield 290 1 PMG housing
33 1 Air outlet grille 291 1 Adaptation shaft
36 1 Shield on exciter end 292 1 Magnetic rotor
37 4 Tie rod 293 1 Stator
41 1 Cover front panel 294 2 Fixing screws
47 1 Cover rear panel 295 1 Tie rod
48 1 Cover top panel 296 1 Cable gland washer + nut
49 34 Fixing screws 297 1 End plate
51 1 Air intake grille 320 1 Hub (43.2 L7 & 44.2 only)
59 3 Inspection door 322 1 Coupling disc
70 1 NDE bearing 323 - Fixing screws
79 1 Preloading wavy washer 324 1 Clamping washer (43.2 S1 to L6)
90 1 Exciter field 325 - Spacer shim (43.2 L7 & 44.2 only)
91 4 Exciter field fixing screw 343 1 Diode bridge assembly
100 1 Exciter armature 347 1 Surge suppressor
107 1 Diode crescent support 349 1 "O" ring

18
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3434 en - 06.2007 / g

LSA 43.2/44.2 - 4-POLE

ALTERNATORS
SPARE PARTS

5.4.2 - Two-bearing LSA 43.2/44.2

49
320
15 217
16 48 47
68
62 59
41 36

347

124

198
207
120

51
90
91
79
349
70
100
107
343
1
28
37
4
33
30
15
63
68
60
67 297
410 296
295
294
293
292
291
290 PMG option

N° Nbr Description N° Nbr Description

1 1 Stator assembly 91 4 Exciter field fixing screw
4 1 Rotor assembly 100 1 Exciter armature
15 1 Fan 107 1 Diode crescent support
16 6 Fixing screws (44.2 only) 120 1 Terminal block support (AREP)
28 1 Earth terminal 124 1 Terminal block
30 1 DE shield 198 1 Voltage regulator (AVR)
33 1 Air outlet grille 207 1 AVR damper seal
36 1 Shield on exciter end 217 1 Terminal block
37 4 Tie rod 290 1 PMG housing
41 1 Cover front panel 291 1 Adaptation shaft
47 1 Cover rear panel 292 1 Magnetic rotor
48 1 Cover top panel 293 1 Stator
49 34 Fixing screws 294 2 Fixing screws
51 1 Air intake grille 295 1 Tie rod
59 3 Inspection door 296 1 Cable gland washer + nut
60 1 DE bearing 297 1 End plate
62 2/4 Bearing retainer fixing screw 320 1 Hub (44.2 only)
63 1 Cable gland washer (43.2 only) 343 1 Diode bridge assembly
67 1 Circlips 347 1 Surge suppressor
68 1 Inner bearing retainer 349 1 "O" ring
70 1 NDE bearing 410 1 End shield
79 1 Preloading wavy washer
90 1 Exciter field

19
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
RCS ANGOULÊME N° B 671 820 223
S.A. au capital de 62 779 000 €

http://www.leroy-somer.com
 4067 en - 11.2006 / a

75 mm

110 0V E+ E- R 250

140 mm
n to
give
t o be r
Slow fuse
F1 250V 8 A
i s
FREQ. & L.A.M. CONFIG.

ual e
m a n e e nd us
This th P1 Voltage
STAB VOLT

KNEE

47.5Hz 50Hz LAM

LAM OFF 9
o OFF
1 13%
SPECIAL
8 901 2 25%
Freq
23
78

KNEE 456 3 OFF

65Hz 7

P2 Stability LAM OFF

KNEE

57Hz
6
5
60Hz
4 13%
25%
LAM
/ 60
and
LAM OFF

ST4 Option
External potentiometrer
for voltage adjusting

R250
A.V.R.
Installation and maintenance
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

This manual concerns the alternator A.V.R. which you have just purchased.

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

following certain important points during installation, use and servicing of your A.V.R.,
you can look forward to many years of trouble-free operation.

SAFETY MEASURES

Before using your machine for the first time,

it is important to read the whole of this WARNING
installation and maintenance manual.

All necessary operations and interventions Warning symbol for an operation

on this machine must be performed by a capable of damaging or destroying the
qualified technician. machine or surrounding equipment.

Our technical support service will be

pleased to provide any additional
information you may require.

The various operations described in this

manual are accompanied by Warning symbol for general danger to
recommendations or symbols to alert the personnel.
user to potential risks of accidents. It is vital
that you understand and take notice of the
following warning symbols.

Warning symbol for electrical danger to

personnel.

Note : LEROY-SOMER reserves the right

to modify the characteristics of its products
at any time in order to incorporate the latest
technological developments.
The information contained in this document
may therefore be changed without notice.

