Professional Documents
Culture Documents
2007 / a
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LEROY-SOMER
4099 en - 03.2007 / a
SAFETY MEASURES
Before using your machine for the first time, it is important to
read the whole of this installation and maintenance manual.
WARNING SYMBOLS
We wish to draw your attention to the following 2 safety
measures which must be complied with:
a) During operation, do not allow anyone to stand in front
of the air outlet guards, in case anything is ejected from
them.
b) Do not allow children younger than 14 to go near the
air outlet guards.
A set of self-adhesive stickers depicting the various warning
symbols is included with this maintenance manual. They
should be positioned as shown in the drawing below once the
machine has been fully installed.
CAUTION
Warning symbol for an operation capable of
damaging or destroying the machine or
surrounding equipment.
LEROY-SOMER
4099 en - 03.2007 / a
CONTENTS
1 - RECEIPT
5 - SPARE PARTS
EC declaration of incorporation...........................19
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics ............................ 5
2.2 - Mechanical characteristics ......................... 5
3 - INSTALLATION
3.1 - Assembly .................................................... 6
3.2 - Checks prior to first use .............................. 6
3.3 - Terminal connection diagrams .................... 7
3.4 - Commissioning ............................................8
4 - SERVICING - MAINTENANCE
4.1 - Safety measures .........................................9
4.2 - Routine maintenance .................................9
4.3 - Fault detection ..........................................10
4.4 - Mechanical defects .................................10
4.5 - Electrical faults .........................................10
4.6 - Dismantling, reassembly ......................... 12
4.7 - Installation and maintenance
of the PMG ............................................. 14
4.8 - Table of characteristics ...........................15
LEROY-SOMER
4099 en - 03.2007 / a
1 - RECEIPT
1.3.1 - Nameplate
1.2 - Inspection
On receipt of your alternator, check that it has not suffered
any damage in transit. If there are obvious signs of damage,
contact the transporter (you may be able to claim on their
insurance) and after a visual check, turn the machine by hand
to detect any malfunction.
1.3 - Identification
1.4 - Storage
Prior to commissioning, machines should be stored:
- Away from humidity: In conditions of relative humidity of
more than 90%, the machine insulation can drop very rapidly,
to just above zero at around 100%; monitor the state of the
anti-rust protection on unpainted parts. For storage over an
extended period, the machine can be placed in a sealed
enclosure (heatshrunk plastic for example) with dehydrating
sachets inside, away from significant and frequent variations
in temperature to avoid the risk of condensation during
storage.
- If the area is affected by vibration, try to reduce the effect of
these vibrations by placing the generator on a damper
support (rubber disc or similar) and turn the rotor a fraction of
a turn once a fortnight to avoid marking the bearing rings.
1.5 - Application
These alternators are mainly designed to produce electricity
in the context of applications involving the use of generators.
ALTERNATEURS
LSA
Date
N 5700 125897 A15
Hz
Min-1/R.P.M. 1500 Protection
Cos /P.F. 0,8 Cl. ther. / Th.class
Rgulateur/A.V.R.
R 438 B
Altit.
m Masse / Weight
Rlt AV/D.E bearing
6302 2 RS C3
Rlt AR/N.D.E bearing 6303 2 RS C3
Graisse / Grease
45g / 3600 h
Valeurs excit / Excit. values
en charge / full load
vide
/ at no load
166631
C
US
ALTERNATORS
PUISSANCE / RATING
Tension
Voltage
V
Ph.
Connex.
kVA
Continue
Continuous
kW
40C
A
kVA
Secours
Std by
kW
27C
A
(*) Tension maxi. / maximum voltage
LEROY-SOMER
4099 en - 03.2007 / a
2 - TECHNICAL CHARACTERISTICS
- Steel frame
- Cast iron end shields
- Protected ball bearings, permanently greased
- Mounting arrangements:
IM 1201 (MD 35) foot and flange mounted, single-bearing
with SAE coupling disc
IM 1001 (B 34) twin-bearing with SAE flange and standard
cylindrical shaft extension
- Drip-proof machine, self-cooled
- Degree of protection: IP 23
AREP SYSTEM
T1
T2
T3
T4
T5
T6
Varistor
EXCITER
Armature
5+
6-
Field coil
R 448 V50
REVOLVING FIELD COIL
Voltage reference
PMG SYSTEM
Varistor
EXCITER
T1
T2
T3
T4
T5
T6
PMG
Armature
5+
6-
Field coil
R 448 V50
Voltage reference
LEROY-SOMER
4099 en - 03.2007 / a
3 - INSTALLATION
Personnel undertaking the various operations indicated
in this section must wear personal protective equipment
appropriate for mechanical and electrical hazards.
