Leroy-Somer R438 Instruction Manual

This manual is to be given to
the end user
3971 en - 11.2006 / c
R438
A.V.R.
Installation and maintenance
X2 X1 Z2 E+ E- 0V
110 22
0
Z1
6-
R 438
1
T
3
50Hz 60Hz
T
5
T10
LAM 13 %
Field
Armature
10 Yellow
11 Red
9 Green
12 Black
Slow fuse
250V 8 A
q
uency
with LAM without LAM
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Installation and maintenance
R438
A.V.R.
2
3971 en - 11.2006 / c
LEROY-SOMER
SAFETY MEASURES
Before using your machine for the first 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
qualified 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-
dations or symbols to alert the user to
potential risks of accidents. It is vital that
you understand and take notice of the
following warning symbols.
This A.V.R. can be incorporated in a
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: 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.
WARNING
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.
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Installation and maintenance
R438
A.V.R.
3971 en - 11.2006 / c
LEROY-SOMER
3
CONTENTS
1 - SUPPLY .............................................................................................................................4
1.1 - AREP excitation system ..............................................................................................4
1.2 - PMG excitation system................................................................................................5
1.3 - SHUNT or separate excitation system.........................................................................5
2 - R438 A.V.R. .......................................................................................................................6
2.1 - Characteristics.............................................................................................................6
2.2 - Frequency compared with voltage (without LAM)........................................................6
2.3 - LAM (Load Acceptance Module) characteristics .........................................................6
2.4 - Typical effects of the LAM with a diesel engine with or without a LAM (U/F only).......7
2.5 - R438 A.V.R. options ....................................................................................................7
3 - INSTALLATION - COMMISSIONING ................................................................................8
3.1 - Electrical checks on the AVR.......................................................................................8
3.2 - Settings........................................................................................................................8
3.3 - Electrical faults...........................................................................................................11
4 - SPARE PARTS ................................................................................................................12
4.1 - Designation................................................................................................................12
4.2 - Technical support service..........................................................................................12
All such operations performed on the A.V.R. should be undertaken by personnel trained
in the commissioning, servicing and maintenance of electrical and mechanical
components.
Copyright 2005 : MOTEURS LEROY-SOMER
This document is the property of :
MOTEURS LEROY-SOMER
It may not be reproduced in any form without prior authorization.
All brands and models have been registered and patents applied for.
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Installation and maintenance
R438
A.V.R.
4
3971 en - 11.2006 / c
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1 - SUPPLY
1.1 - AREP excitation system
For both AREP & PMG excitation systems,
the alternator voltage regulator is the R438.
With AREP excitation, the R438 electronic
AVR is powered by two auxiliary windings
which are independent of the voltage
match circuit.
The first winding has a voltage in proportion
to that of the alternator (characteristic
Shunt), the second has a voltage in
proportion to the stator current (compound
characteristic: Booster effect).
The power supply voltage is rectified and
filtered before being used by the AVR
monitoring transistor. This principle
ensures that regulation is not affected by
distortions generated by the load.
4 x holes Ø 5.8 x
175 x 115 mm
200 mm
140 mm
X2 X1 Z2 E+ E- 0V
110 220 380
Z1
T1 T2 T3
T4 T5 T6
Varistor
5+ 6-
T7 T8 T9
T10 T11 T1
2
R 438
F1
ST3
50Hz 60Hz
ST5
ST10
LAM 13 %
LAM
25 %
P5
ST11
ST2 ST1
P3
P2
P1
ST4
ST9
Option
AREP
PMGPMG
T.I.
Option
S1 P1
Ph.1
P2
S2
R731
Option
AREP SYSTEM
Field
Armature
10 Yellow
11 Red
9 Green
12 Black
MAIN FIELD Aux. windings
Slow fuse
250V 8 A
Frequency
with LAM without LAM
Excitation
ceiling
knee-point: 65 Hz
open
Response
time
normal
fast
Stability
Voltage
Single-
phase
detection
External potentiometer
for adjusting the voltage
Quad
droop
according voltage
STATOR: 6 wires (marked T1 to T6)
STATOR: 12 wires (marked T1 to T12)
in 3-ph. detection ST1 open
3-ph. detection
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Installation and maintenance
R438
A.V.R.