2
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

SUMMARY

1 - SUPPLY .............................................................................................................................4
1.1 - SHUNT excitation system............................................................................................4

2 - R250 A.V.R. .......................................................................................................................5

2.1 - Characteristics .............................................................................................................5
2.2 - U/F fonction and LAM ..................................................................................................5
2.3 - R250 A.V.R. option ......................................................................................................5
2.4 - LAM Characteristics ....................................................................................................6
2.5 - Typical effects of the LAM ...........................................................................................7

3 - INSTALLATION - COMMISIONING ..................................................................................8

3.1 - Electrical checks on the AVR.......................................................................................8
3.2 - Settings........................................................................................................................8
3.3 - Electrical faults.............................................................................................................9

4 - SPARE PARTS ................................................................................................................10

4.1 - Designation................................................................................................................10
4.2 - Technical support service. .........................................................................................10

Any maintenance or breakdown operations on the A.V.R. are to be done by personnel

trained on commisioning, servicing and maintenance for the electrical and mechanical
elements.

Copyright 2005: MOTEURS LEROY-SOMER

This document is the property of:
MOTEURS LEROY SOMER.
It may not be reproduced in any form without prior authorization
All brands and models have been registered and patents applied for.

3
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

1 - SUPPLY The regulator controls the excitation

1.1 - SHUNT excitation system current according to the alternator’s output
voltage. With a very simple conception, the
The SHUNT excitation alternator is auto- SHUNT excitation alternator does not have
excited with a R 250 voltage regulator. a short circuit capacity.

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

SHUNT SYSTEM
T1 T7 T2 T8 T3 T9

Varistor

Induced
5+ 6-
T4 T10 T5 T11 T6 T12
Field

75 mm

110 0V E+ E- R 250
4 x holes Ø 5.8 x
140 mm

50 x 115 mm

Slow fuse
F1 250V 8 A
FREQ. & L.A.M. CONFIG.

P1 Voltage
STAB VOLT

KNEE

47.5Hz 50Hz LAM

LAM OFF 9
o OFF
1 13%
SPECIAL
8 901 2 25%
Frequency selector 50 Hz
23
78

KNEE 456 3 OFF

65Hz 7

P2 Stability LAM OFF

57Hz
KNEE 6
5
60Hz
4 13%
25%
LAM
/ 60 Hz for U/F fonction
and LAM adjustement
LAM OFF

ST4 Option
External potentiometrer
for voltage adjusting

4
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

2 - R250 A.V.R. Operating at 50 Hz: (U/F gradient)

2.1 - Characteristics
0: threshold at 48 Hz without LAM for
- Voltage regulation: around ± 0,5 %. impacts between 30 and 40% of the rated
- Supply range/voltage detection 85 to 139 V load.
(50/60Hz).
- Rapid response time (500 ms) for a 1: threshold at 48 Hz with LAM 13% for
transient voltage variation amplitude of impacts between 40 and 70% of the rated
± 20 %. load.
- Voltage setting P1.
- Stability setting P2. 2: threshold at 48 Hz with LAM 25% for
- Supply protected with an 8 A fuse, slow impacts > 70% of the rated load.
action (supports 10 A for 10 s).
Operating at 60 Hz: (U/F gradient)
2.2 - U/F Fonction and LAM
The threshold position (50 Hz - 60 Hz) to 3: threshold at 58 Hz without LAM for
action the U/F fonction as well as the LAM impacts between 30 and 40% of the rated
setting type is selected using the load.
potentionmeter.
4: threshold at 58Hz with LAM 13% for
impacts 40 and 70% of the rated load.
KNEE
50Hz LAM
47.5Hz o OFF
5: threshold at 58Hz with LAM 25% for
LAM OFF 9 impacts > 70% of the rated load.
1 13%
SPECIAL
8 901 2 25% Specific operating
23
78

KNEE
7
456 3 OFF
65Hz 13%
6: threshold at 57Hz without LAM for speed
LAM OFF 4
KNEE 6 variations at a steady state > 2 Hz
5 25%
57Hz 60Hz LAM
LAM OFF 7: threshold at 65Hz without LAM for
variable speed and tractelec / gearlec (U/F
gradient).

8: special: the factory setting 48Hz 2U/F

gradient ; a special programme is possible
on request. This programme must be
specified before ordering, during the
WARNING: The jumper settings must project study.
correspond to the rated operating
frequency (see the nameplate on the 9: threshold at 47.5 Hz without LAM for
alternator). speed variations at a steady state > 2 Hz
Risk of destruction for the alternator.
2.3 - R250 A.V.R. option
The threshhold position and LAM fonction
settings are done with the jumper. Wireless potentiometer for voltage setting,
1000 Ω / 0,5 W min: setting range ± 5 %.
- Remove the ST4 jumper.

