Leroy-Somer LSA 49.1 Instruction Manual

53
343 107
100
347
78
37
79
349
70
90
1
36
4
28
41
18
51
31
59
91
278
364
269
368
268
279
71
371
177
365
198
172
281
270
21
4
30 33
60
284
68 15
62
22
34
48 49
367
255
254
Caixa de terminais opcionais
6 fios com réguas de ligações
277 280
281
283
172
282
279
278
320
15
Motor, turbina
LSA 49.1 L 11
2014.03 / n
This manual is to be given
to the end user
3007 en -
LSA 49.1 - 4 POLES
ALTERNATORS
Installation and maintenance

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007en -
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 recommenda-
tions or symbols to alert the user to the po-
tential risk of accidents. It is vital that you
understand and take notice of the different
warning symbols used.
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.
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.
WARNING
The alternators must not be put into
service until the machines in which they
are to be incorporated have been
declared compliant with Directives EC
and plus any other directives that may be
applicable.
© - This document is the property of Moteurs
Leroy-Somer, it can not be reproduced in
any form without prior written authorization.
Moteurs Leroy-Somer reserves the right to
modify the design, technical specifications
and dimensions of the products shown in
this document. The descriptions cannot in
any way be considered contractual.
WARNING
This manual concerns the alternator which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007 en -
CONTENTS
1 - RECEIPT ............................................................................................................. 4
1.1 - Standards and safety measures .................................................................................4
1.2 - Inspection ...................................................................................................................4
1.3 - Identification ...............................................................................................................4
1.4 - Storage ......................................................................................................................4
1.5 - Applications ................................................................................................................4
1.6 - Contraindications to use .............................................................................................4
2 - TECHNICAL CHARACTERISTICS .................................................................... 5
2.1 - Electrical characteristics .............................................................................................5
2.2 - Mechanical characteristics .........................................................................................5
3 - INSTALLATION .................................................................................................. 6
3.1 - Assembly ....................................................................................................................6
3.2 - Checks prior to first use ..............................................................................................6
3.3 - Terminal connection diagrams ....................................................................................7
3.4 - Commissioning ........................................................................................................10
3.5 - Setting up .................................................................................................................10
4 - SERVICING - MAINTENANCE ......................................................................... 11
4.1 - Safety measures ...................................................................................................... 11
4.2 - Routine maintenance ............................................................................................... 11
4.3 - Bearings ...................................................................................................................12
4.4 - Mechanical defects ..................................................................................................12
4.5 - Electrical faults .........................................................................................................13
4.6 - Dismantling, reassembly ..........................................................................................15
4.7 - Installation & maintenance of the PMG .....................................................................17
4.8 - Table of characteristics ........................................................................................17-18
5 - SPARE PARTS ................................................................................................. 19
5.1 - First maintenance parts ............................................................................................19
5.2 - Technical support service .........................................................................................19
5.3 - Accessories .............................................................................................................19
5.4 - Exploded views, parts list and tightening torque .......................................................20
EC declaration of incorporation

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LEROY-SOMER 2014.03 / n
ALTERNATORS
R
CUS
IEC 60034-1 & 5 NEMA MG1-32 & 33 www.leroy-somer.com 1.025.002 a
Made in ............................ISO 8528-3
166631
IP LSA
N°:
Th.class.
A.V.R. Excit.
Excit. values full load : V / A
at no load : A
D.E. bearing
N.D.E. bearing
Altitude : m
kVA
kW
A
V
kVA
kW
A
Weight : kg
r.p.m.
P.F. :
Hz
RATINGS
Voltage
Phase
Conn.
Contin.
P.R.
B.R.
40°C.
Std by
27°C.
Date :
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007en -
1 - RECEIPT
1.1 - Standards and safety
measures
Our alternators comply with most
international standards.
See the EC Declaration of Incorporation on
the last page.
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 be 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 machine (see
drawing).
Make sure that the nameplate on the
machine conforms to your order.
So that you can identify your alternator
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 (< 90%); after a long
period of storage, check the machine
insulation. To prevent the bearings from
becoming marked, do not store in an
environment with significant vibration.
1.5 - Application
These alternators are mainly designed to
produce electricity in the context of
applications involving the use of
generators.
1.6 - Contraindications to use
Use of the machine is restricted to operating
conditions (environment, speed, voltage,
power, etc) compatible with the characteri-
stics indicated on the nameplate.

