Users guide and maintenance

manual

Leroy Somer
Alternators
LSA 47.2 – 4 POLES
SHUNT - AREP - PMG

Réf. constructeur :
3742en-04.2003/a Réf. GPAO : 33522060501 ind1
 3742 en - 04.2003 / a

n to
b e give
u a l is to er
h i s man e n d us
T the
349
70
78
100
347
107
343
28
1
4
34
33
15
30

LSA 47.2 - 4 POLES

ALTERNATORS
Installation and maintenance
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

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 leading manufacturer operation.
worldwide, 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 the potential risk of accidents. It is vital that you
understand and take notice of the different warning symbols
used.

WARNING
ARNING

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.

Note: LEROY-SOMER reserves the right to modify the Copyright 2003: LEROY-SOMER
characteristics of its products at any time in order to This document is the property of:
incorporate the latest technological developments. The MOTEURS LEROY-SOMER
information contained in this document may therefore be It may not be reproduced in any form without prior
changed without notice. authorization.
All brands and models have been registered and patents
applied for.

2
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS

CONTENTS

1 - RECEIPT 5 - SPARE PARTS

1.1 - Standards and safety measures ..................... 4 5.1 - First maintenance parts ................................. 24

1.2 - Inspection ........................................................ 4 5.2 - Technical support service ............................ 24

1.3 - Identification .......................................... ......... 4 5.3 - Accessories ................................................. 24

1.4 - Storage ........................................................... 4 5.4 - Exploded views, parts list ............................ 25

2 - TECHNICAL CHARACTERISTICS

2.1 - Electrical characteristics .................................. 5

2.2 - Mechanical characteristics .............................. 5

2.3 - SHUNT excitation system .............................. 6

2.4 - AREP/PMG excitation system ....................... 7

3 - INSTALLATION

3.1 - Assembly ........................................................ 9

3.2 - Checks prior to first use .................................. 9

3.3 - Terminal connection diagrams .......................10

3.4 - Commissioning ..............................................12

3.5 - Setting up .......................................................13

4 - SERVICING - MAINTENANCE

4.1 - Safety measures ............................................16

4.2 - Routine maintenance .....................................16

4.3 - Fault detection ...............................................17

4.4 - Mechanical defects ........................................17

4.5 - Electrical faults ...............................................18

4.6 - Dismantling, reassembly ............................... 20

4.7 - Installation and maintenance of the PMG ..... 22

4.8 - Table of characteristics ................................. 23

3
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
RECEIPT

1 - RECEIPT 1.3 - Identification

The alternator is identified by means of a nameplate fixed on
1.1 - Standards and safety measures the machine (see drawing).
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, for
- the recommendations of the example: LSA 47.2 M7 C6/4 -
International Electrotechnical Commission • LSA: name used in the PARTNER range
IEC 34-1, (EN 60034). M: Marine
- the recommendations of the C: Cogeneration
International Standards Organisation ISO 8528. T: Telecommunications.
- the European Community directive 89/336/EEC on • 47.2: machine type
Electromagnetic Compatibility (EMC). • M7: model
- the European Community directives • C: excitation system
73/23/EEC and 93/68/EEC (Low Voltage Directive) (C: AREP/J: SHUNT or PMG/E: COMPOUND)
They are CE marked with regard to the LVD (Low Voltage • 6/4 : winding number / number of poles.
Directive) in their role as a machine component. A declaration
of incorporation can be supplied on request. 1.3.1 - Nameplate
Before using your generator for the first time, read carefully
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 write its specifications on the nameplate
generator should be undertaken by qualified personnel with below.
specialist training in the commissioning, servicing and
maintenance of electrical and mechanical machinery. This 1.4 - Storage
maintenance manual should be retained for the whole of the
Prior to commissioning, machines should be stored:
machine’s life and be handed over with the contractual file.
- Away from humidity: in conditions of relative humidity of
The various operations described in this manual are
more than 90%, the machine insulation can drop very rapidly,
accompanied by recommendations or symbols to alert the
to just above zero at around 100%; monitor the state of the
user to the potential risk of accidents. It is vital that you
anti-rust protection on unpainted parts. For storage over an
understand and take notice of the different warning symbols
extended period, the machine can be placed in a sealed
used.
enclosure (heatshrunk plastic for example) with dehydrating
sachets inside, away from significant and frequent variations
1.2 - Inspection in temperature to avoid the risk of condensation during
On receipt of your alternator, check that it has not suffered 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 be 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
Tension
N° 5700 125897 A15 Hz Voltage
V
Min-1/R.P.M. 1500 Protection Ph.
Made in France - 1 024 959/a

Cos Ø /P.F. 0,8 Cl. ther. / Th.class Connex.

