Leroy-Somer R220 VSG+CCM Instruction Manual

2013.05 / b
R220 VSG + CCM
5+
6-
E+ E-
U V
R 220 VSG
STAB
VOLT (-) (+)
+-
PT100
+
-
+
U1 U2 U3 V1 V2 V3 W1 W2 W3
LEM batt.
Armature
Exciter
Rotor
Stator
Diode
bridge
300 A
fuse
LEM load
This manual is to be given to
the end user
A.V.R. multi batteries dedicated
Installation and maintenance
4705 en -

2
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
SAFETY MEASURES
Before using your machine for the rst time,
it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions
on this machine must be performed by a
qualied technician.
Our technical support service will be pleased
to provide any additional infor-mation you
may require.
The various operations described in this
manual are accompanied by recommen-da-
tions or symbols to alert the user to po tential
risks of accidents. It is vital that you unders-
tand and take notice of the following warning
symbols.
This A.V.R. can be incorporated in a
machine marked C.E.
Warning symbol for an operation capable
of damaging or destroying the machine
or surround-ing equipment.
Warning symbol for general danger to
personnel.
Warning symbol for electrical danger to
personnel.
Note: All rights are reserved to modify the
characteristics of the products
at any time in order to incorporate the
latest technological developments. The
information contained in this document may
therefore be changed without notice.
WARNING
This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual. By following
certain important points during installation, use and servicing of your A.V.R., you can
look forward to many years of trouble-free operation.

3
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
CONTENTS
1 - SUPPLY ..............................................................................................................................4
1.1 - SHUNT excitation system ............................................................................................4
2 - R220 VSG + CCM ..............................................................................................................4
2.1 - R 220 VSG Characteristics ...........................................................................................4
2.2 - CCM Characteristics ...................................................................................................5
2.3 - Wiring and connection diagram ...................................................................................8
3 - INSTALLATION - COMMISSIONING .................................................................................9
3.1 - Electrical checks on the AVR ........................................................................................9
3.2 - Settings ......................................................................................................................10
3.3 - Electrical faults ...........................................................................................................10
4 - SPARE PARTS ................................................................................................................. 11
4.1 - Designation ................................................................................................................ 11
4.2 - Technical support service ........................................................................................... 11
5 - ANNEX ............................................................................................................................12
5.1 - Battery 1: OpZV type .................................................................................................12
5.2 - Battery 2: SBS EON type ...........................................................................................13
5.3 - Battery 3: Saft Evolion type ........................................................................................14
5.4 - Battery 4: Exide A600 type .........................................................................................15
All such operations performed on the A.V.R. should be undertaken by personnel trained
in the commissioning, servicing and maintenance of electrical and mechanical
components.
The R220 VSG is an IP00 product. It must be installed inside a unit so that this unit’s cover can
provide IP20 minimum total protection (it must only be installed on LS alternators in the
appropriate location so that when viewed externally, it has a higher degree of protection than
IP20).
Copyright 2005 : MOTEURS LEROY-SOMER
This document is the property of :
MOTEURS LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.

4
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
1 - SUPPLY
1.1 - SHUNT excitation system
The alternator with Shunt excitation is self-
excited with an R 220 VSG + CCM voltage
regulator.
The regulator monitors the exciter excitation
current as a function of the alternator output
voltage. Very simple in design, the alternator
with shunt excitation has no sustaining
short-circuit capacity.
2 - R220 VSG A.V.R. + CCM
2.1 - R 220 VSG characteristics
- Storage : -55°C ; +85°C
- Operation : -40°C ; +65°C
- Voltage regulation: ± 0.5%.
- Voltage supply/sensing range 12 to 70 V
(30 to 67 Hz)
- Rapid response time (500 ms) for a
transient voltage variation amplitude of ± 20%
- Voltage setting P1
- Stability setting P2.
- Power supply protected by 8 A fuse, slow-
blow action (tolerates 10 A for 10 s)
The fuse is impregnated in the resin,
therefore it can not be replaced.
- Variable frequency from 30 Hz to 67 Hz.
- The size of the screwdriver tip used to
adjust the potentiometer is 2.5 mm.
124 mm
85 mm 2 holes Ø5.8 x 109 mm
E+ E-
R 220 VSG
P1
P2
VOLT
STAB
(-) (+) (U) (V)
CCM input (±3V)
Voltage
Stability

