Leroy-Somer Nidec LSA PMR 320 Instruction Manual

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LSA PMR 320
Alternator for rail application - 8-pole
Installation and maintenance

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2020.01 / b
Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
This manual concerns the alternator which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.
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 information you
may require.
The various operations described in this
manual are accompanied by recommenda-
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.
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
SAFETY INSTRUCTIONS
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 EC Directives
plus any other directives that may be
applicable.
This manual is to be given to the end
user.
The range of electric alternators and
their derivatives, manufactured by us or
on our behalf, comply with the technical
requirements of the customs Union
directives (EAC).
© - We reserve the right to modify the
characteristics of this product at any time in
order to incorporate the latest technological
developments. The information contained
in this document may therefore be changed
without notice.
This document may not be reproduced in
any form without prior authorisation.
All brands and models have been registered
and patents applied for.
WARNING
The alternators must not be put into
service until the machines in which they
are to be incorporated have been
declared compliant with EC Directives
plus any other directives that may be
applicable.
This manual is to be given to the end
user.
The range of electric alternators and
their derivatives, manufactured by us or
on our behalf, comply with the technical
requirements of the customs Union
directives (EAC).
© - We reserve the right to modify the
characteristics of this product at any time in
order to incorporate the latest technological
developments. The information contained in
this document may therefore be changed
without notice.
This document may not be reproduced in
any form without prior authorisation.
All brands and models have been registered
and patents applied for.

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2020.01 / b
Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
CONTENTS
1 - RECEIPT.............................................................................................................4
1.1 - Standards and safety measures............................................................................... 4
1.2 - Inspection ................................................................................................................. 4
1.3 - Identication ............................................................................................................. 4
1.4 - Storage ..................................................................................................................... 4
1.5 - Applications .............................................................................................................. 4
1.6 - Usage restrictions..................................................................................................... 4
2 - TECHNICAL CHARACTERISTICS ....................................................................5
2.1 - Electrical characteristics ........................................................................................... 5
2.2 - Mechanical characteristics ....................................................................................... 5
3 - INSTALLATION ..................................................................................................5
3.1 - Assembly .................................................................................................................. 5
3.2 - Checks prior to rst use............................................................................................ 5
3.3 - Terminal connection diagrams ................................................................................. 6
3.4 - Commissioning ......................................................................................................... 7
4 - SERVICING - MAINTENANCE...........................................................................8
4.1 - Safety measures....................................................................................................... 8
4.2 - Routine maintenance................................................................................................ 8
4.3 - Bearings ................................................................................................................... 9
4.4 - Mechanical defects................................................................................................... 9
4.5 - Electrical faults ......................................................................................................... 9
4.6 - Dismantling, reassembly ........................................................................................ 10
4.7 - Table of characteristics ........................................................................................... 10
5 - SPARE PARTS .................................................................................................11
5.1 - First maintenance parts ...........................................................................................11
5.2 - Technical support service ........................................................................................11
5.3 - Accessories .............................................................................................................11
5.4 - Exploded views, parts list and tightening torque .................................................... 12
Disposal and recycling instructions

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Electric Power Generation
LSA 000-1-006 e
Moteurs Leroy-Somer - Boulevard Marcellin Leroy,
CS 10015 - 16915 Angoulême Cedex 9 - France
IEC 60034 - 1 & 5. / ISO 8528 - 3. / NEMA MG1 - 32 & 33.
Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
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 - Identication
The alternator is identied by means of a
nameplate xed 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 ll in
its specications 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 signicant vibration.
1.5 - Application
This alternator is mainly designed to
produce electricity in the context of
applications involving the use of
generators.
1.6 - Usage restrictions
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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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics
This alternator is a machine with
permanent magnets, wound as ”full pitch”,
12-wire, with class H insulation.
- 4 PT 1000 stator temperature detection
sensors connected to a fast-on connector.
2.2 - Mechanical characteristics
- Steel frame
- Steel DE and NDE shields
- Regreasable insulated ball bearings
- Double-bearing with SAE ange and
standard cylindrical shaft extension
- Water-cooled enclosed machine
- Degree of protection: IP 69
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 ho-
rizontal. Check how much the machine
weighs before choosing the lifting tool.
During this operation, do not allow
anyone to stand under the load.
• Handling
The generously-sized lifting eyes are for
handling the alternator only. They must not
be used to lift the genset. The choice of
lifting hooks or handles should be
determined by the shape of the lifting eyes.
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.
• Double-bearing coupling
- Semi-exible 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.
3.2 - Checks prior to rst 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.