Régulateur/A.V.R. R 438 B
kVA
Altit. ≤ m Masse / Weight Continue
Continuous kW
Rlt AV/D.E bearing 6302 2 RS C3
40°C A
Rlt AR/N.D.E bearing 6303 2 RS C3
Graisse / Grease 45g / 3600 h Secours kVA
Std by
Valeurs excit / Excit. values kW
en charge / full load 27°C A
à vide / at no load (*) Tension maxi. / maximum voltage

166631 Conforme à C.E.I 60034-1. According to I.E.C 60034-1.

C US

4
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
TECHNICAL CHARACTERISTICS

2 - TECHNICAL CHARACTERISTICS 2.2 - Mechanical characteristics

2.1 - Electrical characteristics - Steel frame
- Cast iron end shields
The LSA 47.2 alternator is a machine without sliprings or - Protected ball bearings, greased for life
revolving armature brushes, wound as “2/3 pitch”, 6 or - Mounting arrangements:
12-wire, with class H insulation and a field excitation system IM 1201 (MD 35) foot and flange mounted, single-bearing
available in either SHUNT, AREP or "PMG" version (see with SAE coupling disc.
diagrams). Interference suppression conforms to standard IM 1001 (B 34) double-bearing with SAE flange and standard
EN 55011, group 1, class B. cylindrical shaft extension.
- Drip-proof machine, self-cooled
2.1.1 - Electrical options - Degree of protection: IP 23

- Stator temperature detection sensors

2.2.1 - Mechanical options
- Bearing sensors (PTC, PT100, etc)
- Space heater - Air inlet filter
- Regreasable ball bearings
- IP 44 protection

MAIN FIELD STATOR : 12-wire (marking T1 to T 12)

SHUNT SYSTEM
T1 T7 T2 T8 T3 T9
EXCITER
Varistor

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

R 230 Power supply / Detection

MAIN FIELD STATOR : 6 or 12-wire (marking T1 to T 12)

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

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

R 448 Voltage reference

MAIN FIELD STATOR : 6 or 12-wire (marking T1 to T12)

PMG SYSTEM
T1 T7 T2 T8 T3 T9
EXCITER
Varistor

PMG

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

R 448 Voltage reference

5
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
TECHNICAL CHARACTERISTICS

2.3 - SHUNT excitation system 2.3.2 - R 230 AVR options

The alternator with Shunt excitation is self-excited with an Potentiometer for remote voltage adjustment, 1000 Ω /0.5 W
R 230 voltage regulator. The regulator monitors the min: adjustment range ± 5%.
excitation current of the exciter as a function of the alternator Remove the ST4 jumper.
output voltage. Very simple in design, the alternator with
shunt excitation has no sustaining short-circuit capacity. Voltage
Bend
48 Hz 57.5 Hz
U/UN
100 %
50 Hz
60 Hz

Frequency
50 Hz 60 Hz Hz

2.3.3 - Additional functions

with the R 448
As an option, the LSA 47.2 SHUNT alternator can work with
2.3.1 - R 230 AVR the R 448 AVR in order to obtain the following functions:
- Parallel operation between alternators with C.T.
- Voltage regulation: around ± 0.5%
- Parallel operation with the mains with C.T. and R 726 module
- Voltage sensing range 85 to 139 V (50/60 Hz)
- 3-phase sensing (R 731 module)
- Rapid response time (500 ms) for a transient voltage
- LAM function integrated in the R 448 AVR
variation amplitude of ± 20%
- Voltage setting P1
In this case, the R 448 AVR replaces the R 230.
- Stability setting P2
- Power supply protected by 8 A fuse, slow action (tolerates
10 A for 10 s) 50Hz ST3
3 ph
ST4
- Frequency: 50 Hz with ST3 jumper - 60 Hz without ST3
jumper S1 R 448 60Hz
- Factory-set underspeed protection P3
S2
Fuse
380 V
220 V
110 V

Voltage reference
4 x Ø5.8 x 50 mm
1A

0V E— E+ Z2 X1 Z1 X2
75 mm L1
E+
0V
110

L2
E-
140 mm
115 mm

S2 P2
L3
5+
S1 P1
F1 Slow fuse
250V 8 A

P1 U V W

R 230 6— 5+ (POWER SUPPLY

Voltage 110 V : 1/2 phase)
EXCITER
6-
P2
Stability
Exciter ALTERNATOR
field
P3
Under-speed
For adjustment and maintenance, refer to section 3.5 of this
manual.