5
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
2.2 - CCM characteristics
The CCM general view is given by the
following gure:
Θ PT100
Battery
type
selection
Battery
capacity
setting
Generator
maximum
current
Speed
change
setting
Figure 1 :
Charge Control Module overview
This module is mainly composed by rotating
switches and Faston terminals:
2.2.1.Rotating switches
A. Battery type selection
One rotating switch is dedicated to the
battery type selection. The assignments list
is the following:
- position 1: OPzV
- position 2: SBS EON
- position 3: Evolion
- position 4: A600 Solar
The remained positions (5 to 9) are reserved
for future assignments (A600 Solar by
default).
B. Battery capacity setting
C batt. = (R2 x1000+R3x100+R4x10+R5x1)
Four (4) rotating switches: selection of
battery capacity from 0 to 1999 Ah.
C. Generator maximum current
I max = (R6x100+R7x10+R8x1)
Three (3) rotating switches: current selection
from 0 to 398A. This allows to prevent the
genset unexpected shutdown during normal
work.
D. Speed change setting (R9)
One (1) rotating switch which denes the
current threshold from which the engine will
change its speed. The positions 1, 2… 8 and
9 respectively correspond to 10%, 20%
…80% and 90% of the generator maximum
current. The position 0 will is interpreted as
10%.

6
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
2.2.2 - CCM terminals description
A. Regulator link (Reg Out)
Two terminals allow communication
between the CCM and the AVR (see annex).
B. Battery sensing (Batt)
Two(2) terminals connected to the diodes
bridge output. This voltage is not only used
for sensing but also for supplying the CCM
(see annex). These terminals (and so the
CCM) are designed to withdraw 150Vdc
without damage.
C. Current sensing (LEMs)
Four (4) terminals for two current sensors:
one for load current measurement and the
other for battery current measurement (see
annex). These two LEM share the same
supply: +12V and -12V.
The supported LEM are the LF 306-S (or
any closed loop current sensors with 1/2000
ratio). Only positive currents are measured.
Warning : The LEM supply polarity
must be respected to avoid damage.
D. Temperature sensing (PT100)
Two terminals for measuring the battery set
temperature. This is used to adapt the
charge strategy to weather conditions.
E. Utility
Two terminals for taking into account the
presence or not of the grid. The description
will be given further.
F. Engine stop and start (Engine)
Two (2) terminals for starting and stopping
the engine depending of the battery state of
charge. Explanation will be given further.
G. Speed change (Speed)
Two (2) terminals allowing to change the
genset speed according to the Current
threshold (see above section) and
depending on the battery state of charge.
2.2.3 - How does the CCM work
The following convention will be used is this
section
Vch: maximum charge voltage (or equalizing
voltage)
V: oating voltage
C: Battery capacity
Vd: Lower voltage alarm threshold
Imax: maximum current that the generator
can provide;
Ib and Iu: respectively battery current and
load (user’s) current.
2.2.3.1 - Charging strategy
The charge module works in charge mode
at constant voltage with 2 levels of voltage.
A. Charge with a current limited to a
threshold given in annex.
B. Charge at constant voltage Vch until the
current is less than 0.03C during 1 minute.
C. Each 60 charge cycles, a charge in
oating mode at constant voltage V is
achieved for some batteries types (see
annex). During this oating charge mode,
the CCM will go back to charge mode if the
current is higher than 0.08C during 5
succesive minutes.
NB: The rst oating charge for those
batteries will be done after 5 normal charges.
D. Discharge phase with genset OFF until
either 40% of the battery capacity is
consumed or the battery voltage is less than
Vd.

