Leroy-Somer LSA 36 Instruction Manual

This manual is to be given to
the end user
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
Installation and maintenance
0
349
1
31 184 183
124
48
49
3945 en - 06.2005/a

2
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
3945 en - 06.2005/a
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 the potential 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.
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.
Copyright 2005: LEROY-SOMER
This document is the property of:
LEROY-SOMER
It may not be reproduced in any form without prior
authorization.
All brands and models have been registered and patents
applied for.
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.
1 - RECEIPT
1.1 - Standards and safety measures ................... 3
1.2 - Inspection...................................................... 3
1.3 - Identification.................................................. 3
1.4 - Storage ......................................................... 3
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics ............................... 4
2.2 - Mechanical characteristics............................ 4
3 - INSTALLATION - COMMISSIONING
3.1 - Assembly ...................................................... 5
3.2 - Coupling........................................................ 5
3.3 - Checks prior to commissioning..................... 5
3.4 - Terminal connection diagrams...................... 6
3.5 - Commissioning and set-up ........................... 6
4 - SERVICING - MAINTENANCE
4.1 - Safety measures........................................... 7
4.2 - Routine maintenance.................................... 7
4.3 - Fault detection .............................................. 7
4.4 - Mechanical faults .......................................... 8
4.5 - Electrical faults.............................................. 8
4.6 - Dismantling, reassembly............................. 10
5 - SPARE PARTS
5.1 - First maintenance parts .............................. 11
5.2 - Technical support service ........................... 11
5.3 - Parts list, exploded view ............................. 12
CAUTION
CAUTION

3
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
RECEIPT
3945 en - 06.2005/a
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
trained in the commissioning, servicing and maintenance of
electrical and mechanical components. 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 the potential risk of accidents. It is vital that you
understand and take notice of the different warning symbols
used.
1.2 - Inspection
On receipt of your alternator, check that it has not suffered
any damage in transit. If there are obvious signs of damage,
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 glued to
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: LSA 36 L12 A1/4
• LSA: Name used in the PARTNER range
• 36: Machine type
• L12: Model
• A: Excitation system
(ACC)
• 1/4: Winding number/number of poles
1.3.1 - Nameplate
So that you can identify your machine quickly and accurately,
we suggest you write its specifications on the nameplate
below.
1.4 - Storage
Prior to commissioning, machines should not be stored in
humid conditions: at relative humidity levels greater than
90%, the machine insulation can drop very rapidly, to just
above zero at around 100%. The state of the anti-rust
protection on unpainted parts should be monitored.
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 every two weeks to avoid marking the bearing
rings.
ALTERNATEURS ALTERNATORS
LSA Date
N 5700 125897 A15 Hz
Min
-1
/R.P.M. 1500 Protection
Altit. ≤m Masse / Weight
Rlt AV/D.E bearing 6302 2 RS C3
Rlt AR/N.D.E bearing 6303 2 RS C3
Made in France - 1 024 959/a
PUISSANCE / RATING (S1)
Conforme à C.E.I 60034-1. According to I.E.C 60034-1.
166631
USC
Temp.
kVA
kW
Voltage
Phase
CosØ/P.F.
Amps
kVA
kW
Voltage
CosØ/P.F.
Amps

4
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
TECHNICAL CHARACTERISTICS
3945 en - 06.2005/a
LEROY-SOMER
2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics
The PARTNER LSA 36 single-phase alternator is a machine
without slip-rings or brushes. It is self-excited by an auxiliary
phase with capacitor (ACC system). Interference suppression
conforms to standard EN 55011, group 1, class B.
2.1.1 - Outline diagram
2.2 - Mechanical characteristics
- Aluminium frame
- Steel or aluminium shields
- Protected ball bearings, permanently greased
- Mounting arrangement
Single-bearing with SAE disc: IM 1201 (MD 35)
- Open drip-proof machine, self-cooled
- Degree of protection: IP23
If mounting horizontally: 90˚ in relation to the original position,
the degree of protection is IP21
- Speed of rotation: 1500 min
-1
or 1800 min
-1
depending on
type
- Clockwise
Main phase
ROTOR
RP1
RP2
Diodes
Diodes
STATOR
C
Green
Red
Black
Blue
White
Auxiliary phase
Brown
Capacitor