ST4 ST3 Frequency

Potentiometer for remote
voltage adjustment
50Hz 60Hz

6
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
TECHNICAL CHARACTERISTICS

2.4 - AREP/PMG excitation system adjustable via potentiometer P4

- max. excitation current adjustment via P5: 4 to 10A
For both AREP & PMG excitation systems, the alternator - 50/60 Hz selection via ST3 jumper
voltage regulator is the R 448.
5+ 6-
ST5 With LAM W/o LAM Field

Response time
ST2 normal fast
Pwr supply
(see 2.3.2)

LAM 15%
200 x 140 mm
ST10 LAM 25% 4 x fl5.8 x 175 x 115

ST3 50Hz 60Hz F1

Slow fuse
Frequency 250V 10 A

With AREP excitation, the electronic AVR is powered by two

auxiliary windings which are independent of the voltage X2
sensing circuit. The first winding (X1, X2) has a voltage Z1
proportional to that of the alternator (Shunt characteristic), the P5
Excitation X1
second (Z1, Z2) has a voltage in proportion with the stator ceiling Z2
current (compound characteristic: Booster effect). The power E+
supply voltage is rectified and filtered before being used by P4 E-
the AVR monitoring transistor. As a result the machine has a
short-circuit current capacity of 3 IN for 10 s, and good
immunity to distortions generated by the load.
Under-
speed
R448 0V
110
220
L3
(W)

P3 380
Stability
With PMG excitation, a permanent magnet generator (PMG)
is added to the alternator. This is fitted at the rear of the P2
machine and connected to the R 448 AVR. The PMG supplies Voltage
the AVR with voltage which is independent of the main
alternator winding. As a result the machine has a short-circuit ST646.2
current capacity of 3 IN for 10 s, and good immunity to 47.1
distortions generated by the load. 49.1
P1 ST9
AREP
Quad droop
The AVR monitors and corrects the alternator output voltage ST1 PMG
Single-phase
by adjusting the excitation current. detection

3-ph detection L2(V)

T.I.
2.4.1 - R448 AVR characteristics 340-520V
Option S1 S2
- shunt power supply: max 140V - 50/60 Hz Option
R731 170-260V
- rated overload current: 10A - 10s
- electronic protection (overload, voltage sensing opening ST4 External potentiometer
for adjusting the voltage 95-140V
short-circuit): excitation overload current for 10 s then return Option

to approximately 1A.
The alternator must be stopped (or the power switched off,
see section 3.5.3) in order to reset the protection. 2.4.2 - R 448 power supply connection
- Fuse:
AREP excitation
• F1 on X1,X2.
- voltage sensing: 5 VA isolated via transformer Yellow
0-110 V terminals = 95 to 140 V R448 X2
Red
0-220 V terminals = 170 to 260 V Z1
0-380 V terminals = 340 to 520 V Green Aux. windings
X1
- voltage regulation ± 0.5% Black
Z2
- normal or rapid response time via ST2 jumper
- voltage adjustment via P2 potentiometer E+ 5+ 6-
other adaptation transformer voltages E-
- current sensing: (parallel operation): Exciter field
C.T. 2.5 VA cl1, secondary 1A (optional)
- quadrature droop adjustment via potentiometer P1
- underspeed protection (U/f) and LAM: frequency threshold

7
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
TECHNICAL CHARACTERISTICS

PMG excitation

R448 14 Voltage
X2
15
Z1 PMG Transient voltage drop
16 UN
X1
Z2
5+ 6-
E+ 0.9
E-
(U/f)
2.4.3 - Frequency compared with voltage 0.8 LAM
(without LAM)
Frequency
Voltage Bend 57.5 Hz Max. speed drop
U/UN 48 Hz LAM
100 %
fN
50 Hz
60 Hz
0.9

0.8
Frequency
50 Hz 60 Hz Hz Power
LAM
2.4.4 - LAM characteristics
Load on the

The LAM system is integrated in the regulator and is active as

shaft (kW)

standard (ST5 with bridge). It can be deactivated by removing

Variation in the load
the ST5 bridge.
The LAM can be adjusted to 15% or 25% by means of the
Load shedding due to "LAM"
ST10 jumper. Time
- Role of the “LAM” (Load Adjustment Module): (s)
On application of a load, the rotation speed of the generator 0 1s 2s 3s
set decreases. When it passes below the preset frequency
threshold, the LAM causes the voltage to drop by Typical effects of the "LAM" with a diesel engine -
approximately 15% or 25% and consequently the amount of with LAM without LAM (U/F only)
active load applied is reduced by approximately 25% to 45%,
until the speed reaches its rated value again.
Hence the LAM can be used either to reduce the speed 2.4.5 - R 448 AVR options
variation (frequency) and its duration for a given applied load,
or to increase the applied load possible for one speed - Current transformer for parallel operation
variation (turbo-charged engine). of ....../1 A - 2.5 VA CL 1 (See the diagram included with this
To avoid voltage oscillations, the trip threshold for the LAM manual).
function should be set approximately 2 Hz below the lowest - Rhe remote voltage adjustment potentiometer:
frequency in steady state. 470 Ω, 3 W min: adjustment range ± 5% (range limited by
Use of the LAM at 25% is recommended for load impacts ≥ internal voltage potentiometer P2). Remove ST4 to connect
70% of the genset rated power. the potentiometer. (A 1 k Ω potentiometer can also be used to
extend the adjustment range to ± 10%).
Voltage Underspeed and LAM - R 731 module: detection of 200 to 500V 3-phase voltage,
ST5 disconnected compatible with parallel operation. Disconnect ST1 to
UN Voltage connect the module; set the voltage via the module
P2
potentiometer.
U/f - R 726 module: regulation system changed to "4-function".
0.85 UN LAM LAM 15 % (See the maintenance manual and connection diagram.)
- P4 trip threshold
• PF regulation ϕ (2F)
for LAM or U/F • voltage matching before paralleling (3 F)
P4 factory preset. • mains connection of alternators already running in parallel
(4F)
48 or 57.5 Hz 50 or 60 Hz The R 726 module is connected in place of ST4.
0 fC
ST3 fN

