4099 en / a LSA POLES ALTERNATORS. Installation and maintenance

Transcription

1 4 This manual is to be given to the end user Installation and maintenance

2 This manual concerns the alternator 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 alternator, 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 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. All necessary operations and interventions on this machine 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 following warning symbols. 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 2005: MOTEURS LEROY-SOMER This document is the property of: LEROY-SOMER It may not be reproduced in any form without prior authorization. All brands and models have been registered and patents applied for. 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

3 CONTENTS 1 - RECEIPT Standards and safety measures Inspection Identification Storage TECHNICAL CHARACTERISTICS Electrical characteristics SPARE PARTS First maintenance parts Technical support service Accessories Exploded views, parts list DECLARATION OF INCORPORATION FOR C.E. MARKING Mechanical characteristics INSTALLATION Assembly Checks prior to first use Terminal connection diagrams Commissioning SERVICING - MAINTENANCE Safety measures Routine maintenance Fault detection Mechanical defects Electrical faults Dismantling, reassembly Installation and maintenance of the PMG Table of characteristics

4 RECEIPT 1 - RECEIPT Standards and safety measures Our alternators comply with most international standards and are compatible with: - The recommendations of the International Electrotechnical Commission IEC 34-1, (EN 60034). - The recommendations of the International Standards Organisation ISO The European Community directive 89/336/EEC on Electromagnetic Compatibility (EMC). - The European Community directives 73/23/EEC and 93/68/EEC (Low Voltage Directive) They are CE marked with regard to the LVD (Low Voltage Directive) in their role as a machine component. A declaration of incorporation can be supplied on request. Before using your generator for the first time, read carefully the contents of this installation and maintenance manual, supplied with the machine. All operations performed on the generator should be undertaken by qualified personnel with specialist training in the commissioning, servicing and maintenance of electrical and mechanical machinery. This maintenance manual should be retained for the whole of the machine's life and be handed over with the contractual file. 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 warning symbols included with the machine 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 Identification The alternator is identified by means of a nameplate fixed on the machine (see drawing). Make sure that the nameplate on the machine conforms to your order. The machine name is defined according to various criteria, for example: LSA 50.2 M6 C 6S/4 - LSA : Name used in the PARTNER range M : Marine C : Cogeneration 50.2 : Machine type M6 : Model C : Excitation system (C: AREP/J: SHUNT or PMG) 6S/4 : Winding number/number of poles Nameplate So that you can identify your machine quickly and accurately, we suggest you write its specifications on the nameplate below 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. ALTERNATEURS LSA Date N A15 Hz Min -1 /R.P.M Protection Cos Ø /P.F. 0,8 Cl. ther. / Th.class Régulateur/A.V.R. R 438 B Altit. m Masse / Weight Rlt AV/D.E bearing RS C3 Rlt AR/N.D.E bearing RS C3 Graisse / Grease 45g / 3600 h Valeurs excit / Excit. values en charge / full load à vide / at no load Tension Voltage Connex. Continue Continuous 40C Secours Std by 27C PUISSANCE / RATING (*) Tension maxi. / maximum voltage V Ph. kva kw A kva kw A Made in France /a C US Conforme à C.E.I According to I.E.C

5 TECHNICAL CHARACTERISTICS 2 - TECHNICAL CHARACTERISTICS Electrical characteristics The LSA 50.2 alternator is a brushless machine, wound as "2/3 pitch", 6-wire, with class H insulation and a field excitation system available in either AREP or "PMG" version (see diagrams and AVR manual ref: 3972) Electrical options - Stator temperature detection sensors - Bearing sensors (PTC, PT100, etc) - Space heater - Current transformer (C.T.) Interference suppression conforms to standard EN 55011, group 1, class B Mechanical 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 Mechanical options - Air inlet filter - Regreasable ball bearings - IP 44 protection (inlet and outlet filters) AREP SYSTEM EXCITER REVOLVING FIELD COIL STATOR: 6 wires (marked T1 to T6) Auxiliary wdgs T1 T2 T3 Varistor Armature Field coil T4 T5 T6 R 448 V50 Voltage reference PMG SYSTEM EXCITER REVOLVING FIELD COIL STATOR: 6 wires (marked T1 to T6) T1 T2 T3 Varistor PMG Armature Field coil T4 T5 T6 R 448 V50 Voltage reference 5

