Leroy-Somer LSA 42.2 Instruction Manual

Thismanualmustbesupplied
totheenduser
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
Installation and maintenance
3433 en - 06. 2007 / e
343
347
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124
120
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132
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2
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
3433 en - 06. 2007 / e
LEROY-SOMER
This manual concerns the alternator which
you have just purchased.
The latest addition to a whole new generation
of alternators, this range benefits from the
experience of the leading manufacturer
worldwide, using advanced technology and
incorporating strict quality control.
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 information you may require.
The various operations described in this manual are
accompanied by recommendations 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.
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.
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.
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.
WARNING SYMBOLS
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.
Copyright 2004 : 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.
WARNING
WARNING

3
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
CONTENTS
3433 en - 06. 2007 / e
LEROY-SOMER
1 - RECEIPT
1.1 - Standards and safety measures ....................4
1.2 - Checks...........................................................4
1.3 - Identification...................................................4
1.4 - Storage ..........................................................4
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics ................................5
2.2 - Mechanical characteristics ............................5
3 - INSTALLATION - COMMISSIONING
3.1 - Assembly .......................................................6
3.2 - Inspection prior to first use.............................6
3.3 - Electrical diagram ..........................................7
3.4 - Commissioning ..............................................9
3.5 - Setting up.......................................................9
4 - SERVICING - MAINTENANCE
4.1 - Safety measures ......................................... 10
4.2 - Regular maintenance.................................. 10
4.3 - Fault detection ............................................ 10
4.4 - Mechanical defects ..................................... 11
4.5 - Electrical faults............................................ 11
4.6 - Dismantling, reassembly............................. 13
4.7 - Characteristics table .................................. 15
5 - SPARE PARTS
5.1 - First maintenance parts .............................. 16
5.2 - Description of bearings ............................... 16
5.3 - Technical support service ........................... 16
5.4 - Exploded view, parts list ............................. 17

4
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
RECEIPT
3433 en - 06. 2007 / e
LEROY-SOMER
1 - RECEIPT
1.1 - 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 8528.
- 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 potential risks of accidents. It is vital that you
understand and take notice of the different warning symbols.
1.2 - Inspection
On receipt of your alternator, check that it has not suffered
any damage in transit. If there are obvious signs of knocks,
contact the transporter (you may able to claim on their
insurance) and after a visual check, turn the machine by hand
to detect any malfunction.
1.3 - Identification
The alternator is identified by means of a nameplate fixed on
the frame.
Make sure that the nameplate on the machine conforms to
your order.
The machine name is defined according to various criteria
(see below).
Example of description for : LSA 42.2 S4 J6/4 -
• LSA : name used in the PARTNER range
M : Marine / C : Cogeneration / T : Telecommunications.
• 42.2 : machine type
• S4 : model
• J : field excitation system
(C:AREP / J:SHUNT / E:COMPOUND)
• 6/4 : winding number / number of poles.
1.3.1 - Nameplate
So that you can identify your machine quickly and accurately,
we suggest you fill in its specifications on the nameplate
below.
1.4 - Storage
Prior to commissioning, machines should be stored :
- Away from humidity : in conditions of relative humidity of
more than 90%, the machine insulation can drop very rapidly,
to just above zero at around 100%; monitor the state of the
anti-rust protection on unpainted parts.
For storage over an extended period, the machine can be
placed in a sealed enclosure (heatshrunk plastic for example)
with dehydrating sachets inside, away from significant and
frequent variations in temperature to avoid the risk of
condensation during storage.
- If the area is affected by vibration, try to reduce the effect of
these vibrations by placing the generator on a damper
support (rubber disc or similar) and turn the rotor a fraction of
a turn once a fortnight to avoid marking the bearing rings.
ALTERNATEURS ALTERNATORS
Valeurs excit / Excit. values
en charge / full load
à vide / at no load
Made by Leroy Somer - 1 024 930/b
Tension
Voltage
Secours
Std by
40C
27C
PUISSANCE / RATING
Conforme à C.E.I 34-1 (1994). According to I.E.C 34-1 (1994).
LR 0021
Connex.
kVA
kW
A
kVA
kW
A
V
Ph.
Continue
Continuous
LSA Date
N Hz
Min
-1
/R.P.M. Protection
Cos ϕ/P.F. Cl. ther. / Th. class
Régulateur/A.V.R.
Altit. m Masse / Weight
Rlt AV/D.E bearing
Rlt AR/N.D.E bearing
Graisse / Grease