8
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

3 - INSTALLATION 3.1.3 - Location

Ensure that the ambient temperature in the room where the
3.1 - Assembly alternator is placed cannot exceed 40°C for standard power
ratings (for temperatures > 40°C, apply a derating
coefficient). Fresh air, free from damp and dust, must be able
to circulate freely around the air intake grilles on the opposite
side from the coupling. It is essential to prevent not only the
All mechanical handling operations must be recycling of hot air from the machine or engine, but also
undertaken using approved equipment. exhaust fumes.
Whilst being handled, the machine should remain
horizontal. 3.2 - Checks prior to first use
3.1.1 - Handling 3.2.1 - Electrical checks
The generously-sized lifting rings are for handling the
alternator alone. They must not be used to lift the genset.
Choose a hoisting system which respects the positioning of
the rings.
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 110 °C (without the regulator)
b) Blow hot air into the air intake, 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 power terminals using
connections capable of supporting the rated current (try not to
exceed 6 A/mm2)
- Insert a clamp ammeter to monitor the current passing
through the short-circuit connections.
- Connect a 24 Volt battery in series with a rheostat of
approximately 10 ohms (50 W) to the exciter field terminals,
3.1.2 - Coupling respecting the polarity.
- Open fully all the alternator openings.
3.1.2.1 - single-bearing alternator
- Run the alternator at its rated speed, and adjust the exciter
Before coupling the machines, check that they are compatible
field current using the rheostat to obtain the rated output
by:
current in the short-circuit connections.
- undertaking a torsional analysis of the transmission
Note: Prolonged standstill: In order to avoid these problems,
- checking the dimensions of the flywheel and its housing, the
we recommend the use of space heaters, as well as turning
flange, coupling discs and offset
over the machine from time to time. Space heaters are only
WARNING
ARNING really effective if they are working continuously while the
machine is stopped.
When coupling the alternator to the prime mover, do not
use the fan to turn the alternator or rotor. 3.2.2 - Mechanical checks
The holes of the coupling discs should be aligned with
the flywheel holes by cranking the engine. Before starting the machine for the first time, check that:
Check that the “O” ring seal and the preloading (wavy) - all fixing bolts and screws are tight
washer are present in the NDE bearing seat. - the cooling air is drawn in freely
Check that there is lateral play on the crankshaft. - the protective grilles and housing are correctly in place
- the standard direction of rotation is clockwise as seen from
3.1.2.2 - double-bearing alternator the shaft end (phase rotation in order 1 - 2 - 3).
- Semi-flexible coupling For anti-clockwise rotation, swap 2 and 3.
Careful alignment of the machines is recommended, - the winding connection corresponds to the site operating
checking that the lack of concentricity and parallelism of both voltage (see section 3.3)
parts of the coupling do not exceed 0.1 mm.
This alternator has been balanced with a 1/2 key.

9
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

3.3 - Terminal connection diagrams

To modify the connection, change the position of the stator
cables on the terminals. The winding code is specified on the
nameplate.
Any intervention on the alternator terminals during
3.3.1 - Terminal connection: 12 wire reconnection or checks should be performed with
The connection accessories are detailed in section 5.3.3. the machine stopped.

Connection codes Voltage L.L Factory connection

A L1(U) Winding 50 Hz 60 Hz
T1 T7
3-phase 6 190 - 208 190 - 240
L3(W)
7 220 - T12 T6 T9 T3
T4 T10 N
L2(V)
T12 T5 8 - 190 - 208
T11 T5 T8 T2
T9 T2
T11 R 230 voltage sensing: L1(U)
T6 0 => (T8) / 110 V => (T11) T10 T4 T7 T1

L3(W) T3 T8 L2(V) R 448 voltage sensing: N NDE

0 => (T3) / 220 V => (T2)

Winding 50 Hz 60 Hz
T1 L1(U)
D 6 380 - 415 380 - 480
3-phase T4 L3(W)
T7
7 440 -
T12 T6 T9 T3
N 8 - 380 - 416 L2(V)
T10
T12 T11 T5 T8 T2
R 230 voltage sensing:
T9 L1(U)
T11 T5 0 => (T8) / 110 V => (T11)
T10 T4 T7 T1
T3 T6 T8 T2
R 448 voltage sensing:
N NDE
L3(W) L2(V) 0 => (T3) / 380 V => (T2)

9 - 600
Winding 9: R 448 voltage sensing + transformer (Diagram on request)