5
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

2.4 - LAM characteristics (Load 2.4.2 - Gradual voltage return function

Acceptance Module) During load impacts, the function helps the
2.4.1 - Voltage drop genset to return to its rated speed faster
thanks to a gradual increase in voltage
The LAM system is integrated in the A.V.R. according to the following principles:
It is active as standard. It can be adjusted
to 13% or 25%. - if the speed drops between 46 Hz and 50 Hz,
the rated voltage follows a fast gradient as
- Role of the «LAM» (Load Adjustment it is restored.
Module):
- if the speed drops below 46 Hz, since the
On application of a load, the rotation speed engine needs more help, the voltage
of the generator set decreases. When it follows a slow gradient as it returns to the
passes below the preset frequency reference value.
threshold, the LAM causes the voltage to
drop by approximately 13% or 25% and
consequently the amount of active load
applied is reduced by approximately 25%
to 50%, until the speed reaches its rated U
value again.
Drop N < 46 Hz
Hence the "LAM" can be used either to
reduce the speed variation (frequency) and Drop N > 46 Hz
its duration for a given applied load, or to Time
increase the applied load possible for one 0
speed variation (turbo-charged engines).
To avoid voltage oscillations, the trip
threshold for the "LAM" function should be
set approximately 2 Hz below the lowest
frequency in steady state.

It is advised to use the "LAM" at 25% for

load impacts > at 70% of the genset rated
power.

Voltage

Voltage
UN

U/f
0,85 UN LAM

48 or 57,5 Hz 50 or 60 Hz
0 fC
ST3 fN

6
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

2.5 - Typical effects of the LAM with

a diesel engine or without a LAM (U/
F only)
2.5.1 - Voltage
Transient voltage drop
UN

0,9
(U/f)
with without LAM
0,8
LAM
Time

0 1s 2s 3s

2.5.2 - Frequency
Max speed drop with
fN LAM

0,9
without
LAM
0,8 Time

0 1s 2s 3s

2.5.3 - Power

LAM
shaft (kW)
Load on

Load variation

Shedding due to "LAM"

Time
0 1s 2s 3s

7
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

3 - INSTALLATION - 3.2.2 - Special type of use

COMMISSIONING
3.1 - Electrical checks on the AVR WARNING
- Check that all connections have been
Excitation circuit E+, E- must not be left
made properly as shown in the attached
open when the machine is running:
wiring diagram.
A.V.R. damage will occur.
- Check that the position of the jumper
corresponds to the operating frequency.
3.2.2.1 - R250 field weakening (SHUNT)
- Check whether the ST4 jumper or the
remote adjustment potentiometer have
been connected.

3.2 - Settings

E+
0V
110

E-
The different settings made during the
trial are to be done by qualified The exciter is switched off by disconnecting
personnel. Respecting the load speed the A.V.R. power supply (1 wire - 0 or 110V).
specified on the nameplate is vital in Contact rating: 16A - 250V AC
order to start a settings procedure. After
operational testing, replace all access 3.2.2.2 - R250 field forcing
panels or covers. (400V - 10A) Diode
The only possible settings on the
machine are to be done with the A.V.R.
t - +
Battery (B Volt)
3.2.1 - R250 settings (SHUNT system)
Initial potentiometer positions
- voltage setting potentiometer P1 for the Excitation Inducer
E+
0V
110

E-

A.V.R.: full left

- remote voltage setting potentiometer: in
the middle.
Operate the alternator at its rated speed: if
the voltage does not rise it is necessary to
re-magnatise the magnetic circuit.
- slowly adjust the voltage potentiometer of
the A.V.R. P1 until the output voltage The battery must be isolated from the
reaches its rated value. mass.
- Stability setting with P2.

Exciter field may be at line potential.