7
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
2.2.3.2 - Light-Emitting Diode (LED)
status
A.Charging LED :
A1. Yellow ON: CCM charges at constant
voltage Vch
A2. Yellow ashing: Vch is not reached yet
or the module does not succeed to reach
this voltage
B. Floating LED :
B1. Green ON: CCM charges at constant
voltage V
B2. Green Flashing: CCM is in discharge
mode or is trying to reach the oating voltage
V
C. Current limitation LED
C1. Yellow ON: the CCM is limiting the
charge current at a threshold, as dened in
annex, or at Imax = Iu + Ib
C2. Yellow ashing: the module is trying to
limit the current or has temporarily shut
down the engine due to emergency
condition: If during charge mode, the CCM
is not able to limit the current, it will stop the
engine to avoid damages. The CCM will
start again the engine and restart the charge
process two (2) minutes later.
D. Speed change LED
The Speed status LED will be ON when the
speed relay is activated.
2.2.4. Relays and dry contact
A. Speed relay
A1. The relay has to go to high speed when
the current is higher than the value dened
by the “speed change” rotating switch
A2.The relay is forced to high speed when
the engine is started by the ON/OFF relay
A3. The relay must go to low speed when
these two following conditions are achieved:
- The charge current is less than 90% of the
current dened the “speed change” rotating
switch
- At least 5 minutes elapsed from the moment
the relay has been forced to “High speed”
B. Engine ON/OFF relay
The relay is ON if the engine has to be
started, OFF if not.
C.Utility dry contact
C1..Dry contact closed: utility ON
If the Grid is ON, the CCM stops the engine
during the duration of the grid presence and
then starts the engine to nish the charge
process. If the grid appears during discharge
phase, the current going through the battery
is integrated over the grid presence to
evaluate the state of charge of the battery.
C2. Dry contact open: Utility OFF
If the grid is OFF during the discharge
phase, the CCM will continue the battery
discharge phase until reaching 40% of the
battery total capacity.
2.2.5. Reset of cycle number before
oating.
The number of charge/discharge cycles
without oating is reset to 60 if the user acts
like following :
- the utility input is closed while the battery
type selection rotating switch (R1) is
positionned to 0 for at least 5 seconds.

8
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
2.3 - WIRING AND CONNECTION
DIAGRAM
5+ 6-
E+ E-
U V
R 220 VSG
STAB
VOLT (-) (+)
+-
PT100
+
-
+
U1 U2 U3 V1 V2 V3 W1 W2 W3
LEM batt.
Armature
Exciter
Rotor
Stator
Diode
bridge
300 A
fuse
LEM load

9
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
3-INSTALLATION -
COMMISSIONING
3.1 - Electrical checks on the AVR
- Check that all connections have been
made properly as shown in the attached
wiring diagram.
- Check that CCM input (±3V) is connected.
3.2 - Settings
The machine is tested and set at the
factory. When rst used with no load,
make sure that the drive speed is correct
and stable (see the nameplate). After
operational testing, replace all access
panels or covers.
The only possible adjustments to the
machine should be made on the AVR.
3.2.1 - R 220 VSG setting (shunt system)
Initial potentiometer settings
- P1 potentiometer (AVR voltage
adjustment): fully anti-clockwise.
- Remote voltage adjustment potentiometer:
centre position.
Run the alternator at its rated speed. If the
voltage does not increase, the magnetic
circuit should be remagnetized (see section
3.3).
- Turn the AVR voltage adjustment
potentiometer P1 slowly until the output
voltage rated value is obtained.
- Adjust the stability setting using P2.
Clockwise: increase the rapidity.
Anti-clockwise: decrease the rapidity.
3.2.2 - Special type of use
Excitation circuit E+, E- must not be left
open when the machine is running : AVR
damage will occur.
3.2.1.1 - R220 VSG eld weakening
(SHUNT)
The exciter is switched off by disconnecting
the AVR power supply (1 wire U or V).
Contact rating : 16A - 250V alt.
The power supply contactor must only be
closed when the alternator is not being
driven
3.2.1.2 - R220 VSG eld forcing
Battery must be isolated from the earth.
Exciter eld may be at line potential.
WARNING
E+ E-
V
U
VOLT (-) (+)
Battery (B Volt)
+
-
t
(400V - 10A) Diode
E+ E-
V
U
Exciter field

10
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
3.3 - Electrical faults
Fault Action Effect Check/Cause
No voltage at
no load on
start-up
Connect a new battery
of 4 to 12 volts to
terminals E- and E+,
respecting the polarity,
for 2 to 3 seconds
The alternator builds up and its
voltage is still correct when the
battery is removed.
- Lack of residual magnetism
The alternator builds up but its
voltage does not reach the rated
value when the battery is
removed.
- Check the connection of the voltage
reference to the AVR
- Faulty diodes
- Armature short-circuit
The alternator builds up but its
voltage disappears when the
battery is removed
- Faulty AVR
- Field windings disconnected
- Main eld winding open circuit - check the
resistance
Voltage too
low Check the drive speed
Correct speed
Check the AVR connections (AVR may be
faulty).
- Check the CCM connection
- Field windings short-circuited
- Rotating diodes burnt out
- Main eld winding short-circuited
- Check the resistance
Speed too low
Increase the drive speed
(Do not touch the AVR voltage pot. (P2)
before running at the correct speed.)
Voltage too
high
Adjust AVR voltage
potentiometer Adjustment ineffective Faulty AVR
Voltage
oscillations
Adjust AVR stability
potentiometer
- Check the speed : possibility of cyclic
irregularity
- Loose connections
- Faulty AVR
- Speed too low when on load (or U/F bend
set too high)
Voltage
correct at no
load and too
low when on
load (*)
Run at no load and
check the voltage
between E+ and E- on
the AVR
- Check the speed (or U/F bend set too high)
- Faulty rotating diodes
- Short-circuit in the main eld. Check the
resistance
- Faulty exciter armature.
(*) Caution : For single-phase operation, check that the sensing wires coming from the AVR are correctly connected to the
operating terminals
Voltage
disappears
during
operation
Check the AVR, the
surge suppressor, the
rotating diodes, and
replace any defective
components
The voltage does not return to the
rated value.
- Exciter winding open circuit
- Faulty exciter armature
- Faulty AVR
- Main eld open circuit or short-circuited
Warning : after operational testing, replace all access panels or covers.