L1(U) Winding 50 Hz 60 Hz
F ( )
Single-phase
T12 T1 6 220 - 240 220 - 240
L3(W)*
or 7 240 - 254
T9 T4 - T12 T6 T9 T3
3-phase T6 T7
L2(V)
8 - 220 - 240
T11 T5 T8 T2
T3 T10
R 230 voltage sensing: L1(U)
L3(W) L2(V)
T11 T8 T5 T2
L 0 => (T8) / 110 V => (T11) T10 T4 T7 T1
L M AR M
Voltage LM = 1/2 voltage LL
R 448 voltage sensing:
0 => (T3) / 220 V => (T2) Operating phases L2 (V), L3 (W)
single phase

In case of reconnection, ensure that AVR voltage sensing is correct!

The factory can supply a set of flexible shunts and special connection links as an option for making these connections (*).

10
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

3.3.2 - Terminal connection: 6 wire (not possible with the R 230)

Connection codes Voltage L.L Factory connection

L1(U) Winding 50 Hz 60 Hz
D T1
3-phase
6S 380 - 415 380 - 480
L3(W)
7S 440 - T6 T3

N - L2(V)
T4
8S 380 - 416
T5 T2
T5 L1(U)
T6 R 448 voltage sensing:
0 => (T3) / 380 V => (T2) T4 T1
T3 T2 N
NDE
L3(W) L2(V)
9S - 600
Winding 9: R 448 voltage sensing + transformer (Diagram on request)

Winding 50 Hz 60 Hz ( )
F
Single-phase
L1(U)
6S 220 - 240 220 - 277 L3(W)
*
T6 T3
or 3-phase T6 7S 240 - 254 -
T1
L2(V)

8S - 220 - 240 T5 T2
L1(U)
T3 T4
T4 T1
R 448 voltage sensing: NDE
T5 T2 0 => (T3) / 220 V => (T2)
L3(W) L2(V) Operating phases: L2 (V), L3 (W) single phase

In case of reconnection, ensure that AVR voltage sensing is correct!

The factory can supply a set of flexible shunts and special connection links as an option for making these connections (*).

3.3.3 - Option connection diagram

A standard alternator is fitted with 3 starting ranges, 1 neutral
connection link.

R 791 T Interference suppression kit (standard for CE marking) Remote voltage potentiometer
Connections A D F

Black T1 T1 T1
Black T2 T2 T2
ST4
Black T3 T3 T3 Voltage adjustment
Blue N N via remote potentiometer
White

11
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

Current transformer connection

D connection - PH 1 D & A connection

In/2 - Secondary 1 A In/2 (D conn.) - Secondary 1 A
T4
P2 T10
6-wire P2
12-wire
P1 Neutral P1
Neutral
T4 link
link T10

Space heater PTC stator temperature sensors

130° C
103 blue wire
Ph1
101 250W - 220 V 150°C
Ph2 black wire
102
Ph3 180° C
104 red/white wire

3.3.4 - Connection checks 3.3.5 - Electrical checks on the AVR

- Check that all connections have been made properly as
shown in the attached wiring diagram.
- Check that the ST3 frequency selection jumper is on the
correct frequency setting.
Electrical installations must comply with the current - Check whether the ST4 jumper or the remote adjustment
legislation in force in the country of use. potentiometer have been connected.
Check that: - Optional operating modes
- The residual circuit-breaker conforms to legislation on • ST1 jumper: open circuit to connect the R 731 3-phase
protection of personnel, in force in the country of use, and has sensing module.
been correctly installed on the alternator power output as • ST2 jumper: open circuit for rapid response time
close as possible to the alternator. (In this case, disconnect • ST5 jumper: open to suppress the LAM function.
the wire of the interference suppression module linking the
neutral).
- Any protection devices in place have not been tripped. 3.4 - Commissioning
- If there is an external AVR, the connections between the
alternator and the cabinet are made in accordance with the
connection diagram.
- There is no short-circuit phase-phase or phase-neutral
between the alternator output terminals and the generator set The machine can only be started up and used if the
control cabinet (part of the circuit not protected by circuit- installation is in accordance with the regulations
breakers or relays in the cabinet). and instructions defined in this manual.
- The machine should be connected with the busbar The machine is tested and set up at the factory. When first
separating the terminals as shown in the terminal connection used with no load, make sure that the drive speed is correct
diagram. and stable (see the nameplate). With the regreasable bearing
option, we recommend greasing the bearings at the time of
commissioning (see 4.2.3).
On application of the load, the machine should achieve its
rated speed and voltage; however, in the event of abnormal
operation, the machine setting can be altered (follow the
adjustment procedure in section 3.5). If the machine still
operates incorrectly, the cause of the malfunction must be
located (see section 4.4).

12
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

3.5 - Setting up 3.5.2 - R 448 settings

SHUNT, AREP or PMG excitation system

WARNING
ARNING
The various adjustments during tests must be Before any intervention on the AVR, make sure that the
made by a qualified engineer. ST9 jumper is closed with AREP excitation and open
circuit with PMG excitation.

