Leroy-Somer R438 Instruction Manual

200 mm
140 mm
X2 X1 Z2 E+ E- 0V
110 220 380
Z1
T1 T2
T3
T4 T5
T6
5+ 6-
T7 T8
T9
T10 T11
T12
R 438
F1
ST5
P5
ST11
ST2 ST1
P3
P2
ST4
ST9
AREP
PMG PMG
T.I.
S1 P1
Ph.1
P2
S2
R731
50Hz 60Hz
ST10
13 %
LAM
25 %
P1
2010.11 / f3971 en -
This manual is to be given to
the end user
R438
A.V.R.
Installation and maintenance
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2
LEROY-SOMER 2010.11 / f
Installation and maintenance
R438
A.V.R.
3971 en -
Before using your machine for the rst time,
it is important to read the whole of this instal-
lation 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 potential
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 ma-
chine marked C.E.
Warning symbol for an operation ca-
pable of damaging or destroying the ma-
chine 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 tech-
nological 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.
SAFETY MEASURES
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Installation and maintenance
R438
A.V.R.
3971 en -
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.
The R438 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 ap-
propriate 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.
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4
LEROY-SOMER 2010.11 / f
Installation and maintenance
R438
A.V.R.
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 rst winding has a voltage in proportion
to that of the alternator (characteristic
Shunt), the second has a voltage in propor-
tion to the stator current (compound charac-
teristic: Booster effect).
The power supply voltage is rectied and
ltered before being used by the AVR moni-
toring transistor. This principle ensures that
regulation is not affected by distortions ge-
nerated 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 T12
R 438
F1
ST5
P5
ST11
ST2 ST1
P3
P2
P1
ST4
ST9
Option
AREP
PMG PMG
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
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
ST3
50Hz 60Hz
ST10
13 %
LAM
25 %
Frequency
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2010.11 / f
Installation and maintenance
R438
A.V.R.
1.2 - PMG excitation system
This excitation system consists of a «PMG»
(permanent magnet generator). This is tted
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 alterna-
tor output voltage by adjusting the excitation
current.
- 50/60 Hz selection via the ST3 jumper.
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
V a r i s t o r
5+ 6-
T7 T8 T9
T10 T11
T12
R 438
F1
ST5
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
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
ST3
50Hz 60Hz
ST10
13 %
LAM
25 %
Frequency
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).
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6
LEROY-SOMER 2010.11 / f
Installation and maintenance
R438
A.V.R.
2 - R438 A.V.R.
2.1 - Characteristics
- Storage : -55°C ; +85°C
- Operation : -40°C ; +70°C
- Standard power supply: AREP or PMG.
- Rated overload current: 8 A - 10 s
- Electronic protection (overload, short-cir-
cuit on opening of voltage sensing circuit):
excitation overload current for 10 seconds
then return to approximately 1A. The alter-
nator 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 trans-
former ;
• 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 potentio-
meter P1.
- Max. excitation current adjustment via P5
(see below).
2.1.1 -
Conguration jumpers function
Pot.
Delivrery
cong. 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
2.1.2 - Setting potentiometers
function
Delivrery
position Pot. Function
0 P1 Quadrature droop ; // operation with C.T.
400V P2 Voltage
Centre P3 Stability
Maxi P5 Excitation current ceiling
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 Mo-
dule) :
On application of a load, the rotation speed
of the generator set decreases. When it
passes below the preset frequency thres-
hold, the LAM causes the voltage to drop by
approximately 13% or 25% and conse-
quently 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 dura-
tion for a given applied load, or to increase
the applied load possible for one speed va-
riation (turbo-charged engine).
To avoid voltage oscillations, the trip thres-
hold for the LAM function should be set ap-
proximately 2 Hz below the lowest frequen-
cy in steady state.
100 %
50 Hz 60 Hz
Hz
50 Hz
48 Hz
57.5 Hz
60 Hz
Voltage
Bend
U/U
N
Frequency
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LEROY-SOMER
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2010.11 / f
Installation and maintenance
R438
A.V.R.
- 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 ac-
cording 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
LAM
UN
0
48 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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8
LEROY-SOMER 2010.11 / f
Installation and maintenance
R438
A.V.R.
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 potentio-
meter P2). Remove ST4 to connect the po-
ten-tiometer. (A 1 kΩ potentiometer can also
be used to extend the adjustment range).
For wiring up the external potentiometer;
the “earth” wires must be isolated as
well as the potentiometer terminals
(wires at the same voltage as the power).
- 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 po-
tentiometer.
- R 734 module: detection of 3-phase current
and voltage for parallel operation on unba-
lanced installations (imbalance > 15%).
- R 726 module: 3 functions (mounted exter-
nally).
P.F. regulation (2F) and voltage sensing cir-
cuit before paralleling (3 F).
- Control through DC voltage used monito-
ring apply to the terminals for connection of a
potentiometer DC voltage :
• internal impedance 1,5 kΩ
• ± 0,5V enable a voltage setting of 10%.
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LEROY-SOMER
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2010.11 / f
Installation and maintenance
R438
A.V.R.
3 - INSTALLATION - COMMISSIONING
3.1 - Electrical checks on the AVR
- Check that all connections have been
made properly as shown in the attached wi-
ring diagram.
- Check that the ST3 frequency selection
jumper is on the correct frequency setting.
- Check whether the ST4 jumper or the re-
mote 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 fac-
tory. When rst used with no load, make
sure that the drive speed is correct and
stable (see the nameplate). After opera-
tional 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 excita-
tion.
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 positio-
ned 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 fre-
quency of 48 Hz for 50 Hz, or 58 for 60 Hz.
g) Set the output voltage to the desired va-
lue 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 ad-
justments (try both directions) observing the
voltage between E+ and E- (approx. 10V
D.C.).
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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10
LEROY-SOMER 2010.11 / f
Installation and maintenance
R438
A.V.R.
The best response times are obtained at the
limit of the instability. If no stable position
can be obtained, try disconnecting or repla-
cing 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 alterna-
tor, 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 in-
creases, 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 pa-
rallel.
- 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 set-
tings.
m) Apply the available load (the setting is only
correct if a reactive load is available)
- By altering the speed, match the kW (or di-
vide the rated power of the units proportionally)
- By altering the quadrature droop potentiome-
ter 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 specied(*).
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 eld. 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).
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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