5
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
INSTALLATION
3945 en - 06.2005/a
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 lifting points are for handling the alternator alone. They
must not be used to lift the genset. Choose a lifting system
which respects the positioning of the rings.
3.2 - Coupling
Before coupling the machines, check that they are
compatible by checking the dimensions, the flywheel
and its housing, the flange, coupling discs and offset.
- Mount the rotor (4) and stator (1) assembly on the flange
adaptor using the 4 screws (31) torque (see section 4.6.2)
- Screw the tie rod (13) onto the motor shaft, tighten the nut
to the required torque (see section 4.6.2) and insert the plug
(53).
After tightening the screws, check that there is lateral play on
the crankshaft.
3.2.1 - Assembly of the single-bearing disc
version IM1201 (see section 5.3.1)
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 fan to turn the alternator rotor.
- Fit the tapered shaft disc kit on the motor flywheel.
- Mount the flange adaptor on the motor tightening torque
(see section 4.6.2).
- Mount the rotor (4) and stator (1) assembly on the flange
adaptor using the 4 screws (31) torque (see section 4.6.2)
- Screw the tie rod (13) onto the motor shaft, tighten the nut
to the required torque (see section 4.6.2) and insert the plug
(53).
After tightening the screws, check that there is lateral play on
the crankshaft.
3.2.2 - Location
Ensure that the ambient temperature in the room where the
alternator is placed cannot exceed 40°C for standard power
ratings (for temperatures > 40°C, apply a derating coefficient).
Fresh air, free from damp and dust, must be able to circulate
freely around the air intake grilles 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.
3.3 - Checks prior to commissioning
3.3.1 - 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 several possible methods for restoring the above
minimum values.
a) Dry out the machine without the cover for 24 hours in a
drying oven at a temperature of approximately 80°C.
b) Blow hot air into the air intake, having made sure that the
machine is rotating.
- Check that the winding connection corresponds to the site
operating voltage (see section 3.4).
3.3.2 - Mechanical checks
Before starting the machine for the first time, check that:
- The feet fixing screws and nuts are tightened to the correct
torque
- The cooling air is drawn in freely
- The coupling is correct
CAUTION
CAUTION
CAUTION
CAUTION

6
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
INSTALLATION
3945 en - 06.2005/a
LEROY-SOMER
3.4 - Terminal connection diagrams
To modify the connection, change the position of the terminal
links. 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.
3.4.1 - Connection checks
Electrical installations must comply with the current
legislation in force in the country of use.
Check that:
- The residual circuit-breaker, in compliance with the
legislation on protection of personnel in force in the country of
use, has been correctly installed on the alternator power
output as close as possible to the alternator.
- The machine has been connected with the busbar
separating the terminals as shown in the terminal connection
diagram.
- Any protection devices in place have not been tripped.
- There is no short-circuit between phases between the
alternator output terminals and the generator set control
cabinet (part of the circuit not protected by the circuit-
breakers or relays in the cabinet).
3.5 - Commissioning and set-up
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). On application of the load,
the machine should achieve its rated speed and voltage;
however in the event of abnormal operation, a search for the
fault must be instigated (see section 4.4).
230 V - 50 Hz/240 V - 60 Hz115 V - 50 Hz/120 V - 60 Hz
red
red
black
black blue
green
red
black
blue
green
green
white
brown
SERIAL CONNNECTION
HIGH VOLTAGE
L1 L2
PARALLEL CONNECTION
L1 L2
LOW VOLTAGE
DE
NDE
DE
NDE
L1 L2 LOW VOLTAGE
red
black
blue
green
blue
white
brown
L1 L2 HIGH VOLTAGE

7
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SERVICING - MAINTENANCE
3945 en - 06.2005/a
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 - Routine 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 permanently greased.
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 agents can
be used, such as:
- Normal petrol (without additives); inflammable
- Toluene (slightly toxic); inflammable
- Benzene (or benzine, toxic); inflammable
- Ciclohexare (non toxic); inflammable
Stator, rotor cleaning
The insulating components and the impregnation system are
not at risk of damage from solvents (see the above 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.
The machine should be cleaned with a degreasing agent,
applied using a brush. Compressed air should used to
remove any dust.
After cleaning the alternator, it is essential to check the
winding insulation (see section 4.5.1).
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 protection devices are fitted correctly
- The connections comply with the diagrams in the manuals
supplied with the machine
- The genset speed is correct (see section 1.3)
Repeat the operations defined in section 3.
CAUTION
CAUTION
CAUTION
CAUTION