WARNING
ARNING
Ensure that the drive speed specified on the
nameplate is reached before commencing
adjustment

1500 min-1/50Hz or 1800 min-1/60 Hz.

Do not try to set the voltage if the frequency or

speed is not correct (risk of irreparable rotor
damage). a) Initial potentiometer settings (see table below)
The AVR is used to make any adjustments to the machine. - Remote voltage adjustment potentiometer: centre (ST4
jumper removed).

Action Factory setting Pot.

Voltage 400V - 50 Hz
After operational testing, replace all access panels (Input
minimum fully anti-clockwise P2
or covers. 0 - 380 V)

3.5.1 - R 230 settings Not set

Stability P3
Shunt excitation system (centre position)

Threshold/LAM or U/F Potentiometer

Underspeed protection factory sealed
and "LAM" trip threshold If ST3 = 50 Hz
Maximum frequency fully (factory) = 48 Hz P4
anti-clockwise If ST3 = 60 Hz
(factory) = 58 Hz
Voltage quadrature droop Not set
(// operation with C.T.) (fully anti-
- 0 quadrature droop fully clockwise) P1
anti-clockwise.
Excitation ceiling
Limit of excitation and 10 A
short-circuit current, maximum P5
minimum fully anti-clockwise
Initial potentiometer settings
- P1 potentiometer (AVR voltage adjustment): fully anti- Adjustments in standalone operation
clockwise
- Remote voltage adjustment potentiometer: centre position b) Install a D.C. analogue voltmeter (needle dial) cal. 100V on
Run the alternator at its rated speed. If the voltage does not terminals E+, E- and an A.C. voltmeter cal 300 - 500 or 1000V
increase, the magnetic circuit should be remagnetized (see on the alternator output terminals.
section 4.5)
- Turn the AVR voltage adjustment potentiometer P1 slowly c) Make sure that the ST3 jumper is positioned on the desired
until the output voltage rated value is obtained frequency (50 or 60 Hz).
- Adjust the stability setting using P2
- Sealed potentiometer P3 is factory set at 48 Hz for 50 Hz d) Voltage potentiometer P2 at minimum, fully anti-clockwise.
and 57.5 Hz for 60 Hz
e) Turn the V/Hz potentiometer P4 fully clockwise.

13
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

f) Turn the stability potentiometer P3 anti-clockwise to 2 3.5.3 - Max. excitation setting (excitation
marks away from the central position. ceiling)
g) Start the engine and set its speed to a frequency of 48 Hz Max. excitation depending on the mains frequency
for 50 Hz, or 58 for 60 Hz. ST3

h) Set the output voltage to the desired value using P2. X2

P5 50Hz 60Hz
A
- Rated voltage UN for solo operation (eg. 400 V) Z1
- Or UN + 2 to 4% for parallel operation with C.T. (eg. 410 V -) X1 Field ~ 10 ohms
P4
Z2
E+ - +
If the voltage oscillates, use P3 to make adjustments (try both P3 R 448
E- A
directions) observing the voltage between E+ and E- (approx. 15A DC
0V
10V D.C.). The best response times are obtained at the limit 110 V
of the instability. If no stable position can be obtained, try P2 220V
ST4
disconnecting or replacing the ST2 jumper (normal/fast). 380V
D
i) Check LAM operation: ST5 closed.
Voltage
j) Turn potentiometer P4 slowly anti-clockwise until there is a Adjustment of the current limit
significant voltage drop (approximately 15%) via potentiometer P5 (fuse rating: 8A-10 seconds).
The maximum factory setting corresponds to that of the
k) Vary the frequency (speed) around 48 or 58 Hz according excitation current required to obtain a 3-phase short-circuit
to the operating frequency, and check the change in voltage current of approximately 3 IN at 50 Hz for industrial power,
from that observed previously (approximately 15%). unless otherwise specified(*).
A static method can be used to reduce this value or adapt the
l) Readjust the speed of the unit to its rated no-load value. Isc to the actual operating power (derated machine), which is
safer for the alternator and the installation. Disconnect power
Adjustments in parallel operation supply wires X1,X2 and Z1,Z2 and the voltage reference (0-
110V-220V-380V) from the alternator.
WARNING
ARNING Connect the mains power supply (200-240V) as indicated
(X1,X2). Install a 10A D.C. ammeter in series with the exciter
Before any intervention on the alternator, make field. Turn P5 fully anti-clockwise and activate the power
sure that the speed droop is identical for all supply. If there is no output current from the AVR, turn
engines. potentiometer P2 (voltage) clockwise until the ammeter
indicates a stable current. Switch the power supply off, then
m) Preset for parallel operation (with C.T. connected to S1, on again, turn P5 clockwise until the required max. current is
S2 on connector J2) obtained (no more than 10 A).
- Potentiometer P1 (quadrature droop) in centre position.
Apply the rated load (cos Ø = 0.8 inductive). Checking the internal protection:
The voltage should drop by 2 to 3%. If it increases, swap the
2 incoming wires of the C.T. secondary. Open switch (D): the excitation current should increase to its
preset ceiling, remain at that level for ≥ 10 seconds and then
n) The no-load voltages should be identical for all the drop to < 1A.
alternators intended to run in parallel. To reset, switch off the power supply by opening switch (A).
- Couple the machines in parallel Note: After setting the excitation ceiling as described, adjust
- By adjusting the speed, try to obtain 0 KW the voltage again (see section 3.5.2.) via P2.
power exchange. (*): In some countries it is a legal requirement to have a short-
- By altering the voltage setting P2 or Rhe on one of the circuit current, so as to offer discriminating protection.
machines, try to cancel (or minimise) the current circulating
between the machines.