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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
• Mechanical checks
Before starting the machine for the rst time,
check that:
- all xing bolts are tight, and there are no
leaks from the water inlet and outlet,
- the length of bolt and the tightening torque
are correct,
- the protective grille is correctly in place,
- the standard direction of rotation is clock-
wise as seen from the drive end (phase
rotation in order 1 - 2 - 3).
For anti-clockwise rotation, swap 2 and 3.
3.3 - Terminal connection diagrams
Any intervention on the alternator
terminals during checks should be
performed with the machine stopped.
In no case should the internal
connections in the terminal box be
subjected to stresses due to cables
connected by the user.
• Three-phase 12-wire
L1(U)
N
L3(W)
T1 T7
T12
T10
T4
T9
T3
T6
T11
T5
T2
T8 L2(V)
A3PH
T6
T4
T3
T2
T1
T5
W (3) – L3
V (2) – L2
U (1) – L1
T9
T8
T7
T10
T11
T12
Connection codes Factory connection
Parallel Star DE
NDE
OUTPUTS TO THE RIGHT

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LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
• 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.
- any protection devices in place have not
been tripped.
- 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 cabinet.
- the machine should be connected with the
busbar separating the terminals as shown in
the terminal connection diagram.
- the earth terminal is connected to the
frame.
The connections inside the terminal box
must never be subjected to stress due to
cables connected by the user.
Diameter M6 M8 M10 M12
Torque 4 Nm 10 Nm 20 Nm 35 Nm
Tolerance ± 15%
3.4 - Commissioning
The machine can only be started up and
used if the installation is in accordance
with the regulations and instructions
dened in this manual.
The machine is tested at the factory.
When rst used with no load, see table
section 4.7.

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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
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, who must
wear personal protective equipment
appropriate for mechanical and electrical
hazards.
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.
Warning: during and after running, the
alternator will reach temperatures hot
enough to cause injury, such as burns.
4.2 - Routine maintenance
• Checks after start-up
After approximately 20 hours of operation,
check that all xing bolts on the machine are
still tight, plus the general state of the
machine and the various electrical
connections in the installation.
• Electrical servicing
Commercially-available volatile degreasing
agents can be used.
WARNING
Do not use: trichlorethylene, perchlo-
rethylene, trichloroethane or any alkaline
products.
These operations must be performed at
a cleaning station, equipped with a
vacuum system that collects and
ushes out the products used.
The insulating components and the
impregnation system are not at risk of
damage from solvents. Avoid letting the
cleaning product run inside the machine by
the terminal box.
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 before closing
the terminal box.
• Mechanical servicing
WARNING
Cleaning the machine using water or a
high-pressure washer is permitted,
provided it is done in accordance with
EN 60529.
Degreasing: use a brush and detergent
(suitable for paintwork).
Dusting: use an air gun.
After cleaning the alternator, it is essential to
check the winding insulation (see sections
3.2 and 4.5).

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LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
4.3 - Bearings
The bearings are regreasable Life of the grease = 700 hours or 1 year
Grease: Mobil Polyrex EM NLGI2
Amount of grease at each regreasing = 51 g minimum
4.4 - Mechanical defects
Fault Action
Bearing
Excessive overheating of one or
both bearings
(temperature above 125°C)
- If the bearing has turned blue or if the grease has turned
black, change the bearing
- Bearing not fully locked (abnormal play in the bearing cage)
- End shields incorrectly aligned
Abnormal
temperature
Excessive overheating of
alternator PT 1000 sensors (more
than 190°C)
- Alternator overloaded
Vibrations
Too much vibration
- Misalignment (coupling)
- Defective mounting or play in coupling
- Rotor balancing fault
Excessive vibration and humming
noise coming from the machine
- Phase imbalance
- Stator short-circuit
Abnormal
noise
Alternator damaged by a
signicant impact, followed by
humming and vibration
- System short-circuit
Possible consequences
- Broken or damaged coupling
- Broken or bent shaft end
- Rotor magnets are demagnetised
4.5 - Electrical faults
Fault Action Effect Check/Cause
No voltage
at no load on
start-up
Check the connections in the
terminal box - -
Voltage too low Check the drive speed Correct speed Magnets demagnetised following a stator
short-circuit
Speed too low Increase the drive speed
Voltage
oscillations
Check the stability of the
motor speed - -
Voltage
disappears
during operation
Check the connections in the
terminal box - -
• Checking the winding
You can check the winding insulation by performing a high voltage test.