8
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

3.3 - Electrical faults

Fault Action Effect Check/cause
The alternator starts up and its - Lack of residual magnetism
voltage is still correct when the
battery is removed.
No voltage at Connect a new battery The alternator starts up but its - Check the connection of the voltage
no load on of 4 to 12 volts to voltage does not reach the rated reference to the A.V.R.
start-up terminals E- and E+ value when the battery is - Faulty diodes
respecting the polarity removed. - Induced short circuit
for 2 to 3 seconds
The alternator starts up but its - Faulty A.V.R.
voltage disappears when the - Exciter field short-circuited
battery is removed - Short-circuit in the main field. Check the
resistance
Check the A.V.R. connections (A.V.R. may
be faulty)
Correct speed - Field windings short-circuited
Voltage too Check the drive speed - Rotating diodes burnt out
low - Main field winding short-circuited
- Check the resistance
Increase the drive speed
Speed too low (Do not touch the A.V.R. pot (P1) before
returning to the correct speed.)
Voltage too Adjust A.V.R. Adjustment ineffective - Faulty A.V.R.
high potentiometer - 1 faulty diode
Voltage Adjust A.V.R. stability - Check the speed: possibility of cyclic
oscillations potentiometer irregularity
- Loose terminals
- Faulty A.V.R.
- Speed too low on load
(or U/F gradient set too high)
Voltage Run at no load and - Check the speed (or U/F gradient set too
correct at no check the voltage high)
load and too between E+ and E- on - Faulty rotating diodes
low when on the A.V.R. - Short-circuit in the main field. Check the
load (*) resistance
- Faulty induced excitaion
(*) Warning: For single-phase operation, check that the sensing wires coming from the A.V.R. are correctly connected to
the operating terminals (see the alternator manual).
Voltage Check the A.V.R., the The voltage does not return to the - Exciter winding open circuit
disappears surge suppressor, the rated value. - Faulty induced excitation
during rotating diodes and - Faulty A.V.R.
operation replace any defective - Main field open circuit or short-circuited
components

Warning: after setting-up or trouble-

shooting, replace all access panels or
covers.

9
 LEROY-SOMER Installation and maintenance 4067 en - 11.2006 / a

R250
A.V.R.

4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R. R 250 AEM 110 RE 019

4.2 - Technical support service

Our technical support service will be
pleased to help you with any information
needed.

For replacement part orders, it is necessary

to indicate the type and the code number of
the A.V.R.

Please contact your usual correspondant.

An extensive network of service centres is

available to rapidly supply any necessary
parts.
In order to ensure the correct operation and
safety of our machines, we strongly
recommend that original manufacturer’s
spare parts are used.
Failure to do so, will discharge the
manufacturer from liabilty in the case of
damage.

10
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX -
FRANCE
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 ¤
3971c_NotRegR438_en.fm Page 1 Jeudi, 9. novembre 2006 10:13 10

3971 en - 11.2006 / c

Armature
6-

Field
10 Yellow
11 Red
12 Black
9 Gr
een

giv en to
i s t o be
ual er
man e end us
This t h 1 Slow fuse
250V 8 A
X2 Z1 X1 Z2 E+ E- 0V 110 220

T5
with LAM without LAM

T3
quency 50Hz 60Hz

LAM 13 %
R 438
T10

R438
A.V.R.
Installation and maintenance
 3971c_NotRegR438_en.fm Page 2 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

This manual concerns the alternator A.V.R. which you have just purchased.

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

following certain important points during installation, use and servicing of your A.V.R.,
you can look forward to many years of trouble-free operation.

SAFETY MEASURES

Before using your machine for the first time, WARNING

it is important to read the whole of this
installation and maintenance manual.
Warning symbol for an operation
All necessary operations and interventions capable of damaging or destroying the
on this machine must be performed by a machine or surround-ing equipment.
qualified technician.

Our technical support service will be

pleased to provide any additional infor-
mation you may require.

The various operations described in this Warning symbol for general danger to
manual are accompanied by recommen- personnel.
dations or symbols to alert the user to
potential risks of accidents. It is vital that
you understand and take notice of the
following warning symbols.

This A.V.R. can be incorporated in a Warning symbol for electrical danger to

machine marked C.E. personnel.

Note: LEROY-SOMER reserves the right to

modify the characteristics of its products at
any time in order to incorporate the latest
technological developments. The information
contained in this document may therefore be
changed without notice.

2
3971c_NotRegR438_en.fm Page 3 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

CONTENTS

1 - SUPPLY .............................................................................................................................4
1.1 - AREP excitation system ..............................................................................................4
1.2 - PMG excitation system ................................................................................................5
1.3 - SHUNT or separate excitation system.........................................................................5

2 - R438 A.V.R. .......................................................................................................................6

2.1 - Characteristics .............................................................................................................6
2.2 - Frequency compared with voltage (without LAM)........................................................6
2.3 - LAM (Load Acceptance Module) characteristics .........................................................6
2.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only).......7
2.5 - R438 A.V.R. options ....................................................................................................7

3 - INSTALLATION - COMMISSIONING ................................................................................8

3.1 - Electrical checks on the AVR.......................................................................................8
3.2 - Settings........................................................................................................................8
3.3 - Electrical faults...........................................................................................................11

4 - SPARE PARTS ................................................................................................................12

4.1 - Designation................................................................................................................12
4.2 - Technical support service ..........................................................................................12

All such operations performed on the A.V.R. should be undertaken by personnel trained
in the commissioning, servicing and maintenance of electrical and mechanical
components.