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LEROY-SOMER
5
1.2 - PMG excitation system
This excitation system consists of a " PMG "
(permanent magnet generator). This is
fitted at the rear of the machine and
connected to the R438 AVR.
The PMG supplies the AVR with constant
voltage which is independent of the main
alternator winding. As a result the machine
has a short-circuit current capacity and
good immunity to distortions generated by
the load.
The AVR monitors and corrects the
alternator output voltage by adjusting the
excitation current.
- 50/60 Hz selection via the ST3 jumper.
1.3 - SHUNT or separate excitation system
A.V.R. can be operated with SHUNT supply (with a transformer / secondary 50V or a 48V
battery).
4 x holes Ø 5.8 x
175 x 115 mm
200 mm
140 mm
X2 X1 Z2 E+ E- 0V
110 220 380
Z1
T1 T2 T3
T4 T5 T6
Varistor
5+ 6-
T7 T8 T9
T10 T11 T12
R 438
F1
ST3
50Hz 60Hz
ST5
ST10
LAM 13 %
LAM
25 %
P5
ST11
ST2 ST1
P3
P2
P1
ST4
ST9
Option
AREP
PMG
14 15 16
PMG
T.I.
Option
S1 P1
Ph.1
P2
S2
R731
Option
PMG SYSTEM
Field
Armature
MAIN FIELD
Slow fuse
250V 8 A
Frequency
with LAM without LAM
Excitation
ceiling
knee-point: 65 Hz
open
Response
time
normal
fast
Stability
Voltage
Single-
phase
detection
External potentiometer
for adjusting the voltage
Quad
droop
according voltage
STATOR : 6 wires (marked T1 to T6)
STATOR : 12 wires (marked T1 to T12)
in 3-ph. detection ST1 open
3-ph. detection
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Installation and maintenance
R438
A.V.R.
6
3971 en - 11.2006 / c
LEROY-SOMER
2 - R438 A.V.R.
2.1 - Characteristics
- Standard power supply: AREP or PMG.
- Rated overload current: 8 A - 10 s
- Electronic protection (overload, short-
circuit on opening of voltage sensing
circuit): excitation overload current for 10
seconds then return to approximately 1A.
The alternator must be stopped (or the
power switched off) in order to reset the
protection.
- Fuse : F1 on X1, X2. 8A ; slow - 250V
- Voltage sensing : 5 VA isolated via
transformer ;
• 0-110 V terminals = 95 to 140 V,
• 0-220 V terminals = 170 to 260 V,
• 0-380 V terminals = 340 to 520 V.
- Voltage regulation ± 1%.
- Normal or rapid response time via ST2
jumper (see below).
- Voltage adjustment via potentiometer P2 .
other voltages via adapter transformer
- Current sensing (parallel operation): C.T.
2.5 VA cl1, secondary 1 A (optional).
- Quadrature droop adjustment via
potentiometer P1 .
- Max. excitation current adjustment via P5
(see below).
2.1.1 -
Configuration jumpers function
2.1.2 -
Setting potentiometers
function
2.2 - Frequency compared with
voltage (without LAM)
2.3 - LAM (Load Acceptance
Module) characteristics
2.3.1 - Voltage drop
The LAM system is integrated in the R 438
AVR as standard.
Role of the "LAM" (Load Adjustment
Module) :
On application of a load, the rotation speed
of the generator set decreases. When it
passes below the preset frequency
threshold, the LAM causes the voltage to
drop by approximately 13% or 25% and
consequently the amount of active load
applied is reduced by approximately 25%
to 50%, until the speed reaches its rated
value again.
Hence the LAM can be used either to
reduce the speed variation (frequency) and
its duration for a given applied load, or to
increase the applied load possible for one
speed variation (turbo-charged engine).