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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
4.6 - Dismantling, reassembly
During the warranty period, this
operation should only be carried out in
an approved workshop or in our factory,
otherwise the warranty may be
invalidated.
Check how much the machine weighs
before choosing the lifting method.
• Tools required
To fully dismantle the machine, we
recommend using the tools listed below:
- 1 ratchet spanner + extension
- 1 torque wrench
- 1 set of at spanners: 7, 8, 10, 12 mm
- 1 socket set: 8, 10, 13, 16, 18, 21, 22,
24 mm
- 1 Allen key: size 5 (eg. Facom: ET5), size 6
(ET6), size 10 (ET10, size 14 (ET14)
- 1 T20 and T30 TORX bit
- 1 puller (U35)/(U32/350)
• Screw tightening torque
See section 5.4.
• Access to connections
The terminals are accessed directly by
removing the terminal box cover [136].
• Replacing the DE bearing
- Remove the alternator from the genset.
- Remove the DE protective grille [33].
- Remove the screws [62] holding the bearing
retainer (68) in place.
- Remove the screws [31] holding the DE
shield [30] on the frame.
- Pull on the DE shield to separate it from the
frame with a suitable tool (which we can
provide).
- The rotor will stick to the stator, and is likely
to make a noise.
- Remove the circlip [67] from the DE bearing
[60].
- Push the bearing retainer [68] back along
the shaft.
- Pull out the DE bearing [60].
- Fit the new DE bearing, taking care not to
overheat it.
- Ret the DE shield [30] by repeating these
steps in reverse order.
- Grease and t a new seal.
• Replacing the NDE bearing
- Remove the alternator from the genset.
- Remove the cover plate from the NDE
shield [73].
- Open the terminal box (132).
- Undo the power connections [124] and
sensors [197].
- Detach the clamps holding the wiring in the
terminal box and the NDE shield [36].
- Undo the screws [62] holding the bearing
retainer (68) in place.
- Remove the screws [37] holding the shield
on the frame.
- Remove the DE shield with a suitable tool
(which we can provide).
- The rotor will stick to the stator, and is likely
to make a noise.
- Push the bearing retainer [68] back along
the shaft.
- Pull out the NDE bearing [60].
- Fit the new NDE bearing, taking care not to
overheat it.
- Ret the NDE shield [36] by repeating
these steps in reverse order.
4.7 - Table of characteristics
Table of average values:
alternator - 8-pole - 800 rpm to 2000 rpm
All values are given at ± 10% (for exact
values, consult the test report) and are
subject to change without prior warning.
• Resistance at 20°C - L/N stator:
0.0245 ohms
• No-load voltage as a function of
the speed
Speed (rpm) U1-2 (V)
800 590
1000 730
1200 885
1400 1020
1600 1180
1800 1330
2000 1470
• Total weight: 900 kg - Rotor: 330 kg
WARNING

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2020.01 / b
Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
5.2 - Technical support service
Our technical support service will be
pleased to provide any additional
information you may require.
For all spare parts orders or technical
support requests, send your request to
[e-mail] or your
nearest contact, whom you will nd at
www.lrsm.co/support indicating the comp-
lete type of machine, its number and the
information indicated on the nameplate.
Part numbers should be identied from the
exploded views and their description from
the parts list.
To ensure that our products operate correctly
and safely, we recommend the use of
original manufacturer spare parts.
In the event of failure to comply with this
advice, the manufacturer cannot be held
responsible for any damage.
After operational testing, it is essential
to replace all access panels or covers.
5.3 - Accessories
• PT 1000 temperature sensors
4 PT 1000 temperature sensors at the hottest points on the winding, connected to a fast-on
connector.
10
12
9
11
4
8
1
5
11 951
12 10 84
3
7
62 A
B
red red
red
red
red red
red red
SENSOR 1 SENSOR 2 SENSOR 3
SENSOR 4
HARTING CONNECTOR
09120123101
EXTERNAL SIDE
After wiring up the terminal box, it is
essential to replace all access panels or
covers.
5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an
option.
Double-bearing kit: consult us.