From now on, do not touch the voltage settings.

o) Apply the available load (the setting is only correct if a
reactive load is available)
- By altering the speed, match the KW (or divide the rated
power of the units proportionally)
- By altering the quadrature droop potentiometer P1, match or
divide the currents.

14
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
INSTALLATION

3.5.4 - Special type of use

- Field weakening

X2 AREP / PMG
Z1
X1
Z2
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.
Connection is identical for resetting the AVR internal
protection.

- Field forcing

(400V - 10A) Diode

X2
R 448

Z1 t - +
X1 Battery (B Volt)
Z2
E+
~ 10 ohms
E-
Exciter field

Field forcing
B Volt

Time

Applications B volts Time t

Guaranteed voltage build-up 12 (1A) 1 -2 s
Parallel operation, de-energized 12 (1A) 1 -2 s
Parallel operation, at standstill 24 (2A) 5 - 10 s
Frequency starting 48 (4A) 5 - 10 s
Sustained voltage on overload 48 (4A) 5 - 10 s

15
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
SERVICING - MAINTENANCE

4 - SERVICING - MAINTENANCE 4.2.4 - Electrical servicing

Cleaning product for the windings
4.1 - Safety measures

WARNING
ARNING
Do not use: trichlorethylene, perchlorethylene,
Servicing or troubleshooting must be carried out trichloroethane or any alkaline products.
strictly in accordance with instructions so as to
avoid the risk of accidents and to maintain the Certain strictly defined pure volatile degreasing agents can be
machine in its original state. used, such as:
- Normal petrol (without additives)
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable
- Ciclohexare (non toxic); inflammable
All such operations performed on the alternator
should be undertaken by personnel trained in the Cleaning of the stator, rotor, exciter and diode bridge
commissioning, servicing and maintenance of The insulating components and the impregnation system are
electrical and mechanical components. not at risk of damage from solvents (see the above list of
authorised products).
Before any intervention on the machine, ensure that it cannot Avoid letting the cleaning product run into the slots. Apply the
be started by a manual or automatic system and that you product with a brush, sponging frequently to avoid
have understood the operating principles of the system. accumulation in the housing. Dry the winding with a dry cloth.
Let any traces evaporate before reassembling the machine.
4.2 - Routine maintenance
4.2.5 - Mechanical servicing
4.2.1 - Checks after start-up
After approximately 20 hours of operation, check that all fixing WARNING
ARNING
screws on the machine are still tight, plus the general state of
the machine and the various electrical connections in the Cleaning the machine using water or a high-
installation. pressure washer is strictly prohibited.
Any problems arising from such treatment are not
4.2.2 - Cooling circuit covered by our warranty.
It is advisable to check that circulation of air is not reduced by
Degreasing: Use a brush and detergent (suitable for
partial blocking of the air intake and outlet grilles: mud, fibre,
paintwork).
grease, etc.
Dusting: Use an air gun.
If filters have been added to the machine after manufacture
4.2.3 - Bearings and do not have thermal protection, the service personnel
The bearings are regreasable (option). It is advisable to should clean the air filters periodically and systematically, as
lubricate the machine during operation. Time intervals and often as is necessary (every day in very dusty atmospheres).
quantity of grease are given in the table below. The filter cant be cleaned with air gun in case of dry dust.
NDE/DE bearing 6318 C3 6315 C3 The filter must be changed in case of greasy dust.
After cleaning the alternator, it is essential to check the
Quantity of grease 41 g 30 g winding insulation (see sections 3.2 and 4.8).
Regreasing interval 3500 hrs 4500 hrs

Lubrication intervals are given for grease type

LITHIUM - standard - NLGI 3.
In the factory, the grease used for lubrication is:
SHELL - ALVANIA G3.
Before using another grease, check for compatibility with the
original one. Monitor the temperature rise in the bearings,
which should not exceed 50°C above the ambient
temperature. Should this value be exceeded, the machine
must be stopped and checks carried out.