11
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
4 - SPARE PARTS
4.1 - Designation
Description Type Code
A.V.R.
A.V.R.
R 220 VSG
CCM
AEM 110 RE 035
AEM 056 CT 001
4.2 - Technical support service
Our technical support service will be happy
to provide any information you require.
When ordering spare parts, you should
in dicate the complete machine type, its
serial number and the information indi-
cated on the nameplate.
Part numbers should be identied from
the exploded views and their description
in the parts list.
Our extensive network of «service stations»
can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our alternators, we recommend the use of
original manufacture spare parts.
In the event of failure to comply with this ad-
vice, the manufacturer cannot be held res-
ponsible for any damage.

12
0
50
100
150
200
250
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Current(A)
Voltage (V)
Temperature (°C)
Charge caracteristics for OpZV type battery
Vcharge (V)
Vfloat (V)
Vd (V)
Ilim(C=1000Ah) (A)
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
5 - ANNEX
Types of batteries supported by the CCM
5.1 - Battery 1: OpZV type
End of charge condition: the charge current
is less than 3% of the total capacity of the
battery
Switch to charge mode condition: 40% of
the total capacity of the battery has been
consumed in discharge mode.
Maximum charge duration: 12hours
Normal duration of oating mode: 14hours
Switch from oating to charge mode condi-
tion: Ibatt = 8% of the total capacity of the
battery
Minimum duration of oating: 5min
Number of cycles between two oating
modes: 59

13
0
200
400
600
800
1000
1200
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Current(A)
Voltage (V)
Temperature (°C)
Charge characteristics for SBS EON type battery
Vcharge (V)
Vfloat (V)
Vd (V)
Ilim(C=1000Ah) (A)
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
5.2 - Battery 2: SBS EON type
End of charge condition: the charge current
is less than 3% of the total capacity of the
battery
Switch to charge mode condition: 40% of
the total capacity of the battery has been
consumed in discharge mode.
Maximum charge duration: 12hours
Normal duration of oating mode: 14hours
Switch from oating to charge mode condi-
tion: Ibatt = 8% of the total capacity of the
battery
Minimum duration of oating: 5min
Number of cycles between two oating
modes: 59

14
0
100
200
300
400
500
600
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Current(A)
Voltage (V)
Temperature(°C)
Charge characteristics for Saft Evolion type battery
Vcharge (V)
Vd (V)
Ilim(C=1000Ah) (A)
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
5.3 - Battery 3: Saft Evolion type
End of charge condition: the charge current
is less than 3% of the total capacity of the
battery
Switch to charge mode condition: 40% of
the total capacity of the battery has been
consumed in discharge mode.
Maximum charge duration: 12hours
NB: No oating mode required

15
0
50
100
150
200
250
300
350
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Current(A)
Voltage(V)
Temperature (°C)
Charge Characteristics for Exide A600 type battery
Vcharge (V)
Vfloat (V)
Vd (V)
Ilim(C=1000Ah) (A)
4705 en -
Installation and maintenance
R220 VSG + CCM
A.V.R.
LEROY-SOMER 2013.05 / b
5.4 - Battery 4: Exide A600 type
End of charge condition: the charge current
is less than 3% of the total capacity of the
battery
Switch to charge mode condition: 40% of
the total capacity of the battery has been
consumed in discharge mode.
Maximum charge duration: 16hours
Normal duration of oating mode: 8hours
Switch from oating to charge mode condi-
tion: Ibatt = 8% of the total capacity of the
battery
Minimum duration of oating: 5min
Number of cycles between two oating
modes: 59