Copyright 2005 : MOTEURS LEROY-SOMER

This document is the property of :
MOTEURS LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.

3
 3971c_NotRegR438_en.fm Page 4 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

1 - SUPPLY to that of the alternator (characteristic

1.1 - AREP excitation system Shunt), the second has a voltage in
proportion to the stator current (compound
For both AREP & PMG excitation systems, characteristic: Booster effect).
the alternator voltage regulator is the R438. The power supply voltage is rectified and
With AREP excitation, the R438 electronic filtered before being used by the AVR
AVR is powered by two auxiliary windings monitoring transistor. This principle
which are independent of the voltage ensures that regulation is not affected by
match circuit. distortions generated by the load.
The first winding has a voltage in proportion

STATOR: 6 wires (marked T1 to T6)

MAIN FIELD STATOR: 12 wires (marked T1 to T12)
AREP SYSTEM Aux. windings
T1 T7 T2 T8 T3 T9
Varistor

Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field
10 Yellow
11 Red
12 Black
9 Gr
een

according voltage

140 mm

X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

200 mm

Slow fuse
F1 250V 8 A 175 x 115 mm

ST5
with LAM without LAM Quad
P1 droop

ST3 AREP
Frequency 50Hz 60Hz ST9 PMG

LAM 13 %
R 438
T.I. P2
ST10 LAM 25 %
S2
Option
S1 Ph.1
P1
Excitation
P5 ceiling
ST4 Option
open
ST11 knee-point: 65 Hz
External potentiometer
for adjusting the voltage

Response normal
ST2 time fast ST1 P2 Option

Single- Voltage R731 3-ph. dete ction

P3 Stability phase
detection in 3-ph. detection ST1 op
en

4
3971c_NotRegR438_en.fm Page 5 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

1.2 - PMG excitation system alternator winding. As a result the machine

This excitation system consists of a "PMG" has a short-circuit current capacity and
(permanent magnet generator). This is good immunity to distortions generated by
fitted at the rear of the machine and the load.
connected to the R438 AVR. The AVR monitors and corrects the
The PMG supplies the AVR with constant alternator output voltage by adjusting the
voltage which is independent of the main excitation current.
- 50/60 Hz selection via the ST3 jumper.
STATOR : 6 wires (marked T1 to T6)
MAIN FIELD STATOR : 12 wires (marked T1 to T12)
PMG SYSTEM
T1 T7 T2 T8 T3 T9

Varistor
PMG

Armature
5+ 6-
T4 T10 T5 T11 T6 T12
Field

according voltage
14 15 16
140 mm

X2 Z1 X1 Z2 E+ E- 0V 110 220 380 4 x holes Ø 5.8 x

200 mm

Slow fuse
F1 250V 8 A 175 x 115 mm

ST5
with LAM without LAM Quad
P1 droop

ST3 AREP
Frequency 50Hz 60Hz ST9 PMG

LAM 13 %
R 438
T.I. P2
ST10 LAM 25 %
S2
Option
S1 Ph.1
P1
Excitation
P5 ceiling
ST4 Option
open
ST11 knee-point: 65 Hz
External potentiometer
for adjusting the voltage

Response normal
ST2 time fast ST1 P2 Option

Single- Voltage R731 3-ph. detection

P3 Stability phase
detection in 3-ph. detection ST1 open

1.3 - SHUNT or separate excitation system

A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48V
battery).

5
 3971c_NotRegR438_en.fm Page 6 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