To avoid voltage oscillations, the trip
threshold for the LAM function should be
set approximately 2 Hz below the lowest
frequency in steady state.
Pot.
Delivrery
config. Position Function
Open Closed
ST1 3-ph. Mono Open for module
installation tri detection
ST2 Fast Normal Response time
ST3 50 ou 60 Hz Frequency selection
ST4
External
potentio-
meter
Without Potentiometer
ST5 Without With LAM
ST9 Others
(PMG...) AREP Supply
ST10 13% or 25% LAM voltage drop
amplitude
ST11 65 Hz 48 or
58 Hz
U/f function bend
position
Delivrery
position Pot. Function
0 P1 Quadrature droop ; // operation with C.T.
400V P2 Voltage
Centre P3 Stability
Maxi P5 Excitation current ceiling
100 %
50 Hz 60 Hz Hz
50 Hz
48 Hz
57.5 Hz
60 Hz
Voltage Bend
U/UN
Frequency
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Installation and maintenance
R438
A.V.R.
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7
- LAM : action eliminated by cutting the ST5
jumper.
2.3.2 - Gradual voltage return function
During load impacts, the function helps the
genset to return to its rated speed faster
thanks to a gradual increase in voltage
according to the principle:
- If the speed drops between 46 and 50 Hz,
the rated voltage follows a fast gradient as
it is restored.
- If the speed drops below 46 Hz, since the
engine needs more help, the voltage
follows a slow gradient as it returns to the
reference value.
2.4 - Typical effects of the LAM with
a diesel engine with or without a
LAM (U/F only)
2.4.1 - Voltage
2.4.2 - Frequency
2.4.3 - Power
2.5 - R438 A.V.R. options
- Current transformer for parallel operation
of ....../1A. 5 VA CL 1.
- Remote voltage adjustment potentiometer :
470 Ω , 0.5 W min: adjustment range ± 5%
(range limited by internal voltage
potentiometer P2 ). Remove ST4 to connect
the poten-tiometer. (A 1 k
Ω potentiometer
can also be used to extend the adjustment
range).
- R 731 external module : sensing of 3-
phase voltage 200 to 500 V, compatible with
parallel operation. Disconnect ST1 to
connect the module; set the voltage via the
module potentiometer.
- R 734 module : detection of 3-phase
current and voltage for parallel operation on
unbalanced installations (imbalance > 15%).
- R 726 module : 3 functions (mounted
externally)
P.F. regulation (2F) and voltage sensing
circuit before paralleling (3 F).
- Control through DC voltage used
monitoring apply to the terminals for
connection of a potentiometer DC voltage :
• internal impedance 1,5 k
Ω
• ± 0,5V enable a voltage setting of 10%.
LAM
UN
048 or 57.5 Hz
0.85 UN
Voltage
U/f
50 or 60 Hz
fC fN
Voltage
ST5 disconnected
ST3
P2
Underspeed and LAM
0
Time
Drop N ≤46 Hz
U
Drop N > 46 Hz
U N
0
0,9
0,8
(U/f)
with
LAM Time
without LAM
1 s 2 s 3 s
Transient voltage drop
0,9
0,8
f N
Max speed drop
0
with
LAM
Time
without
LAM
1 s 2 s 3 s
01 s 2 s 3 s
Time
LAM
Variation in the load
Load on the shaft (kW)
Load shedding due to "LAM"
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Installation and maintenance
R438
A.V.R.
8
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LEROY-SOMER
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 the ST3 frequency selection
jumper is on the correct frequency setting.
- Check whether the ST4 jumper or the
remote adjustment potentiometer have
been connected.
- Optional operating modes.
• ST1 jumper : open to connect the R
731or R 734 3-phase
sensing module.
• ST2 jumper : open if rapid response time
used
• ST5 jumper : open to suppress the LAM
function.