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Electric Power Generation
77 71
37
36
4
60
67
30
349
68
31
79
68
60 69
1
77
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21
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132 136
62
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73
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33
Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
5.4 - Exploded view, parts list and tightening torque
• Double-bearing

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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
Ref. Qty Description Screw
Ø
Torque
N.m Ref. Qty Description Screw Ø
Torque
N.m
1 1 Stator assembly - - 67 1 Circlip - -
4 1 Rotor assembly - - 68 2 Inner bearing retainer - -
21 4 Lifting eye M16 100 69 3 Bleeder - -
30 1 DE shield - - 71 1 NDE shield cover - -
31 12 Fixing bolt M10 40 73 1 Cover plate - -
33 1 Protective grille M6 4 77 2 Grease nipple - -
36 1 NDE shield - - 79 1 Preloading (wavy)
washer - -
37 8 Fixing bolt M10 40 124 1 Terminal plate M10 24
42 1 Cable gland plate - - 132 1 Terminal box - -
43 3 Cable gland - - 136 1 Terminal box cover - -
60 2 DE and NDE bearing - - 197 1 Sensors connector - -
62 12 Fixing bolt M8 20 349 1 Seal - -

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Electric Power Generation Installation and maintenance
LSA PMR 320
Alternator for rail application - 8-pole
5785 en -
Disposal and recycling instructions
We are committed to limiting the
environmental impact of our activity. We
continuously monitor our production
processes, material sourcing and product
design to improve recyclability and minimise
our environmental footprint.
These instructions are for information
purposes only. It is the user’s responsibility
to comply with local legislation regarding
product disposal and recycling.
Recyclable materials
Our alternators are mainly constructed from
iron, steel and copper materials, which can
be reclaimed for recycling purposes.
These materials can be reclaimed through a
combination of manual dismantling,
mechanical separation and melting
processes. Our technical support depart-
ment can provide detailed directions on how
to dismantle products on request.
Waste & hazardous materials
The following components and materials
require special treatment and must be
separated from the alternator before the
recycling process:
- major plastic components, such as the
terminal box cover and the terminal plate.
These components are usually marked with
information concerning the type of plastic.
All materials listed above need special
treatment to separate waste from
reclaimable materials and should be
entrusted to specialist recycling companies.
The oil and grease from the lubrication
system should be treated as hazardous
waste and must be treated in accordance
with local legislation.
Our alternators have a specied lifetime of
20 years. After this period, the operation of
the product should be stopped, regardless
of its condition. Any further operation after
this period will be under the sole responsi-
bility of the user.

[e-mail] www.lrsm.co/support
Design
Life Extension
Optimisation
Start-up
Operation
•Consulting & specication
•Maintenance
contracts
•Reconditioning
•System upgrade
•Monitoring
•System audit
•Commissioning
•Training
•Genuine spare parts
•Repair services
Our worldwide service network of over 80 facilities is at your service.
This local presence is our guarantee for fast and efcient repair, support and
maintenance services.
Trust your alternator maintenance and support to electric power generation experts.
Our eld personnel are 100% qualied and fully trained to operate in all environments
and on all machine types.
We have a deep understanding of alternator operation, providing the best value
service to optimise your cost of ownership.
Where we can help:
Contact us:
Americas: [phone]
Europe & Rest of the world: [phone]
Asia Pacic: [phone]
China: [phone]
India: [phone]
Middle East: [phone] Scan the code or go to:
Service & Support

www.emersonindustrial.com
- 2020.01 / b
www.leroy-somer.com/epg
5785 en
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