2 - R438 A.V.R. 2.1.2 - Setting potentiometers

2.1 - Characteristics function
- Standard power supply: AREP or PMG. Delivrery
Pot. Function
position
- Rated overload current: 8 A - 10 s
- Electronic protection (overload, short- 0 P1 Quadrature droop ; // operation with C.T.
circuit on opening of voltage sensing 400V P2 Voltage
circuit): excitation overload current for 10 Centre P3 Stability
seconds then return to approximately 1A.
Maxi P5 Excitation current ceiling
The alternator must be stopped (or the
power switched off) in order to reset the
protection. 2.2 - Frequency compared with
- Fuse : F1 on X1, X2. 8A ; slow - 250V
- Voltage sensing : 5 VA isolated via voltage (without LAM)
transformer ; Voltage Bend 57.5 Hz
• 0-110 V terminals = 95 to 140 V, 48 Hz
100 %
• 0-220 V terminals = 170 to 260 V, U/UN 50 Hz
• 0-380 V terminals = 340 to 520 V. 60 Hz
- Voltage regulation ± 1%.
- Normal or rapid response time via ST2 Frequency
jumper (see below). 50 Hz 60 Hz Hz
- Voltage adjustment via potentiometer P2.
other voltages via adapter transformer 2.3 - LAM (Load Acceptance
- Current sensing (parallel operation): C.T. Module) characteristics
2.5 VA cl1, secondary 1 A (optional).
- Quadrature droop adjustment via 2.3.1 - Voltage drop
potentiometer P1. The LAM system is integrated in the R 438
- Max. excitation current adjustment via P5 AVR as standard.
(see below). Role of the "LAM" (Load Adjustment
Module) :
2.1.1 - Configuration jumpers function On application of a load, the rotation speed
Delivrery of the generator set decreases. When it
Pot. config. Position Function passes below the preset frequency
Open Closed threshold, the LAM causes the voltage to
ST1 3-ph. Mono
Open for module drop by approximately 13% or 25% and
installation tri detection
consequently the amount of active load
ST2 Fast Normal Response time
ST3 50 ou 60 Hz Frequency selection
applied is reduced by approximately 25%
External
to 50%, until the speed reaches its rated
ST4 potentio- Without Potentiometer value again.
meter Hence the LAM can be used either to
ST5 Without With LAM reduce the speed variation (frequency) and
ST9
Others
AREP Supply its duration for a given applied load, or to
(PMG...)
LAM voltage drop
increase the applied load possible for one
ST10 13% or 25%
amplitude speed variation (turbo-charged engine).
48 or U/f function bend To avoid voltage oscillations, the trip
ST11 65 Hz
58 Hz position threshold for the LAM function should be
set approximately 2 Hz below the lowest
frequency in steady state.

6
3971c_NotRegR438_en.fm Page 7 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

- LAM : action eliminated by cutting the ST5 2.4.2 - Frequency

jumper.
Max speed drop with
Voltage Underspeed and LAM
fN LAM

ST5 disconnected
UN Voltage
P2
0,9
without
U/f LAM
LAM 0,8 Time
0.85 UN
0 1s 2s 3s

2.4.3 - Power
48 or 57.5 Hz 50 or 60 Hz
0 ST3 fC fN
LAM
2.3.2 - Gradual voltage return function
Load on the
shaft (kW)

During load impacts, the function helps the Variation in the load
genset to return to its rated speed faster
thanks to a gradual increase in voltage Load shedding due to "LAM"
according to the principle:
Time
- If the speed drops between 46 and 50 Hz, 0 1s 2s 3s
the rated voltage follows a fast gradient as
it is restored.
- If the speed drops below 46 Hz, since the 2.5 - R438 A.V.R. options
engine needs more help, the voltage - Current transformer for parallel operation
follows a slow gradient as it returns to the of ....../1A. 5 VA CL 1.
reference value. - Remote voltage adjustment potentiometer:
470 Ω, 0.5 W min: adjustment range ± 5%
(range limited by internal voltage
U
potentiometer P2). Remove ST4 to connect
the poten-tiometer. (A 1 kΩ potentiometer
Drop N ≤ 46 Hz can also be used to extend the adjustment
range).
Drop N > 46 Hz
Time - R 731 external module: sensing of 3-
0 phase voltage 200 to 500 V, compatible with
parallel operation. Disconnect ST1 to
2.4 - Typical effects of the LAM with connect the module; set the voltage via the
module potentiometer.
a diesel engine with or without a - R 734 module: detection of 3-phase
LAM (U/F only) current and voltage for parallel operation on
unbalanced installations (imbalance > 15%).
2.4.1 - Voltage - R 726 module: 3 functions (mounted
externally)
Transient voltage drop P.F. regulation (2F) and voltage sensing
UN circuit before paralleling (3 F).
- Control through DC voltage used
0,9 monitoring apply to the terminals for
(U/f) connection of a potentiometer DC voltage :
0,8
with without LAM • internal impedance 1,5 kΩ
LAM
Time • ± 0,5V enable a voltage setting of 10%.
0 1s 2s 3s

7
 3971c_NotRegR438_en.fm Page 8 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

3 - INSTALLATION - COMMISSIONING a) Initial potentiometer settings (see table

3.1 - Electrical checks on the AVR below)
- Remote voltage adjustment potentiometer :
- Check that all connections have been centre (ST4 jumper removed).
made properly as shown in the attached
wiring diagram. Action Factory setting Pot.
- Check that the ST3 frequency selection
400V - 50 Hz
jumper is on the correct frequency setting. Voltage
(Input
- Check whether the ST4 jumper or the minimum fully anti-clockwise P2
0 - 380 V)
remote adjustment potentiometer have
been connected. Not set
- Optional operating modes.
Stability
(centre position)
P3
• ST1 jumper : open to connect the R
Voltage quadrature droop Not set
731or R 734 3-phase (// operation with C.T.) (fully anti-
sensing module. - 0 quadrature loop fully clockwise) P1
• ST2 jumper : open if rapid response time anti-clockwise.
used Excitation ceiling
• ST5 jumper : open to suppress the LAM Limit of excitation and 10 A
function. short-circuit current, maximum P5
minimum fully anti-clockwise.