6 INSTALLATION 3 - INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards Assembly All mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal. Check the weight of the machine on the nameplate before choosing the lifting tool 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. rotor. The holes of the coupling discs should be aligned with the flywheel holes by turning the engine flywheel. Make sure the alternator is securely bedded in position during coupling. Check that there is lateral play on the crankshaft twin-bearing alternator - Semi-flexible coupling Careful alignment of the machines is recommended, checking that the deviation of concentricity and parallelism of both parts of the coupling do not exceed 0.1 mm. This alternator has been balanced with a 1/2 key Location Ensure that the ambient temperature in the room where the 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 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 Inspection prior to first use Electrical checks During this operation, do not allow anyone to stand under the load Coupling 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 Under no circumstances should an alternator, new or otherwise, be operated if the isolation is less than 1 megohm for the stator and 100,000 ohms for the other windings. There are several 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 AVR). 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, respecting the polarity. - Open fully all the alternator openings. - Run the alternator at its rated speed, and adjust the exciter field current using the rheostat to obtain the rated output current in the short-circuit connections. Note : Prolonged standstill: In order to avoid these problems, we recommend the use of space heaters, as well as a periodic maintenance run of the machine. Space heaters are only really effective if they are working continuously while the machine is stopped. 6

7 INSTALLATION Mechanical checks 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 ) 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 Terminal connection diagrams A standard alternator is fitted with 3 phase coppers and 1 neutral connection terminal. The winding code is specified on the nameplate. Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped. D 3-phase T3 L3(W) Connection code L.L voltage Factory connection T1 T4 T6 L1(U) T5 T2 N L2(V) Winding 6S 7S 8S 50 Hz 60 Hz R 448 V50 voltage sensing: 0 => (T3) / 380 V => (T2) 9S With winding 9: R transfo voltage sensing (Diagram on request) T6 T5 T4 NDE T3 T2 T1 L3(W) L2(V) L1(U) N F 3-phase T3 L1(U) T6 T1 T4 Winding 6S 7S 8S 50 Hz Hz T6 T5 T3 T2 ( * ) L3(W) L2(V) L1(U) L3(W) T5 T2 L2(V) R 448 V50 voltage sensing: 0 => (T3) / 220 V => (T2) 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 (*) Option connection diagram R791 T interference suppression kit (standard for CE marking) External voltage potentiometer Connections D F Black Black Black Blue White T1 T2 T3 N T1 T2 T ohms ST4 Voltage adjustment via remote potentiometer 7

8 INSTALLATION Connection of current transformer Space heater PTC stator sensors D connection - PH 1 In/4 Secondary 1 A 6 wires Neutral link P2 Shield PT100 P1 T4 T W V White Ph1 Ph2 Ph3 130 ºC blue wire 150 ºC black wire 180 ºC red/white wire White 103 White 105 White 107 White 122 Red DE Red 106 Red 108 Red Red Red 106 Red 108 Red White 124 Red 124 Red NDE PH 1 PH 2 PH Connection checks Commissioning Electrical installations must comply with the current legislation in force in the country of use. Check that: - The residual circuit-breaker conforms to the legislation on protection of personnel in force in the country of use, and has been correctly installed on the alternator power output as close as possible to the alternator. (In this case, disconnect the interference suppression module wire that links the neutral). - Any protection devices in place have not been tripped. - If there is an external AVR, the connections between the alternator and the panel are made in accordance with the connection diagram. - There is no phase-phase or phase-neutral short-circuit between the alternator output terminals and the genset control panel (part of the circuit not protected by circuitbreakers or relays in the panel). - The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram. The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual. The machine is tested and set up at the factory. When first used with no load, make sure that the drive speed is correct 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 and 4.5) Setting up The various adjustments during tests must be made by a qualified technician. 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 the only means of making adjustments to the machine. 8