3.1 - Assembly
3.1.1 - Handling
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. The choice of lifting hooks or handles should be
determined by the shape of these rings.
3.1.3 - Location
Ensure that the ambient temperature in the room where the
alternator is placed cannot exceed 40C for standard power
ratings (for temperatures > 40C, apply a derating
coefficient). Fresh air, free from damp and dust, must be able
to circulate freely around the air intake guards on the opposite
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.
3.1.2 - Coupling
3.1.2.1 - single-bearing alternator
Before coupling the machines, check that they are compatible
by:
- undertaking a torsional analysis of the transmission
- Checking the dimensions of the flywheel and its housing, the
flange, coupling discs and alternator offset
CAUTION
When coupling the alternator to the prime
mover, do not use the fan to turn the alternator
rotor.
LEROY-SOMER
4099 en - 03.2007 / a
Before starting the machine for the first time, check that:
- The winding connection corresponds to the site operating
voltage (see section 3.3)
- All fixing bolts and screws are tight
- The cooling air is drawn in freely
- The protective guards 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 phases 2 and 3 and derate
the machine by 5%.
If mounting a C.T. for parallel operation, reverse the
secondary wires S1, S2 on the AVR.
Connection code
L.L voltage
L1(U)
T1
3-phase
T4
Factory connection
Winding
50 Hz
60 Hz
6S
380 - 415
380 - 480
7S
8S
440
380 - 416
L3(W)
T6
T3
L2(V)
T5
T5
T6
T3
T2
L1(U)
T4
L2(V)
L3(W)
T2
9S
NDE
T1
600
L1(U)
F
3-phase
T6
T1
T3
Winding
50 Hz
60 Hz
6S
220 - 240
220 - 277
7S
240 - 254
8S
( )
L3(W)
T6
T3
L2(V)
220 - 240
T5
T2
T4
L1(U)
T2
T5
L2(V)
L3(W)
T4
NDE
T1
If the alternator is reconnected, check that the AVR is sensing the voltage!
As an option, the factory can provide special connector bars to make these connections (*).
T1
T2
T3
N
T1
T2
T3
1000 ohms
ST4
Voltage adjustment via remote
potentiometer
LEROY-SOMER
4099 en - 03.2007 / a
P1
Neutral link
Ph1
130 C
blue wire
Ph2
150 C
black wire
103
T4
P2
6 wires
Space heater
500W - 220 V
101
102
T4
Ph3
104
Shield PT100
121
122
122
123
124
124
180 C
red/white
wire
White
121 White
122 Red
122 Red
DE
123 White
124 Red
124 Red
NDE
103
104
104
103 White
104 Red
104
Red
PH 1
105
106
106
105 White
106 Red
106
Red
PH 2
107
108
108
107 White
108 Red
108
Red
PH 3
3.4 - Commissioning
3.5 - Setting up
LEROY-SOMER
4099 en - 03.2007 / a
4 - SERVICING - MAINTENANCE
4.1 - Safety measures
CAUTION
All such operations performed on the alternator
should be undertaken by personnel trained in the
commissioning, servicing and maintenance of
electrical and mechanical components, who must
wear personal protective equipment appropriate
for mechanical and electrical hazards.
Before any intervention on the machine, ensure that it cannot
be started by a manual or automatic system and that you
have understood the operating principles of the system.
4.2.3 - Bearings
6226 2Z C3
6320 2Z C3
Code
Replacement
6226 C3
6320 C3
Code
Quantity of grease
50 g
50 g
Lubrication interval
3600 hrs
3600 hrs
CAUTION
Cleaning the machine using water or a highpressure washer is strictly prohibited.
Any problems arising from such treatment are not
covered by our warranty.
Degreasing: Use a brush and detergent (suitable for
paintwork).
Dusting: Use an air gun.
If filters have been added to the machine after manufacture
and do not have thermal protection, the service personnel
should clean the air filters periodically and systematically, as
often as is necessary (every day in very dusty atmospheres).
With dry dust, the filter can be cleaned
with an air gun.
With greasy dust, the filter must always be changed.