8
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SERVICING - MAINTENANCE
3945 en - 06.2005/a
LEROY-SOMER
4.4 - Mechanical faults
4.5 - Electrical faults
4.5.1 - Measurement of STATOR winding
resistances
During this procedure, make sure that the alternator is
stopped and disconnected from any external load.
- Unscrew the 4 cover fixing screws.
- Disconnect the capacitor wires in order to read the auxiliary
phase resistance.
- Disconnect the wires from the winding to the terminal block
in order to read the main phase resistance.
Fault Action and possible consequences
Bearing
Excessive temperature rise in one or both bearings
(temperature > 80°C on the antifriction bearings
with or without abnormal noise)
- If the bearing has turned blue or if the grease has turned black, change
the bearing
- Bearing not properly seated
- End shields misaligned (flanges not properly fitted)
Temperature
abnormal
Excessive temperature rise of alternator frame
(more than 40°C above the ambient
temperature)
- Air flow (intake/outlet) partially clogged or hot air is being recycled from
the alternator or engine
- Alternator operating at too high a voltage (> 105% of Un on load)
- Alternator overloaded
Vibration
Excessive vibration
- Misalignment (coupling)
- Faulty mounting or play in coupling
Excessive vibration and humming noise coming
from the machine
- Stator short-circuit
Abnormal noise
Alternator damaged by a significant impact,
followed by humming and vibration
- System short-circuit
- Broken or damaged coupling
- Broken or bent shaft end
- Shifting and short-circuit of revolving field winding
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes
Fault Action Effect Check/cause
No voltage
at no load
on start-up
Apply 6 V DC to one of the
capacitors for 1 second
The alternator builds up and its voltage
is still correct when the battery is
removed
- Lack of residual magnetism
- Check the capacitor voltage (approximately 10 to 15 V
at the auxiliary winding terminals, with the capacitor
disconnected)
The alternator builds up but its
voltage does not reach the rated
value when the battery is removed
- Check whether there is a break in the capacitor circuit
or one of the capacitors
The alternator builds up but its
voltage disappears when the battery
is removed
- If the voltage is too low, the diodes are faulty.
Voltage too low Check the drive speed Correct speed
- Disconnection of the auxiliary winding
- Rotating diodes burnt out
- Main field winding short-circuited - check the resistance
Speed too low Increase the drive speed
Voltage too high Reduce the speed Genset speed too high
Voltage correct
at no load and too
low when on load
- Speed drop too great when on load
- Check the speed
- Genset overloaded
- Short-circuit in the revolving field coil. Check the
resistance
Ω

9
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SERVICING - MAINTENANCE
3945 en - 06.2005/a
LEROY-SOMER
4.5.2 - Measurement of ROTOR winding
resistances
During this procedure, make sure that the alternator is
disconnected from any external load.
- Unscrew the 4 fixing screws (31) on the flange adaptor
(265).
- Remove the stator (1), taking care with the windings, then
access the diodes (110).
4.5.3 - Checking the diodes
- Proceed in the same way as for reading the rotor resistance
by unsoldering a single side of the diodes.
A diode in good working order should allow the current to flow
only in the anode-to-cathode direction.
4.5.4 - Checking the capacitors
During this procedure, make sure that the alternator is
disconnected from any external load.
- Unscrew the 4 cover fixing screws.
- Disconnect the capacitor wires and connect it to an AC
supply in series with a switch and an ammeter.
Rd: Discharging resistor (5000 Ω - 20 W)
The currents are indicated at ±10%
4.6 - Dismantling, reassembly (see
section 5.3.1)
During the warranty period, this operation should only be
carried out in a LEROY-SOMER approved workshop or in
our factory, otherwise the warranty may be invalidated.
While being handled, the machine should remain
horizontal (rotor not locked when moved).
4.6.1 - Tools required
To fully dismantle the machine, we recommend using the
tools listed below:
- 1 ratchet spanner
- 1 torque wrench
- 1 8 mm/13 mm socket
- 1 TORX T20 bit
- 1 puller
Resistances
Ω
4 P stator
Main stator winding
50 Hz 60 Hz
110 V 230 V 120 V 240 V
LSA 36 L12 0.23 0.9 0.17 0.67
Resistances
Ω
4 P stator
Auxiliary stator winding
50 Hz 60 Hz
LSA 36 L12 1.64 1.46
Rotor winding 50/60 Hz
Resistances
Ω
4 P rotor
RP1 RP2 Total
LSA 36 L12 3.2 3.2 6.4
rotor
Ω
C
A
Anode Cathode
-
C
A
+-
CA
+
Capacitor (...µF-450V - 3000H)
50 Hz 220 V 60 Hz 240 Hz
4 poles µF I (A) µF I (A)
LSA 36 L12 2 x 22.5 10.0 2 x 22.5 11.8
220V 50 Hz
240 V 60 Hz
Capacitors
A
Rd
CAUTION
CAUTION