3.2 - Settings
Stability adjustments in standalone
operation

b) Install a D.C. analogue voltmeter

(needle dial) cal. 50V on terminals E+, E-
and an A.C. voltmeter cal 300 - 500 or
The machine is tested and set at the 1000V on the alternator output terminals.
factory. When first used with no load,
make sure that the drive speed is c) Make sure that the ST3 jumper is
correct and stable (see the nameplate). positioned on the desired frequency (50 or
After operational testing, replace all 60 Hz).
access panels or covers.
The only possible adjustments to the d) Voltage potentiometer P2 at minimum,
machine should be made on the AVR. fully anti-clockwise.

3.2.1 - R438 settings (AREP or PMG e) Stability potentiometer P3 to around 1/3

system) of the anti-clockwise limit.

WARNING f) Start the engine and set its speed to a

frequency of 48 Hz for 50 Hz, or 58 for 60
Hz.
Before any intervention on the A.V.R.,
make sure that the ST9 jumper is closed g) Set the output voltage to the desired
with AREP excitation and disconnected value using P2.
with PMG or SHUNT or separate - Rated voltage UN for solo operation (eg.
excitation. 400 V)
- Or UN + 2 to 4% for parallel operation with
C.T. (eg. 410 V)
If the voltage oscillates, use P3 to make
adjustments (try both directions) observing

8
3971c_NotRegR438_en.fm Page 9 Jeudi, 9. novembre 2006 10:13 10

LEROY-SOMER Installation and maintenance 3971 en - 11.2006 / c

R438
A.V.R.

the voltage between E+ and E- (approx. 3.2.2 - Max. excitation setting (excitation
10V D.C.). The best response times are ceiling)
obtained at the limit of the instability. If no
Depending on Main
stable position can be obtained, try Max. excitation the mains frequency (50/60 Hz supply)
disconnecting or replacing the ST2 jumper
ST3
(normal/fast). 48 V
X2
P5
h) Check LAM operation : ST5 closed. 50Hz 60Hz Z1
A
X1
Z2
i) Vary the frequency (speed) around 48 or E+ Field
R 438 – +
58 Hz according to the operating P3
E- A
~ 5 ohms

frequency, and check the change in voltage 0V 10 A CC/DC

from that observed previously (~ 15%). 110 V

P2 220 V
ST4
380 V
j) Readjust the speed of the unit to its rated 110/220/380 V D
no-load value.
Adjustments in parallel operation Voltage

Before any intervention on the Static adjustment of the current limit,

alternator, make sure that the speed potentiometer P5 (factory setting: 7.5 A,
droop is identical for all engines. fuse rating: 8 A - 10 seconds).
The maximum factory setting corresponds
k) Preset for parallel operation (with C.T. to that of the excitation current required to
connected to S1, S2) obtain a 3-phase short-circuit current of
- Potentiometer P1 (quadrature droop) in approximately 3 IN at 50 Hz for industrial
centre position. power, unless otherwise specified(*).
Apply the rated load (cos ϕ = 0.8 inductive). A static method can be used to reduce this
The voltage should drop by 2 to 3%. If it value or adapt the Isc to the actual
increases, check that V and W and also S1 operating power (derated machine), which
and S2 have not been reversed. is safer for the alternator and the
installation. Disconnect power supply wires
l) The no-load voltages should be identical X1,X2 and Z1,Z2 and the voltage reference
for all the alternators intended to run in (0-110V-220V-380V) on the alternator.
parallel. Connect the mains power supply using a
- Couple the machines in parallel. transformer (200-240V) as indicated
- By adjusting the speed, try to obtain 0 KW (X1,X2 : 48V). Install a 10A D.C. ammeter
power exchange. in series with the exciter field. Turn P5 fully
- By altering the voltage setting P2 on one anti-clockwise and activate the power
of the machines, try to cancel (or minimise) supply. If there is no output current from the
the current circulating between the AVR, turn potentiometer P2 (voltage)
machines. clockwise until the ammeter indicates a
- From now on, do not touch the voltage stable current. Switch the power supply off,
settings. then on again, turn P5 clockwise until the
required max. current is obtained (no more
m) Apply the available load (the setting is only than 8 A).
correct if a reactive load is available)
- By altering the speed, match the kW (or Checking the internal protection :
divide the rated power of the units Open switch (D) : the excitation current
proportionally) should increase to its preset ceiling, remain
- By altering the quadrature droop at that level for ≥ 10 seconds and then drop
potentiometer P1, match or divide the to < 1A.
currents.