5
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
TECHNICAL CHARACTERISTICS
3433 en - 06. 2007 / e
LEROY-SOMER
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics
The PARTNER LSA 42.2 alternator is a machine without
sliprings and revolving field brushes, wound as "2/3 pitch";
12-wire, with class H insulation and a field excitation system
available in either "SHUNT" or "AREP" version (see sections
2.3, 2.4). Interference suppression conforms with standard
EN 55011, group 1, class B.
2.1.1 - Options
- Stator temperature detection probes.
- Space heaters.
2.2 - Mechanical characteristics
- Steel frame
- End shields in cast iron
- Greasable ball bearings
- Mounting arrangement
MD 35 :
single bearing with standard feet and SAE flanges/coupling
discs.
B 34 :
two-bearing with SAE flange and standard cylindrical shaft
extension.
- Drip-proof machine, self-cooled
- Degree of protection : IP 23
2.2.1 - Options
- Protection against harsh environmentsh.
- Air input filter, air output labyrinth cowling.
Alternators fitted with air inlet filters should be derated by 5%
(power)
To prevent excessive temperature rise caused by clogged
filters, it is advisable to fit the stator winding with thermal
sensors (PTC or PT100).
.
T1 T2 T3
T4 T5 T6
Varistor
+-
Field
STATOR : 12 wires (T1 to T12 identification)
Exciter
T7 T8 T9
T10 T11 T12
+-
Armature
MAIN FIELD
R 250 Voltage reference
5+
6 -
Red Black
Aux. windings
Green
Yellow
Red
Black
T1 T2 T3
T4 T5 T6
Varistor
+-
Field
STATOR : 12 wires (T1 to T 12 identification)
Voltage reference
5+
Exciter
6-
T7 T8 T9
T10 T11 T12
+-
Armature
MAIN FIELD
R 438
White Blue

6
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
INSTALLATION
3433 en - 06. 2007 / e
LEROY-SOMER
3 - INSTALLATION
3.1 - Assembly
All mechanical handling operations must be undertaken
using approved equipment.
While being handled, the machine should remain
horizontal.
3.1.1 - Handling
The generously-sized lifting rings are for handling the
alternator alone. They must not be used to lift the genset.
Choose a lifting system which respects the positionning of the
rings.
3.1.2 - Coupling
3.1.2.1 - single bearing alternator
Before coupling to the prime mover, check that both are
compatible by:
- Undertaking a torsional analysis of the transmission.
-Checking the dimensions of the flywheel and its housing, the
flange, coupling discs and offset.
When coupling the alternator to the prime mover, the
holes of the coupling discs should be aligned with the
flywheel holes by cranking the engine.
Do not use the alternator fan to turn the rotor.
Tighten the coupling discs screws to the recommended
torque (see section 4.6.2.) and check that there is lateral play
on the crankshaft.
3.1.2.2 - two-bearing alternator
- Semi-flexible coupling
Careful alignement of the machines by measuring the
concentricity and parallelism of the two parts of the coupling
is recommended, the difference between the teadings should
not exceed the specified values (say 0,1 mm).
This alternator has been balanced with a 1/2 key.
3.1.3 - Location
Ensure that the ambient temperature in the room where the
alternator is placed cannot exceed 40°C for standard power
ratings (for temperatures above 40°C, apply a derating
coefficient). Fresh air, free from damp and dust, must be able
to circulate freely around the air input louvres on the opposite
side from the coupling. It is essential to prevent not only the
recycling of hot air from the machine or engine, but also
exhaust fumes.
3.2 - Inspection prior to first use
3.2.1 - Electrical checks
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 two possible methods for restoring the above
minimum values.
a) Dry out the machine for 24 hours in a drying oven at a
temperature of approximately 110 °C.
b) Blow hot air into the air input, 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 output phases 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 48 Volt battery in series with a rheostat of
approximately 10 ohms (50 Watts), to the exciter field
terminals, respecting the polarity.
- Open fully all the alternator orifices.
- Run the alternator at rated speed . 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 turning
over the machine from time to time. Space heaters are only
really effective if they are working continuously while the
machine is stopped.
WARNING
WARNING
WARNING
WARNING