9 SERVICING - MAINTENANCE 4 - SERVICING - MAINTENANCE Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state. 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 Regular maintenance Checks after start-up After approximately 20 hours of operation, check that all fixing screws on the machine are still tight, plus the general state of the machine and the various electrical connections in the installation Cooling circuit It is advisable to check that circulation of air is not reduced by partial blocking of the air intake and outlet guards: mud, fibre, soot, and to check whether the ventilation guards are corroded or scratched Bearings The bearings are permanently greased (special grease) and they have a life of (20,000 hrs) or 3 years. NDE/DE bearing Z C Z C3 Code RLT 130 HV 001 RLT 100 HV 001 Replacement 20,000 hrs or 3 yrs 20,000 hrs or 3 yrs As an option, they are regreasable. It is advisable to lubricate the machine during operation. Time intervals and quantity of grease are given in the table below. NDE/DE bearing 6226 C C3 Code RLT130 OU020 RLT100 OU030 Quantity of grease 50 g 50 g Lubrication interval 3600 hrs 3600 hrs Lubrication intervals are given for a grease of grade LITHIUM - standard - NLGI 3. In the factory, the grease used for lubrication is: ESSO UNIREX N3. 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 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); flammable - Toluene (slightly toxic); flammable - Benzene (or benzine, toxic); flammable - Ciclohexare (non toxic); flammable Cleaning the stator, rotor, exciter and diode bridge. These operations must be performed at a cleaning station, equipped with a vacuum system that collects and flushes out the products used. The insulating components and the impregnation system are not at risk of damage from solvents (see the list of authorised products). Avoid letting the cleaning product run into the slots. Apply the product with a brush, sponging frequently to avoid accumulation in the housing. Dry the winding with a dry cloth. Let any traces evaporate before reassembling the machine Mechanical servicing 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. 9

10 SERVICING - MAINTENANCE After cleaning the alternator, it is essential to check the winding insulation (see sections 3.2 and 4.8) 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 set correctly - The connections comply with the diagrams in the manuals supplied with the machine - The genset speed is correct (see section 1.3) Repeat the operations defined in section Mechanical defects Fault Bearing Abnormal temperature Vibrations Abnormal noise Excessive overheating of one or both bearings (temperature > 80 C on the bearing retainers with or without abnormal noise) Excessive temperature rise of alternator frame (more than 40 C above the ambient temperature) Too much vibration Excessive vibration and humming noise coming from the machine Alternator damaged by a significant impact, possibly followed by humming and vibration 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 the alternator or engine - Alternator operating at too high a voltage (> 105% of Un on load) - Alternator overloaded - Misalignment (coupling) - Defective mounting or play in coupling - Rotor balancing fault - Phase imbalance - Stator short-circuit - System short-circuit - Mis-paralleling Possible consequences - Broken or damaged coupling - Broken or bent shaft end - Shifting and short-circuit of revolving field winding - Fan fractured or coming loose on shaft - Destruction of the rotating diodes or AVR 10

11 4.5 - Electrical faults SERVICING - MAINTENANCE Fault Action Effect Check/Cause The alternator builds up and its voltage is still correct when the battery is removed - Lack of residual magnetism No voltage at no load on start-up Voltage too low Voltage too high Voltage oscillations Voltage correct at no load and too low when on load Voltage disappears during operation Connect a new battery of 4 to 12 V to terminals E- and E+, respecting the polarity, for 2 to 3 seconds Check the drive speed The alternator builds up but its voltage does not reach the rated value when the battery is removed The alternator builds up but its voltage disappears when the battery is removed Correct speed Speed too low Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR Adjust the AVR stability potentiometer Run at no load and check the voltage between E+ and E- on the AVR Check the AVR, the surge suppressor, the rotating diodes, and replace any defective components If no effect: try normal or fast stability modes (ST2) Voltage between E+ and E- (DC) AREP / PMG < 10V Voltage between E+ and E- AREP / PMG > 15V The voltage does not return to the rated value - Check the connection of the AVR voltage reference - Faulty diode - Armature short-circuit - Faulty AVR - Auxiliary windings open circuit (check windings) - PMG open circuit Check the AVR connections (possible AVR failure) - Field windings short-circuited - Rotating diodes burnt out - Revolving field coil short-circuited - Check the resistance Increase the drive speed (Do not touch the AVR voltage pot. (P2) before running at the correct speed). - Check the speed: possibility of cyclic irregularity - Loose connections - Faulty AVR - Speed too low when on load (or LAM set too high) - Check the speed (or LAM set too high) - Faulty rotating diodes - Short-circuit in the revolving field coil. Check the resistance - Faulty exciter armature. Check the resistance. - Exciter winding open circuit - Faulty exciter armature - Faulty AVR - Revolving field coil open circuit or short-circuited Checking the winding You can check the winding insulation by performing a high voltage test. In this case, you must disconnect all AVR wires Checking the diode bridge A diode in good working order should allow the current to flow only in the anode-to-cathode direction CAUTION Damage caused to the AVR in such conditions is not covered by our warranty. After operational testing, replace all access panels or covers. 11