LEROY-SOMER
4099 en - 03.2007 / a
Abnormal
temperature
Vibrations
Abnormal
noise
10
Causes
- If the bearing has turned blue or if the grease has turned black, change
the bearing.
- Bearing not properly seated.
- End shields misaligned (flanges not properly fitted)
- Air flow (intake/outlet) partially clogged or hot air is being recycled from
Excessive temperature rise of
the alternator or engine
alternator frame (more than 40C
- Alternator operating at too high a voltage (> 105% of Un on load)
above the ambient temperature)
- Alternator overloaded
- Misalignment (coupling)
Too much vibration
- Defective mounting or play in coupling
- Rotor balancing fault
Excessive vibration and humming
- Phase imbalance
noise coming from the machine
- Stator short-circuit
- System short-circuit
- Mis-paralleling
Possible consequences
Alternator damaged by a significant
- Broken or damaged coupling
impact, possibly followed by humming
- Broken or bent shaft end
and vibration
- Shifting and short-circuit of revolving field winding
- Fan fractured or coming loose on shaft
- Destruction of the rotating diodes or AVR
LEROY-SOMER
4099 en - 03.2007 / a
No voltage at
no load on
start-up
Action
Effect
The alternator builds up and its
voltage is still correct when the
battery is removed
The alternator builds up but its
voltage does not reach the rated
Connect a new battery value when the battery is
of 4 to 12 V to terminals removed
E- and E+, respecting
The alternator builds up but its
the polarity, for 2 to
voltage disappears when the
3 seconds
battery is removed
Correct speed
Voltage too
low
Voltage too
high
Voltage
oscillations
Adjust the
AVR stability
potentiometer
Voltage
correct
at no load and
too low when
on load
Voltage
disappears
during
operation
Check/Cause
CAUTION
Damage caused to the AVR in such conditions is
not covered by our warranty.
11
LEROY-SOMER
4099 en - 03.2007 / a
Cathode
C C C
A A A
~ ~ ~
~ ~ ~
+
-
ASSEMBLY B
40
50
10
90
100
1A diode
80
Variac
A A A
5+
60
20
6 - Field coil
70
C C C
30
Anode
220V
AV
12V
DC
ASSEMBLY A
6 - Field coil
1A diode
5+
50 -300W rh.
12V battery
12
LEROY-SOMER
4099 en - 03.2007 / a
Screw
M8
M6
M12
M12
M20
M6
M6
M12
M12
Torque N.m
20
4
69
69
340
5
5
35
35
- Fit the new antifriction bearing onto the shaft after heating it
by induction to approximately 80 C.
- Mount the new preloading (wavy) washer (79) + the new O
ring seal (349) in the shield (36).
- Screw a threaded rod into the inner bearing cap (78).
- Refit the end shield on the machine using a dowel and nut
in the shaft extension (see drawing).
- Slide the threaded rod into the shield hole to make it easier
to assemble (see diagram).
78 36
Threaded rod
Dowel
Nut
Rotor
NDE shield
- Fit a inner bearing cap screw (78), remove the threaded rod,
fit the other screws and tighten up the assembly.
- Tighten the shield screws (37).
- Reconnect exciter field wires E+, E-.
- Finish reassembling the cover.
CAUTION
When dismantling the shields, you will need to
change the antifriction bearings, the "O" ring seal
and the preloading (wavy) washer.
13
LEROY-SOMER
4099 en - 03.2007 / a
CAUTION
- Remove the grille (417) then take out the filter (418). Change
the filter if necessary; please refer to section 4.2.5 for
cleaning the filter.
To replace, follow the instructions in reverse order.
- On certain versions, the filters are incorporated in the
terminal box panels.
- Screw an M20 threaded rod into the shaft NDE hole and use
it to guide and support the rotor.
- Remove the DE shield (30) (see 4.6.6.) if it is a twin-bearing
machine.
- Support the DE rotor (4) with a strap or with a support
constructed in accordance with the following drawing.
- Move the strap as the rotor moves in order to distribute the
weight evenly over it.
51
418
417
CAUTION
When dismantling the rotor involves changing
parts or rewinding, the rotor must be rebalanced.
- Mount the rotor (4) in the stator (1) (see drawing above)
taking care not to knock the windings.
- Slide the threaded rod into the shield hole to make it easier
to assemble (see diagram).
- Fit an inner bearing cap screw (78), remove the threaded
rod, fit the other screw and tighten up the assembly.
- Tighten the shield screws (37).
- Reconnect exciter field wires E+, E-.