16
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
SERVICING - MAINTENANCE

4.3 - Fault detection

If, when commissioned, the alternator does not work
normally, the source of the malfunction must be identified.
To do this, check that:
- the protection devices are fitted correctly
- the connections comply with the diagrams in the manuals
supplied with the machine
- the speed of the unit is correct (see section 1.3)
Repeat the operations defined in section 3.

4.4 - Mechanical defects

Fault Action
- If the bearing has turned blue or if the grease has turned black, change
Bearing Excessive temperature rise in one or the bearing.
both bearings (bearing temperature
more than 80 °C) with or without - Bearing not fully locked (abnormal play in the bearing cage).
abnormal bearing noise.
- Check the end shield alignment (flange not properly fitted).
- Air flow (intake-outlet) partially clogged or hot air is being recycled from
Excessive temperature rise in the the alternator or engine
Abnormal alternator housing (more than 40° C
temperature above the ambient temperature) - Alternator operating at too high a voltage (> 105% of Un on load)

- Alternator overloaded
- Misalignment (coupling)
Excessive vibration
Vibration - Defective mounting or play in coupling

- Rotor balancing fault (Engine - Alternator)

Excessive vibration and humming - Phase imbalance
noise coming from the machine
- Stator short-circuit
- System short-circuit

- Mis-paralleling

Possible consequences:

- Broken or damaged coupling

Abnormal Alternator damaged by a significant
noise impact, followed by humming and - Broken or bent shaft extension.
vibration
- Shifting and short-circuit of revolving field winding.

- Fan fractured or coming loose on shaft.

- Irreparable damage to rotating diodes or AVR.

17
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

ALTERNATORS
SERVICING - MAINTENANCE

4.5 - Electrical faults

Fault Action Effect Check/Cause
The alternator builds up and its
voltage is still correct when the - Lack of residual magnetism
battery is removed.
No voltage at Connect a new battery The alternator builds up but its - Check the connection of the voltage reference to the
no load on of 4 to 12 volts to voltage does not reach the AVR
start-up terminals E- and E+, rated value when the battery is
respecting the polarity, removed. - Faulty diodes
for 2 to 3 seconds
- Armature short-circuit
The alternator builds up but its - Faulty AVR
voltage disappears when the
battery is removed - Field windings open circuit (check winding)

- Revolving field coil open circuit (check the

resistance)
Check the AVR connections (AVR may be faulty)
- Field windings short-circuited

- Rotating diodes burnt out

Correct speed
- Revolving field coil short-circuited
Voltage too Check the drive speed
low - 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
- Check the speed: possibility of cyclic irregularity

- Loose connections
Voltage Adjust the If no effect: try normal or fast
oscillations AVR stability stability modes (ST2) - Faulty AVR
potentiometer
- Speed too low when on load (or LAM set too high)
Voltage between E+ and E-
(DC) - Check the speed (or LAM set too high)
SHUNT/AREP/PMG < 10V
Voltage Run at no load and
correct check the voltage - Faulty rotating diodes
at no load and between E+ and E- on Voltage between E+ and E-
too low when the AVR - Short-circuit in the revolving field coil. Check the
on load SHUNT/AREP/PMG > 15V resistance

- Faulty exciter armature. Check the resistance.

- Exciter winding open circuit
Voltage Check the AVR, the
disappears surge suppressor, the The voltage does not return to - Faulty exciter armature
during rotating diodes, and the rated value
operation replace any defective - Faulty AVR
components
- Revolving field coil open circuit or short-circuited

18
 LEROY-SOMER INSTALLATION AND MAINTENANCE 3742 en - 04.2003 / a

LSA 47.2 - 4 POLES

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.
ASSEMBLY A 6 - Exciter field 5 +
WARNING
ARNING
Diode 1A Rh. 50½ -300W
Damage caused to the AVR in such conditions is
not covered by our warranty.
+
-

12V battery
After operational testing, replace all access panels
or covers.

4.5.2 - Checking the diode bridge Assembly B: Connect a “Variac” variable power supply and
a diode bridge on both exciter field wires (5+) and (6-).
A diode in good working order should allow the current to flow
Both these systems should have characteristics which are
only in the anode-to-cathode direction
compatible with the field excitation power of the machine (see
the nameplate).
Anode A Cathode 3) Run the unit at its rated speed.
C 4) Gradually increase the exciter field current by adjusting the
- + rheostat or the variac and measure the output voltages on L1
C C C A C - L2 - L3, checking the excitation voltage and current at no
load and on load (see the machine nameplate or ask for the
factory test report).
When the output voltage is at its rated value and balanced
A A A 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
- - -
C A 6 - Exciter field 5+
C C C
40
50 60 +
30

70

Diode 1A
20

80
10

90

A A A 0 100

- DC
Variac AC 12V
4.5.3 - Checking the windings and rotating 220V
diodes using separate excitation

During this procedure, make sure that the

alternator is disconnected from any external load
and inspect the terminal box to check that the
connections are fully tightened.

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

2) There are two ways of creating an assembly with separate
excitation.

19