12 SERVICING - MAINTENANCE Anode A C C C A A A C Cathode - + A C 4) Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1 - L2 - L3, checking the excitation voltage and current at no load 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 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 (i.e. sensing, auxiliary windings). + ~ ~ ~ Field coil 5 + ~ ~ ~ - - C C C - + C A A diode 90 ASSEMBLY B A A A Variac 220V AV - 12V DC Checking the windings and rotating diodes using separate excitation Dismantling, reassembly (see sections & 5.4.2) CAUTION 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. During the warranty period, this operation must only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty may be invalidated. Whilst being handled, the machine should remain horizontal (rotor not locked when moved). Check the weight of the machine on the nameplate before choosing the lifting method. Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms W and a diode on both exciter field wires (5+) and (6-). ASSEMBLY A 6 - Field coil 5 + 1A diode 50Ω -300W rh V battery Assembly B: Connect a "Variac" variable power supply and a diode bridge on both exciter field wires (5+) and (6-). Both these systems should have characteristics which are compatible with the field excitation power of the machine (see the nameplate). 3) Run the unit at its rated speed. 12

13 SERVICING - MAINTENANCE Tools required To fully dismantle the machine, we recommend using the tools listed below: - 1 ratchet spanner + extension - 1 torque wrench - 1 set of flat spanners: 8 mm, 10 mm, 18 mm - 1 socket set: 8, 10, 13, 16, 18, 21, 24, 30 mm - 1 socket with male ferrule: 5 mm - 1 puller Screw tightening torque IDENTIFICATION Screw Ø Torque N.m Field screw M 8 20 Diode nut M6 4 Flange/frame screw M12 69 NDE shield/frame screw M12 69 Disc/Hub screw M Grille screws M6 5 Cover screws M6 5 Terminal block nut M12 35 Earth screw M Take out the antifriction bearing (70) using a puller with a central screw (see drawing below). - 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) Access to diodes - Open the air intake grille (51). - Disconnect the diodes. - Check the 12 diodes using an ohmmeter or a battery lamp (see section 4.5.2). If the diodes are faulty, - Remove the surge suppressor (347). - Remove the "H" mounting nuts for the diode bridges on the support and the links to the armature. - Change the fitted caps, respecting the polarity Rotor Threaded rod Dowel Nut Access to connections and the regulation system Access directly by removing the top of the cover (48) or the AVR access door (466) Replacing the NDE bearing - Remove the air intake grille (51). - Remove the lid of the protective cover (48) and the side panels (366) and (367). - Remove the hook (21) and the cover rear panel (365). - Replace the hook (21) in order to manipulate the flange. - Disconnect the exciter wires (5+,6-). - Remove the screws (72) from the inner bearing cap (78). - Remove the screws (37). - Remove the shield (36). 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 Replacing the DE bearing - Remove the air outlet grille (33). - Remove the screws (31) from the DE shield and the 4 screws (62) from the inner bearing retainer. - Remove the shield (30). - Take out the ball bearing (60) using a puller with a central screw (see section 4.6.5). 13

14 SERVICING - MAINTENANCE - Fit the new bearing, after heating it by induction to approximately 80 C. - Screw two threaded rods into the inner bearing cap (68). - Refit the shield (30) on the machine. - Slide the threaded rods into the shield holes to make it easier to assemble (see basic diagram). - Tighten the bottom inner bearing cap screws (78), remove the threaded rod and fit the other screws. - Tighten the shield screws (31). - Refit the air outlet grille (33). CAUTION When dismantling the machine, always change the antifriction bearings Dismantling the rotor assembly - Screw an M20 threaded rod into the shaft NDE hole and use it to guide and support the rotor. - Remove the DE shield (30) as described in section 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. If using a twin-bearing machine: - Finish reassembling the cover. - Screw a threaded rod into the inner bearing cap (68). - Refit the shield (30) on the machine. - Slide the threaded rod into the shield hole to make it easier to assemble (see diagram). - Fit the inner bearing cap screws (68), remove the threaded rod, fit the other screw and tighten up the assembly. - Tighten the shield screws (31). - Refit the air outlet grille (33). - Check that the machine assembly is correctly mounted and that all screws are tightened Dismantling and reassembling the filters - Remove the grille (417) then take out the filter (418). Change the filter if necessary; please refer to section for cleaning the filter. To replace, follow the instructions in reverse order. - On certain versions, the filters are incorporated in the terminal box panels CAUTION When dismantling the rotor involves changing parts or rewinding, the rotor must be rebalanced Reassembling the machine - 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) Installation and maintenance of the PMG For the LSA 50.2, the PMG reference is: PMG Mechanical characteristics The components are: - A shaft adapter (to position the rotor on the shaft extension) - An M20 tie rod for mounting the rotor on the shaft - A rotor - An assembly consisting of: housing + wound stator + plastic connection sheath + plastic ferrules - The end plate - 4 HM6 screws (mounted on the NDE shield) If mounting in kit form, follow the instructions below. 1 - Remove the alternator NDE shield seal (71). 14