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007 en -
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics
PARTNER LSA 49.1 alternator is a
machine without sliprings or revolving
field brushes, wound as “2/3 pitch”; 6 or
12-wire, with class H insulation and a field
excitation system available in either AREP
or “SHUNT+PMG” version (see diagrams
and AVR maintenance manual).
• Options
- Stator temperature detection sensors
- Space heaters
- Terminal box with connector links for
mounting protection or measurement C.T.
In order to conform to standard EN 61000-
6.3, EN 61000-6.2, the R 791 interference
suppression kit is needed.
2.2 - Mechanical characteristics
- Steel frame
- Cast iron end shields
- Greasable ball bearings
- Mounting arrangement
IM 1201 (MD 35): Single-bearing with feet
and SAE flanges/coupling discs
IM 1001 (B 34): Twin-bearing with SAE
flange and standard cylindrical shaft
extension
- Drip-proof machine, self-cooled
- Degree of protection: IP 23
• Options
- Protection against harsh environments
- Air inlet filter, air outlet labyrinth seals: IP 44
To prevent excessive temperature rise
caused by clogged filters, it is advisable to
monitor the stator winding with thermal
sensors (PTC or PT100).
AREP system with R 450
SHUNT + PMG system with R 450
T1 T2 T3
T4 T5 T6
Surge suppressor
5+ 6-
T7 T8 T9
T10 T11 T12
R 450
Aux. windings
STATOR : 12 wires (marked T1 to T 12)
Exciter
Field
Armature
MAIN FIELD
Voltage reference
STATOR : 6 wires (marked T1 to T6)
T1 T2 T3
T4 T5 T6
Surge suppressor
5+ 6-
T7 T8 T9
T10 T11 T12
R 450
PMG
STATOR : 12 wires (marked T1 to T 12)
Exciter
Field
Armature
MAIN FIELD
Voltage reference
STATOR : 6 wires (marked T1 to T 6)

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007en -
3 - INSTALLATION
Personnel undertaking the various
operations indicated in this section must
wear personal protective equipment
appropriate for mechanical and electrical
hazards.
3.1 - Assembly
All mechanical handling operations must
be undertaken using suitable equipment
and the machine must be horizontal.
Check how much the machine weighs
(see 4.8) before choosing the lifting tool.
During this operation, do not allow
anyone to stand under the load.
• Handling
The generously-sized lifting rings are for
handling the alternator alone. They must not
be used to lift the genset. The choice of lifting
hooks or handles should be determined by
the shape of these rings. Choose a lifting
system which respects the integrity and the
environment of the machine.
During this operation, do not allow
anyone to stand under the load.
• Single-bearing coupling
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 offset.
WARNING
When coupling the alternator to the
prime mover, do not use the fan to turn
the alternator or rotor.
The holes of the coupling discs should
be aligned with the flywheel holes by
cranking the engine.
Make sure the machine is securely
bedded in position during coupling.
Check that there is lateral play on the
crankshaft.
• Double-bearing coupling
- Semi-flexible coupling
Careful alignment of the machines is
recommended, checking that the lack 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
The room where the alternator is placed
must be ventilated to ensure that the
ambient temperature cannot exceed the
data on the nameplate.

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007 en -
3.2 - Checks prior to first use
• Electrical checks
Under no circumstances should an
alternator, new or otherwise, be
operated if the insulation is less than 1
megohm for the stator and 100,000
ohms for the other windings.
There are 2 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 regulator).
b) Blow hot air into the air intake, having
made sure that the machine is rotating
with the exciter field disconnected.
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.
Ensure that the alternator has the
degree of protection matching the
defined environmental conditions.
• Mechanical checks
Before starting the machine for the first
time, check that:
- all fixing bolts and screws are tight,
- the cooling air is drawn in freely,
- the protective grilles and housing are
cor-rectly in place,
- the standard direction of rotation is clock-
wise 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 stator cables on the
terminals. 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.
WARNING