3.2 - Settings
The machine is tested and set at the
factory. When first 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 - R438 settings (AREP or PMG
system)
Before any intervention on the A.V.R.,
make sure that the ST9 jumper is closed
with AREP excitation and disconnected
with PMG or SHUNT or separate
excitation.
a) Initial potentiometer settings (see table
below)
- Remote voltage adjustment potentiometer :
centre (ST4 jumper removed).
Stability adjustments in standalone
operation
b ) Install a D.C. analogue voltmeter
(needle dial) cal. 50V on terminals E+, E-
and an A.C. voltmeter cal 300 - 500 or
1000V on the alternator output terminals.
c ) Make sure that the ST3 jumper is
positioned on the desired frequency (50 or
60 Hz).
d ) Voltage potentiometer P2 at minimum,
fully anti-clockwise.
e ) Stability potentiometer P3 to around 1/3
of the anti-clockwise limit.
f ) Start the engine and set its speed to a
frequency of 48 Hz for 50 Hz, or 58 for 60
Hz.
g ) Set the output voltage to the desired
value using P2 .
- Rated voltage UN for solo operation (eg.
400 V)
- Or UN + 2 to 4% for parallel operation with
C.T. (eg. 410 V)
If the voltage oscillates, use P3 to make
adjustments (try both directions) observing
WARNING
WARNING
P2
P3
P1
P5
10 A
maximum
400V - 50 Hz
(Input
0 - 380 V)
Not set
(centre position)
Not set
(fully anti-
clockwise)
Excitation ceiling
Limit of excitation and
short-circuit current,
minimum fully anti-clockwise.
Voltage quadrature droop
(// operation with C.T.)
- 0 quadrature loop fully
anti-clockwise.
Voltage
minimum fully anti-clockwise
Stability
Action Factory setting Pot.
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Installation and maintenance
R438
A.V.R.
3971 en - 11.2006 / c
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9
the voltage between E+ and E- (approx.
10V D.C.). The best response times are
obtained at the limit of the instability. If no
stable position can be obtained, try
disconnecting or replacing the ST2 jumper
(normal/fast).
h ) Check LAM operation : ST5 closed.
i) Vary the frequency (speed) around 48 or
58 Hz according to the operating
frequency, and check the change in voltage
from that observed previously (~ 15%).
j ) Readjust the speed of the unit to its rated
no-load value.
Adjustments in parallel operation
Before any intervention on the
alternator, make sure that the speed
droop is identical for all engines .
k ) Preset for parallel operation (with C.T.
connected to S1, S2)
- Potentiometer P1 (quadrature droop) in
centre position.
Apply the rated load (cos
ϕ = 0.8 inductive).
The voltage should drop by 2 to 3%. If it
increases, check that V and W and also S1
and S2 have not been reversed.
l ) The no-load voltages should be identical
for all the alternators intended to run in
parallel.
- Couple the machines in parallel.
- By adjusting the speed , try to obtain 0 KW
power exchange.
- By altering the voltage setting P2 on one
of the machines, try to cancel (or minimise)
the current circulating between the
machines.
- From now on, do not touch the voltage
settings.
m ) 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 .
3.2.2 - Max. excitation setting (excitation
ceiling)
Static adjustment of the current limit,
potentiometer P5 (factory setting: 7.5 A,
fuse rating: 8 A - 10 seconds).
The maximum factory setting corresponds
to that of the excitation current required to
obtain a 3-phase short-circuit current of
approximately 3 IN at 50 Hz for industrial
power, unless otherwise specified(*).
A static method can be used to reduce this
value or adapt the Isc to the actual
operating power (derated machine), which
is safer for the alternator and the
installation. Disconnect power supply wires
X1,X2 and Z1,Z2 and the voltage reference
(0-110V-220V-380V) on the alternator.
Connect the mains power supply using a
transformer (200-240V) as indicated
(X1,X2 : 48V). Install a 10A D.C. ammeter
in series with the exciter field. Turn P5 fully
anti-clockwise and activate the power
supply. If there is no output current from the
AVR, turn potentiometer P2 (voltage)
clockwise until the ammeter indicates a
stable current. Switch the power supply off,
then on again, turn P5 clockwise until the
required max. current is obtained (no more
than 8 A).