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R438
A.V.R.

To reset, switch off the power supply by Connection is identical for resetting the
opening switch (A). AVR internal protection.
Note: After setting the excitation ceiling as
described, adjust the voltage again (see
section 2.1.1)
(*) In some countries it is a legal
requirement to have a short-circuit current
of 3 IN, so as to offer selective protection. In case of using the de-excitation,
provide a forced excitation.
3.2.3 - Special type of use
3.2.3.3 - R438 field forcing
WARNING (400V - 10A) Diode
X2
Excitation circuit E+, E- must not be left Z1 t - +
open when the machine is running : X1 Battery (B Volt)
AVR damage will occur. Z2
E+
3.2.3.1 - R438 field weakening (SHUNT) E-
Exciter field

X2 Forced excitation
B Volt
Z1
X1 t

Z2 Time
E+
E- Applications B volts Time t

Guaranteed voltage build-up 12 (1A) 1-2 s

The exciter is switched off by disconnecting Parallel operation, de-energized 12 (1A) 1-2 s
the AVR power supply (1 wire - X1 or X2).
Contact rating 16 A - 250V A.C. Parallel operation, at standstill 24 (2A) 5 - 10 s

Frequency starting 48 (4A) 5 - 10 s

3.2.3.2 - R438 field weakening (AREP/
PMG) Sustained voltage on overload 48 (4A) 5 - 10 s

X2
Z1
X1
Z2
E+
E-

The exciter is switched off by disconnecting

the AVR power supply (1 wire on each
auxiliary winding) - contact rating 16 A -
250V A.C.

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R438
A.V.R.

3.3 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its - Lack of residual magnetism
voltage is still correct when the
battery is removed.
No voltage at Connect a new battery The alternator builds up but its - Check the connection of the voltage
no load on of 4 to 12 volts to voltage does not reach the rated reference to the AVR
start-up terminals E- and E+, value when the battery is - Faulty diodes
respecting the polarity, removed. - Armature short-circuit
for 2 to 3 seconds
The alternator builds up but its - Faulty AVR
voltage disappears when the - Field windings disconnected
battery is removed - Main field winding open circuit - check the
resistance
Check the AVR connections (AVR may be
faulty)
Correct speed - Field windings short-circuited
Voltage too Check the drive speed - Rotating diodes burnt out
low - Main field winding short-circuited - Check
the resistance
Increase the drive speed
Speed too low (Do not touch the AVR voltage pot. (P2)
before running at the correct speed.)
Voltage too Adjust AVR voltage Adjustment ineffective Faulty AVR
high potentiometer
Voltage Adjust AVR stability If no effect : try normal / fast - Check the speed : possibility of cyclic
oscillations potentiometer recovery modes (ST2) irregularity
- Loose connections
- Faulty AVR
- Speed too low when on load (or U/F bend
set too high)
Voltage between E+ and E-
Voltage Run at no load and SHUNT < 20 V - AREP / PMG < - Check the speed (or U/F bend set too
correct at no check the voltage 10V high)
load and too between E+ and E- on Voltage between E+ and E- - Faulty rotating diodes
low when on the AVR SHUNT > 30V - AREP / PMG > - Short-circuit in the main field. Check the
load (*) 15V resistance
- Faulty exciter armature.
(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to
the operating terminals
Voltage Check the AVR, the The voltage does not return to the - Exciter winding open circuit
disappears surge suppressor, the rated value. - Faulty exciter armature
during rotating diodes, and - Faulty AVR
operation (**) replace any defective - Main field open circuit or short-circuited
components
(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)

Warning : after operational testing,

replace all access panels or covers.

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R438
A.V.R.

4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R. R 438 AEM 110 RE 017

4.2 - Technical support service

Our technical support service will be happy
to provide any information you require.

When ordering spare parts, you should in-

dicate the complete machine type, its serial
number and the information indicated on
the nameplate.

Part numbers should be identified from

the exploded views and their description
in the parts list.
Our extensive network of "service stations"
can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacture spare parts.
In the event of failure to comply with this ad-
vice, the manufacturer cannot be held res-
ponsible for any damage.

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R438
NOTES

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MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE

338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 €

www.leroy-somer.com