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007en -
• Terminal connection : 12-wire
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
R 450 voltage detection :
0 => (T3) / 220 V => (T1)
R 450 voltage detection :
0 => (T3) / 380 V => (T2)
OPTION
L1(U)
N
L3(W)
T1 T7
T12
T10
T4
T9
T3
T6
T11
T5
T2
T8 L2(V)
A
3-phases
3-phases
3-phases
60 Hz50 Hz
190 - 208
190 - 208
208 - 220
190 - 240
6
7
8
6
7
8
6
7
8
9
N
T1
T7
T12
T10
T4
T9
T3 T6
T11 T5
T2
T8
L1(U)
L3(W) L2(V)
D
L1(U)
L2(V)
L3(W)
N
T9
T8
T7
T3
T2
T1
T4
T6
T10
T11
T12
T5
T3
T2
T1
T3
T2
T1
60 Hz50 Hz
380 - 415
380 - 416
415 - 440
500 - 525
380 - 480
600
L1(U)
L2(V)
L3(W)
N
T9
T8
T7
T4
T6
T10
T11
T12
T5
60 Hz50 Hz
220 - 240
220 - 240
240 - 254
220 - 240
L1(U)
L2(V)
L3(W)
T9
T8
T7
T4
T6
T10
T11
T12
T5
F
L1(U)
L3(W)
T1
T7
T12
T10
T4
T9
T3
T6
T11 T5 T2
T8
L2(V)
LL
L1(U)
M
L3(W)
T1
T7
T12
T10
T4
T9
T3
T6
T11 T5 T2
T8
L2(V)
LL
NDE
T3
T2
T1
L1(U)
L2(V)
L3(W)
M
T9
T8
T7
T4
T6
T10
T11
T12
T5
Winding 9 : R 450 voltage detection + transformer (See specific diagram AREP or PMG)
Delta / Edison
Caution : M point connection
is a factory modification.
Winding
Winding
Winding
NDE
NDE
NDE
Connection code Voltage L.L Factory connection

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007 en -
• Terminal connection : 6-wire version
NDE NDE
Optional 6-wire terminal box with connector links for mounting protection and (or) measurement C.Ts.
N
T1
T2
T3
T4
T5
T6 T1
T2
T3
T4
T5
T6
380
0
220
0
Connection code Voltage L.L Factory connection
Star
Delta
T3
T2
T1
T3
T2
T1
L1(U)
L2(V)
L3(W)
N
T4
T5
T6
L1(U)
L2(V)
L3(W)
L1(U)
L2(V)
L3(W)
L1(U)
L2(V)
L3(W)
T4
T5
T6
3-phases
N
T1
T4
T3
T6
T5
T2
L1(U)
L3(W) L2(V)
D
L1(U)
L3(W)
T1
T4
T3
T6
T5 T2 L2(V)
F
Delta
F
single-phase
or
3-phases
60 Hz50 Hz
6S
7S
8S
220 - 240 220 - 240
240 - 254
220 - 240
6S
7S
8S
9
60 Hz50 Hz
380 - 415
380 - 416
415 - 440
500 - 525
380 - 480
600
R 450 voltage detection :
0 => (T3) / 220 V => (T2)
R 450 voltage detection :
0 => (T3) / 380 V => (T2)
Winding 9 : R 450 voltage detection + transformer (See specific diagram AREP or PMG)
Winding
Winding
AR
AR
Star
D
• Option connection diagram
R 791 T interference suppression kit
(standard for CE marking) Connection of the optional current transformer
External voltage potentiometer
or ext. source 1V (resistance 1.5 KΩ)
Black
Black
Black
Blue
White
Connections
T1 T1 T1 T1
T2 T2 T2 T2
T3 T3 T3 T3
N N
Adjusting the voltage
via a remote
potentiometer
ST4
A C D F
Neutral link
In/2 (D conn.)
Secondary 1 A
12-wire 6-wire
A / D connection
P1
P2 T10
Neutral link
In/4 (D conn.)
Secondary 1 A
D connection
P1
P2 T4

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LEROY-SOMER 2014.03 / n
Installation and maintenance
LSA 49.1 - 4 POLES
ALTERNATORS
3007en -
• Connection checks
Electrical installations must comply with
the current legislation in force in the
country of use.
Check that:
- The residual 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.
(In this case, disconnect the wire of the
interference suppression module linking
the
neutral).
- Any protection devices in place have not
been tripped.
- If there is an external AVR, the connections
between the alternator and the cabinet are
made in accordance with the connection
diagram.
- There is no short-circuit phase-phase or
phase-neutral between the alternator
output terminals and the generator set
control cabinet (part of the circuit not
protected by circuitbreakers or relays in the
cabinet).
- The machine should be connected with the
busbar separating the terminals as shown
in the terminal connection diagram.
- The alternator earth terminal inside the
terminal box is connected to the electrical
earth circuit
- The earth terminal (ref 28) is connected to
the frame.
The connections inside the terminal box
must never be subjected to stress due to
cables connected by the user.
3.4 - Commissioning
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
section 4.3).
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).
3.5 - Setting up
The various adjustments during tests
must be made by a qualified engineer.
Ensure 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 used to make any adjustments
to the machine.