15 SERVICING - MAINTENANCE 2 - Mount the housing + stator assembly [290] on the shield using the 4 HM6 screws. 3 - Mount the magnetised rotor on the shaft adapter, slide the assembly onto the tie rod. 4 - Install the cable gland washer [296]. 5 - Lock the assembly with torque of 340 Nm. 6 - Close the PMG with the cover [297]. 7 - Remove the plastic plug on the NDE panel and fit the plastic sheath and its ferrule. 8 - Connect the PMG to the AVR (section 4.7.2) Electrical connection - Connect the 3 PMG wires (14/15/16), the 2 exciter wires (5/6) and the above-mentioned 2 voltage sensing wires (2/3) according to the connection diagram (see section 2.2). Mounting the PMG on an AREP machine: - Connect the 3 PMG wires (14/15/16), to terminals X1,X2,Z2 on the AVR. The 4 auxiliary winding wires X1.X2.Z1.Z2 should be isolated according to the current rules and regulations. Both exciter field wires (5/6) and both voltage sensing wires (2/3) remain in place. Electrical characteristics of the PMG 5 Stator phase/phase resistance 20 C: 0.87 Ω No-load A.C. voltage between phases at 1500 rpm: 130 V. CAUTION With the PMG, check that the ST9 jumper is open circuit. After operational testing, replace all access panels or covers Exploded view of the PMG Table of electrical characteristics Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. (400V for the excitation values) The voltage and current values are given for no-load operation and operation at rated load with separate field excitation. All values are given to within ± 10% and may be changed without prior notification (for exact values, consult the test report) Average values for the LSA 50.2 Resistances at 20 C (Ω) LSA 50.2 L/N stator Rotor Exciter field Armature S M L L VL Resistance of AREP auxiliary windings at 20 C (Ω) LSA 50.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2 S M L L VL Field excitation current i exc (A) Symbols: "i exc": excitation current of the exciter field. LSA 50.2 No load At rated load S M L7 1 4 L VL For 60 Hz machines, the "i exc" values are approximately 5 to 10% lower Voltage of auxiliary windings at no load LSA 50.2 Auxil wdg: X1, X2 Auxil wdg: Z1, Z2 50 Hz 100 V 5 V 60 Hz 120 V 6 V Table of weights LSA 50.2 Total weight (kg) Rotor (kg) S4 M6 L7 L8 VL10 15

16 SPARE PARTS 5 - SPARE PARTS First maintenance parts Emergency repair kits are available as an option. They contain the following items: AREP repair kit R448 V50 automatic voltage regulator AEM 110 RE 022 Set of direct diodes ADE 491 EQ 013 Set of reverse diodes ADE 491 EQ 012 Surge suppressor CII PM 010 Single bearing kit NDE bearing RLT 100 HV 001 'O' ring seal JOI 215 TB 001 Preloading wavy washer RLT 215 RB 005 Twin bearing kit NDE bearing RLT 100 HV 001 DE bearing RLT 130 HV 001 'O' ring seal JOI 215 TB 001 Preloading wavy washer RLT 215 RB Technical support service Our technical support service will be pleased to provide any additional information you may require. When ordering spare parts, you should indicate the complete machine type, its serial number and the information given on the nameplate Accessories Space heater for use when stopped The space heater must run as soon as the alternator stops. It is installed at the rear of the machine. Its standard power is 500W with 220V or 250W with 110V on request. Caution: The power supply is present when the machine is stopped Temperature sensors with thermistors (PTC) These are thermistor triplets with a positive temperature coefficient installed in the stator winding (1 per phase). There can be a maximum of 2 triplets in the winding (at 2 levels: warning and trip) and 1 or 2 thermistors in the shields. These sensors must be linked to adapted sensing relays (supplied optionally). Cold resistance of cold thermistor sensors: 100 to 250 Ω per sensor Connection accessories - 6-wire machines Requirements for coupling (F): - 3 shunts. Address your enquiry to your usual contact. Part numbers should be identified from the exploded views and their description from the parts list. 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. After operational testing, replace all access panels or covers. 16