7
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
INSTALLATION
3433 en - 06. 2007 / e
LEROY-SOMER
3.2.2 - Physical and visual checks
Before starting the machine for the first time, check that:
- the fixing bolts on the feet are tight
- the cooling air is drawn in freely
- the protective louvres and housing are correctly in place
- the standard direction of rotation is clockwise as seen from
the shaft end (phase rotation in order 1 - 2 - 3). For anti-
clockwise rotation, swap 2 and 3.
- the winding connection corresponds to the site operating
voltage (see section § 3.3)
3.3 - Terminal connection diagrams
To modify the connection, change the position of the terminal
cables. 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.
Connection codes L.L voltage Factory connection
L1(U)
N
L3(W)
T1 T7
T12
T10
T4
T9
T3
T6
T11
T5
T2
T8
L2(V)
A
3 phase
3 phase
Winding
60 Hz50 Hz
190 - 208 190 - 240
220 - 230 -
- 190 - 208
6
7
8
N
T1
T7
T12
T10
T4
T9
T3 T6
T11 T5
T2
T8
L1(U)
L3(W) L2(V)
D
F
L1(U)
M
L3(W)
T1
T7
T12
T10
T4
T9
T3
T6
T11 T5 T2
T8
L2(V)
Voltage LM = 1/2 voltage LL
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 438 voltage detection :
0 => (T3) / 220 V => (T2)
N
L1(U)
L2(V)
L3(W)
NDE
T9
T8
T7
T12
T10
T11
T4
T3
T2
T1
T5 T6
Winding
60 Hz50 Hz
380 - 415 380 - 480
440 - 460 -
- 380 - 416
6
7
8
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 438 voltage detection :
0 => (T3) / 380 V => (T2) NDE
N
L1(U)
L2(V)
L3(W)
L1(U)
L2(V)
L3(W)
T9
T8
T7
T12
T10
T11
T4
T3
T2
T1
T5
T6
1 phase
1 phase
or
3 phase
FF
FF
Winding
60 Hz50 Hz
220 - 240 220 - 240
220 - 240
200
250 - 260 -
6
7
8
R 250 voltage detection :
0 => (T1) / 110 V => (T4)
R 438 voltage detection :
0 => (T10) / 220 V => (T1) NDE
M
L
L
L
L
T9
T8
T7
T12
T10
T11 T4
T3
T2
T1
T5
T6
Winding
60 Hz50 Hz
220 - 240 220 - 240
220 - 240
200
250 - 260 -
6
7
8
NDE
T9
T8
T7 T12
T10
T11
T4
T3
T2
T1
T5
T6
L
LL
T1 T7
T12
T10
T4
T9
T3
T6
T11
T5
T2 T8
L
M
Voltage LM = 1/2 voltage LL
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 438 voltage detection :
0 => (T3) / 220 V => (T2)

8
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
INSTALLATION
3433 en - 06. 2007 / e
LEROY-SOMER
3.3.1 - Connection diagram for options
T1 T4
T3
T2
PARALLEL CONNECTION
SERIES CONNECTION
LL
M
SINGLE PHASE 4 LEADS - WINDING DEDICATED type M or M1
Voltage 50/60 Hz Output
L - L
220
230
240
110
115
120
T2 - T3 T2 - T3T1 T4
L - M L L MConnect
R 250 voltage detection : 0 => (T1) / 110 V => (T2)
T1
T4
T3
T2
LL
Voltage 50/60 Hz Output
L - L
-
-
-
110
115
120
T1 - T3
T2 - T4 -T1-T3 T2 - T4
L - M L L MConnect
R 250 voltage detection : 0 => (T1) / 110 V => (T2)
1 PH
M
T1
T7
T12
T10
T4
T9
T3
T6
T11
T5
T2
T8
LM voltage = 1/2 LL voltage
Connection
not recommended
Connection codes L.L voltage Factory connection
L
L
GWinding 60 Hz50 Hz
220 - 240 220 - 240
250 - 260
200
-
220 - 240
6
7
8
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 438 voltage detection :
0 => (T3) / 220 V => (T2)
M
L
L
NDE
T9
T8
T7
T12
T10
T11
T4
T3
T2
T1
T5
T6
1 phase
or
3 phase
L1(U)
L2(V)
L3(W)
L
L
Winding 60 Hz50 Hz
110 - 120 120
110 - 120
-
120 - 130
-
6
7
8
R 250 voltage detection :
0 => (T8) / 110 V => (T11)
R 438 voltage detection :
0 => (T3) / 110 V => (T2) NDE
T9
T8
T7
T12
T10
T11
T4
T3
T2
T1
T5
T6
LL
L3(W)
T1
T7
T10
T9 T3
T6
T11
T5 T2
T8
L2(V)
B
T12
T4
L1(V)
R 791 T interference suppression kit (standard for CE marking) Voltage potentiometer
Black
Black
Black
Blue
White
Connections
T1 T1 T1 T1 T1 T2
T2 T2 T2 T2 T9 T4
T3 T3 T3 T3 T3 T3
N N
Voltage adjustment
via remote potentiometer
ST4
5
0
10
20
30
40
50
60
70
80
90
ADFBF/F G
Thermistor (PTC) temperature
Ph1
Ph2
Ph3
Anti condensation heater
101
102
103
104
130 C
blue
150C
black
180 C
red/white