10
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SERVICING - MAINTENANCE
3945 en - 06.2005/a
LEROY-SOMER
4.6.2 - Screw tightening torque
4.6.3 - Access to diodes
- Unscrew the 4 fixing screws (31) on the flange adaptor
(265).
- Remove the stator (1), taking care with the windings, then
access the diodes (110).
4.6.4 - Access to connections and capacitors
Unscrew the 4 fixing screws (49), then remove the cover.
4.6.5 - Replacing the NDE bearing
- Unscrew the 4 fixing screws (31) on the flange adaptor (265)
for the single-bearing version.
- Remove the stator (1), taking care with the windings.
- Extract the antifriction bearing (70) using a puller with a
central screw (see drawing).
- Replace the antifriction bearing and the 'O' ring seal (349).
4.6.6 - Dismantling the rotor
- Unscrew the 4 fixing screws (31) on the flange adaptor (265)
- Remove the stator (1), taking care with the windings
- Unscrew the armature rod (13) and remove it from the rotor
(4)
- Insert a Ø10 tie rod in the rotor
- Position it in contact with the face of the motor shaft end
(determine the length of the tie rod which should be 10 mm
less than the rotor)
- Using an M12 screw, remove the rotor assembly (4)
4.6.7 - COMPLETE REASSEMBLY
- Simply reverse the dismantling procedure.
NOTE: When performing the various maintenance
operations, check that the 'O' ring seal is present in the
stator housing.
IDENTIFICATION Screw Ø Torque N.m
Flange adaptor screw (31 frame) M8 20 N.m
Tie rod (SAE J609) 5/16 - UNF 17 N.m
Cover fixing M5 4 N.m
4
M12 Ø10
CAUTION
CAUTION

11
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SPARE PARTS
3945 en - 06.2005/a
LEROY-SOMER
5 - SPARE PARTS
5.1 - First maintenance parts
Emergency repair kits are available as an option.
They contain the following items:
5.2 - Technical support service
Our technical support service will be pleased to provide any
additional information you may require.
When ordering spare parts, you should indicate the
complete machine type, its serial number and the
information given on the nameplate.
Address your inquiry to your usual contact, or to:
LEROY-SOMER
Usine de Sillac/Alternateurs
16015 ANGOULEME CEDEX - FRANCE
Tel.: [phone]
Technical Support Service:
(33) 05.45.64.43.66 - (33) 05.45.64.43.67 -
(33) 05.45.64.43.68 - (33) 05.45.64.43.69
Fax: [phone]
email: [email protected]
Part numbers should be identified from the exploded
views and their description from the parts list.
Our extensive network of service centers can dispatch
the necessary parts without delay.
To ensure correct operation and the safety of our
machines, 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.
Ref. Designation Code
183 Kit: capacitor + 4 clamps -
48 Kit: cover + plain faceplate + 4
screws -
31 Kit: motor coupling fixing screws -
109 Kit: diode support + NDE bearing -
-Kit: SAE 5, 6 1/2 flange + rod +
coupled disc -
CAUTION
CAUTION

12
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SPARE PARTS
3945 en - 06.2005/a
LEROY-SOMER
5.3 - Parts list, exploded view
5.3.1 - LSA 36 - single-bearing with coupling
disc
47
15
4
70
349
109
1
31 184 183
13 53
124
48
49
23 265
322
324
323
No. Nbr Description No. Nbr Description
1 1 Stator assembly 265 1 Flange adaptor
4 1 Rotor assembly 322 1 Coupling disc
13 1 Tie rod + nut 323 6 Fixing screws
15 1 Fan 324 1 Clamping washer
23 1 Shaft end 349 1 ‘O' ring seal
31 4 Fixing screws
47 1 Faceplate
48 1 Cowling
49 4 Cover screws
53 1 Plug
70 1 NDE bearing
109 1 Diode support
124 1 Terminal block
183 2 Capacitor
184 4 Clamp

13
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SPARE PARTS
3945 en - 06.2005/a
LEROY-SOMER

14
INSTALLATION AND MAINTENANCE
LSA 36 - 4-POLE - SINGLE-PHASE
ALTERNATORS
SPARE PARTS
3945 en - 06.2005/a
LEROY-SOMER

LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE
RCS ANGOULÊME N° B 671 820 223
Limited company with capital of 62,779,000 €
www.leroy-somer.com