17 SPARE PARTS Exploded views, parts list Single-bearing LSA Ref. Qty Description Ref. Qty Description 1 1 Stator assembly Voltage regulator (AVR) 4 1 Rotor assembly Coupling hub 15 1 Fan Coupling disc 21 1 Lifting ring Fixing screw 30 1 DE flange Diode bridge assembly 33 1 Protective grille 'O' ring seal 36 1 Exciter end shield Terminal box side lid 41 1 Cover front panel Terminal box side lid with inspection door 42 1 Cable gland plate AVR inspection door 47 1 Teminal box rear lid 48 1 Terminal box top lid 50 1 Lower inspection door 51 1 Air intake grille 70 1 NDE bearing 71 1 Cover 78 1 Inner bearing cap 79 1 Preloading wavy washer 90 1 Exciter field Exciter armature Terminal support Terminals Starting range Neutral link

18 Twin-bearing LSA 50.2 SPARE PARTS Ref. Qty Description Ref. Qty Description 1 1 Stator assembly Terminals 4 1 Rotor assembly Starting range 15 1 Fan Neutral link 21 1 Lifting ring Voltage regulator (AVR) 30 1 Drive end shield Hub 33 1 Protective grille Diode bridge assembly 36 1 Exciter end shield 'O' ring seal 41 1 Cover front panel Terminal box rear lid 42 1 Cable gland plate Terminal box side lid 47 1 Terminal box rear lid Terminal box side lid with inspection door 48 1 Terminal box top lid AVR inspection door 50 1 Inspection door 51 1 Air intake grille 60 1 DE bearing 68 1 Inner bearing cap 70 1 NDE bearing 71 1 Cover 78 1 Inner bearing cap 79 1 Preloading wavy washer 90 1 Exciter field Exciter armature Terminal support 18

19 DECLARATION OF INCORPORATION FOR C.E. MARKING 6 - DECLARATION OF INCORPORATION FOR C.E. MARKING Département Alternateurs Basse Tension Usine de Sillac JD /C Angoulême, le 30 Mars 2006 DECLARATION d INCORPORATION (pour composants électriques prévus pour utilisation dans des machines soumises à la Directive n 98/37/CE) Le fabricant : Moteurs LEROY-SOMER Département Sillac Boulevard Marcellin Leroy ANGOULEME (France) déclare par la présente que les générateurs synchrones des types suivants : LSA LSA 35 - LSA36 - LSA 37 - LSA LSA LSA LSA LSA LSA472 - LSA LSA , 4 et 6 pôles ainsi que les séries dérivées de type LSAC, LSAK, LSAM, LSAT, sont conformes aux normes harmonisées : EN (CEI 34) et donc satisfont aux exigences essentielles de la Directive Basse Tension n 73/23/CEE du 19 février 1973, modifiée par la Directive n 93/68/CEE du 22 juillet La conception de ces composants (générateurs) leur permet d être utilisés dans des machines (1) qui doivent satisfaire : - à la Directive Machine n 98/37/CE - à la Directive CEM n 89/336/CEE (amendée par la Directive 92/31/CEE du 28 avril 1992), modifiée par la Directive N 93/68/CEE du 22 juillet 1993, en ce qui concerne les caractéristiques intrinsèques des niveaux d émission et d immunité (2) à condition que l installation soit réalisée correctement par le fabricant de la machine (par exemple : en répondant à nos instructions d installation et d incorporation et à la norme EN «Equipement Electrique des Machines Industrielles»). Les composants ci-dessus mentionnés ne doivent pas être mis en service tant que les machines dans lesquelles ils doivent être incorporés n ont pas été déclarées conformes à la Directive Machine n 98/37/CE et aux autres directives éventuellement applicables. Pascal ROSSIGNOL Responsable Qualité Département Alternateurs Basse Tension (1) par «Machine» on entend un groupe complet de génération d énergie, (2) les composants mentionnés ci-dessus sont capables de supporter une impulsion de tension avec une valeur crête limitée à 2000 V (si nécessaire un écrêteur de tension devra être installé par le fabricant de la machine). 19

20 16015 ANGOULÊME CEDEX - FRANCE RCS ANGOULÊME Limited company with capital of 62,779,000 euro