9
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
INSTALLATION
3433 en - 06. 2007 / e
LEROY-SOMER
3.3.2 - Connection checks
Electrical installations must comply with the current
legislation in force in the country of use.
Check that:
- the differential circuit-breaker conforms to 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. (Disconnect the blue wire
of the R 791 interference suppression module linking the
neutral).
- any protective devices in place have not tripped,
- if there is an external regulator, the connections between the
alternator and the cubicle are made in accordance with the
connection diagram,
- there is no short-circuit between phase or phase-neutral
between the alternator output terminals and the generator set
control cabinet (part of the circuit not protected by circuit-
breakers or cubicle relays)
- the machine should be connected with the terminal lugs on
top of one another as shown in the terminal connection
diagrams.
3.4 - Commissioning
The machine can only be started up and used if the
installation is in accordance with the instructions and
advice defined in this manual.
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). On application of the load, the
machine should maintain 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).
3.5 - Setting up
The various adjustments during tests must be made by a
qualified engineer. 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 A.V.R. is used to make any adjustments to the machine.

10
INSTALLATION AND MAINTENANCE
LSA 42.2 - 2 & 4 POLE
ALTERNATORS
SERVICING - MAINTENANCE
3433 en - 06. 2007 / e
LEROY-SOMER
4 - SERVICING - MAINTENANCE
4.1 - 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.
Before any intervention on the machine, ensure that it cannot
be started by a manual or automatic system and that you
have understood the operating principles of the system.
4.2 - Regular maintenance
4.2.1 - 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.
4.2.2 - Cooling circuit
It is advisable to check that circulation of air is not reduced by
partial blocking of the air intake and outlet grilles : mud, fibre,
grease, etc.
4.2.3 - Bearings
The bearings are greased for life: approximate life of the
grease (depending on use) = 20,000 hours or 3 years.
Monitor the temperature rise in the bearings, which should not
exceed 90°C above the ambient temperature. Should this
value be exceeded, the machine must be stopped and checks
carried out.
4.2.4 - Electrical servicing
Cleaning product for the windings
Do not use : trichlorethylene, perchlorethylene,
trichloroethane or any alkaline products.
Certain strictly defined pure volatile degreasing products can
be used, such as :
- Normal petrol (without additives) ; inflammable
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable
- Ciclohexare (non toxic); inflammable
Cleaning of the stator, rotor, exciter and diode bridge
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.
4.2.5 - Mechanical servicing
Cleaning the machine using water or a high-pressure
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 necessary (every day in very dusty atmospheres).
Cleaning can be performed using water for dry dust or in a
bath containing soap or detergent in the case of greasy dust.
Petrol or chloroethylene can also be used.
After cleaning the alternator, it is essential to check the
winding insulation (see sections 3.2. and 4.8.).
4.3 - 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 protective devices are fitted correctly
- the connections comply with diagrams in the manuals
supplied with the machine
- the speed of the unit is correct (see section 1.3).
Repeat the operations defined in section 3.
WARNING
WARNING
WARNING
WARNING