Checking the internal protection :
Open switch (D) : the excitation current
should increase to its preset ceiling, remain
at that level for
≥ 10 seconds and then drop
to < 1A.
Depending on
the mains frequency Main
(50/60 Hz supply)
Max. excitation
Voltage
Field
~ 5 ohms
X2
Z1
X1
Z2
E+
E-
0V
110 V
220 V
380 V
50Hz 60Hz
P2
P3
P5
ST3
10 A CC/DC
48 V
110/220/380 V
R 438
ST4
A+
–
A
D
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Installation and maintenance
R438
A.V.R.
10
3971 en - 11.2006 / c
LEROY-SOMER
To reset, switch off the power supply by
opening switch (A).
Note: After setting the excitation ceiling as
described, adjust the voltage again (see
section 2.1.1)
(*) In some countries it is a legal
requirement to have a short-circuit current
of 3 I
N
, so as to offer selective protection.
3.2.3 - Special type of use
Excitation circuit E+, E- must not be left
open when the machine is running :
AVR damage will occur.
3.2.3.1 - R438 field weakening (SHUNT)
The exciter is switched off by disconnecting
the AVR power supply (1 wire - X1 or X2).
Contact rating 16 A - 250V A.C.
3.2.3.2 - R438 field weakening (AREP/
PMG)
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.
In case of using the de-excitation,
provide a forced excitation.
3.2.3.3 - R438 field forcing
WARNING
WARNING
X2
Z1
X1
Z2
E+
E-
X2
Z1
X1
Z2
E+
E-
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
X2
Z1
X1
Z2
E+
E-
Battery (B Volt)
+
-
t
(400V - 10A)
Exciter field
Diode
t
B Volt
Forced excitation
Time
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Installation and maintenance
R438
A.V.R.
3971 en - 11.2006 / c
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11
3.3 - Electrical faults
Warning : after operational testing,
replace all access panels or covers.
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 field winding open circuit - check the
resistance
Voltage too
low Check the drive speed Correct speed
Check the AVR connections (AVR may be
faulty)
- Field windings short-circuited
- Rotating diodes burnt out
- Main field 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 If no effect : try normal / fast recovery modes (ST2) - 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
Voltage between E+ and E-
SHUNT < 20 V - AREP / PMG <
10V - Check the speed (or U/F bend set too high)
Voltage between E+ and E-
SHUNT > 30V - AREP / PMG >
15V
- Faulty rotating diodes
- Short-circuit in the main field. 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 field open circuit or short-circuited
(**) Caution : Internal protection may be activated (overload, open circuit, short-circuit)
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Installation and maintenance
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12
3971 en - 11.2006 / c
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4 - SPARE PARTS
4.1 - Designation
4.2 - Technical support service
Our technical support service will be happy
to provide any information you require.
When ordering spare parts, you should in-
dicate the complete machine type, its serial
number and the information indicated on
the nameplate.
Part numbers should be identified from
the exploded views and their description
in the parts list.
Our extensive network of "service stations"
can dispatch the necessary parts without
delay.
To ensure correct operation and the safety
of our machines, we recommend the use of
original manufacture spare parts.
In the event of failure to comply with this ad-
vice, the manufacturer cannot be held res-
ponsible for any damage.
Description Type Code
A.V.R. R 438 AEM 110 RE 017
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R438
NOTES
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13
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R438
NOTES
14
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Installation and maintenance
R438
NOTES
3971 en - 11.2006 / c
LEROY-SOMER
15
3971c_NotRegR438_en.fm Page 15 Jeudi, 9. novembre 2006 10:13 10

MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
338 567 258 RCS ANGOULÊME
S.A. au capital de 62 779 000 €
www.leroy-somer.com
3971c_NotRegR438_en.fm Page 16 Jeudi, 9. novembre 2006 10:13 10