- Finish reassembling the cover.
- Refit the flange (30) on the stator (1).
- Tighten the screws (31).
14
LEROY-SOMER
4099 en - 03.2007 / a
CAUTION
With the PMG, check that the ST9 jumper is open circuit.
LSA 50.2
S4
M6
L7
L8
VL10
L/N stator
0.00208
0.00159
0.00137
0.00123
0.00103
Rotor
0.390
0.434
0.461
0.506
0.555
Exciter
field
11.1
11.1
11.1
11.1
11.1
Armature
0.06
0.06
0.06
0.06
0.06
No load
0.9
0.9
1
0.9
0.9
At rated load
4
4.1
4
3.9
3.7
290
291
292
293
294
296
295
297
LSA 50.2
S4
M6
L7
L8
VL10
Rotor (kg)
855
956
1027
1105
1215
15
LEROY-SOMER
4099 en - 03.2007 / a
5 - SPARE PARTS
5.3 - Accessories
- 6-wire machines
16
LEROY-SOMER
4099 en - 03.2007 / a
42
47
50
367
466
366
323
325
322
30
130
41
36
128
21
33
15
Ref.
1
4
15
21
30
33
36
41
42
47
48
50
51
70
71
78
79
90
100
120
124
128
130
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
Description
Stator assembly
Rotor assembly
Fan
Lifting ring
DE flange
Protective grille
Exciter end shield
Cover front panel
Cable gland plate
Teminal box rear lid
Terminal box top lid
Lower inspection door
Air intake grille
NDE bearing
Cover
Inner bearing cap
Preloading wavy washer
Exciter field
Exciter armature
Terminal support
Terminals
Starting range
Neutral link
320
124
Ref.
198
320
322
323
325
343
349
366
367
466
198
120
Qty
1
1
3
8
1
1
1
1
1
343
100
90
78
70
349
79
51
71
Description
Voltage regulator (AVR)
Coupling hub
Coupling disc
Fixing screw
Spacer shim
Diode bridge assembly
'O' ring seal
Terminal box side lid
Terminal box side lid with inspection door
AVR inspection door
17
LEROY-SOMER
4099 en - 03.2007 / a
42
47
50
367
466
366
30
33
60
68
130
41
36
128
21
15
320
Ref.
1
4
15
21
30
33
36
41
42
47
48
50
51
60
68
70
71
78
79
90
100
120
18
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Stator assembly
Rotor assembly
Fan
Lifting ring
Drive end shield
Protective grille
Exciter end shield
Cover front panel
Cable gland plate
Terminal box rear lid
Terminal box top lid
Inspection door
Air intake grille
DE bearing
Inner bearing cap
NDE bearing
Cover
Inner bearing cap
Preloading wavy washer
Exciter field
Exciter armature
Terminal support
124
Ref.
124
128
130
198
320
343
349
365
366
367
466
198
120
343
Qty
3
1
1
1
1
1
1
1
1
1
100
90
78
70
349
79
51
71
Description
Terminals
Starting range
Neutral link
Voltage regulator (AVR)
Hub
Diode bridge assembly
'O' ring seal
Terminal box rear lid
Terminal box side lid
Terminal box side lid with inspection door
AVR inspection door
LEROY-SOMER
4099 en - 03.2007 / a
Alternator Division
6 June 2007
EC DECLARATION OF INCORPORATION
Concerns electric generators designed to be incorporated in machines subject to Directive no. 98/37/EC.
The manufacturer :
Moteurs LEROYSOMER
Boulevard Marcellin Leroy
16015 ANGOULEME (France)
Herein declares that the electric generators in the PARTNER range (low voltage) and those series based on them
conform to the following standards and directives:
EN and IEC 600341 and 600345
ISO 85283 (Design of alternators for generator applications)
Low Voltage Directive no. 73/23/EC dated 19 February 1973, modified by Directive no. 93/68/EC
dated 22 July 1993
These generators are designed to be used in complete power generating sets which must comply with the
following standards and directives:
Machinery directive no. 98/37/EC
- EMC directive no. 89/336/EC modified by Directives nos. 92/31 EC dated 28 April 1992 and 93/68/EC
dated 22 July 1993, concerning the intrinsic characteristics of emission and immunity levels.
WARNING:
The abovementioned generators must not be commissioned until the machines in which they are to be
incorporated have been declared as conforming to Directives nos. 98/37/EC and 89/336 EC and any other
directives that may be applicable.
19