Nidec Leroy-Somer Gearlec Series Instruction Manual

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GEARLEC - TRACTELEC
GT3 / TF3 / TM3
Low Voltage Alternator - 4 pole
Installation and maintenance

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GEARLEC - TRACTELEC
GT3 / TF3 / TM3
3472 en -
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
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.
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 Directives EC
and 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
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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GEARLEC - TRACTELEC
GT3 / TF3 / TM3
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CONTENTS
1 - ACCEPTANCE.................................................................................................... 4
1.1 - Inspection ........................................................................................................................4
1.2 - Identication.....................................................................................................................4
1.3 - Storage ............................................................................................................................4
1.4 - Applications......................................................................................................................4
1.5 - Usage restrictions ...........................................................................................................4
2 - TECHNICAL CHARACTERISTICS .................................................................... 5
2.1 - Operating principle ..........................................................................................................5
2.2 - Electrical characteristics ..................................................................................................5
2.3 - Mechanical characteristics...............................................................................................5
2.4 - Voltage regulation with electronic regulator......................................................................6
3 - INSTALLATION AND COMISSIONNING ........................................................... 8
3.1 - Assembly .........................................................................................................................8
3.2 - Inspection prior to rst use ....................................................................................................... 8
3.3 - Settings............................................................................................................................9
3.4 - Electrical diagram ............................................................................................................9
3.5 - Commissioning .............................................................................................................10
4 - SERVICING/MAINTENANCE........................................................................... 10
4.1 - Safety measures............................................................................................................10
4.2 - Routine maintenance..................................................................................................... 11
4.3 - Fault detection ............................................................................................................... 11
4.4 - Mechanical faults ........................................................................................................... 11
4.5 - Electrical faults...............................................................................................................12
4.6 - Electronic faults..............................................................................................................12
4.7 - Dismantling the gearbox ................................................................................................12
5 - SPARE PARTS ................................................................................................. 13
5.1 - Technical support service ..............................................................................................13
5.2 - Exploded view and parts list GT3 / TF3 / TM3 ...............................................................14
Disposal and recycling instructions
Declaration of EC compliance and incorporation

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1 - ACCEPTANCE
1.1 - Inspection
Upon receipt of your generator, check that it
has not suffered any damage in transit. If
there are obvious signs of damage, express
your concerns to the transporter
(it may be possible to claim via the
transporter’s insurance) and after a visual
inspection, turn the generator by hand to
detect any potential malfunction.
1.2 - Identication
GEARLEC/TRACTELEC are identied by a
self-adhesive black/orange nameplate xed
on the machine’s cowling.
Make sure that the name plate on the
machine corresponds with your order.
GEARLEC/TRACTELEC incorporate alter-
nators from the Low Voltage range that are
adapted and set up for agricultural use.
The GEARLEC/TRACTELEC range con-
sists of 2 products:
- the GEARLEC: GT3 is a product aimed at
the builder of the genset or installer,
- the TRACTELEC is a nished product,
ready for use, available :
• as a xed version: TF3 (unit without a
3-point chassis),
• as a mobile version: TM3 (unit with a
chassis used to x the TRACTELEC to the
tractor’s 3-point linkage).
1.2.1 - Dimensions
The dimensions of the GEARLEC and
TRACTELEC range are dened in our
commercial catalogues.
1.3 - Storage
Whist awaiting commissioning, the
machines must be stored:
- away from moisture: in effect, at relative
humidity levels above 90%, the machine
insulation can drop very rapidly, to just
above zero at around 100%; the condition of
the anti-rust protection on unpainted parts
should be monitored,
- if the area is affected by vibrations, 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.
1.4 - Applications
These alternators are mainly designed to
produce electricity in the context of
applications involving the use of generators.
1.5 - Usage restrictions
Use of the machine is restricted to operating
conditions (environment, speed, voltage,
power, etc.) compatible with the
characteristics indicated on the nameplate.

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2 - TECHNICAL
CHARACTERISTICS
2.1 - Operating principle
The GEARLEC or TRACTELEC is a
generator towed by an agricultural tractor. A
gearbox compensates for the difference in
speed between the tractor power take-off
shaft and the alternator. This oil gearbox is
coupled to the alternator.
2.2 - Electrical characteristics
- class H insulation,
- overload capacity: the alternators are
capable of starting electric motors whose
starting current is 1.5 times the rated
alternator current,
- voltage regulation: the voltage is
proportional to the speed (U/F),
- automatic build-up on the remanent
voltage.
2.3 - Mechanical characteristics
- steel frame,
- aluminium or cast iron shields,
- sealed ball bearings (permanently
greased),
- mounting arrangements: two-bearing with
feet, standard splined shaft extension,
- open machine, self-cooling,
- degree of protection: IP23,
- rotation speeds on the tractor power take-
off shaft (see table):
TRACTELEC
Three-phase 50 Hz
Emergency power
KVA
Power take-off shaft speed
(min-1)
TF3 / TM3 - 16.5 16.5 429
TF3 / TM3 - 20 19.5 429
TF3 / TM3 - 27.5 27.5 429
TF3 / TM3 - 30 30 429
TF3 / TM3 - 35 35 429
TF3 / TM3 - 40 40 420
TF3 / TM3 - 45 45 420
TF3 / TM3 - 50 50 420
TF3 / TM3 - 55 55 420
TF3 / TM3 - 66 66 420

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GEARLEC - TRACTELEC
GT3 / TF3 / TM3
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GEARLEC
Three-phase 50 Hz
Emergency power
KVA
Power take-off shaft speed
(min-1)
GT3 - 16.5 16.5 429
GT3 - 20 19.5 429
GT3 - 27.5 27.5 429
GT3 - 30 30 429
GT3 - 35 35 429
GT3 - 40 40 420
GT3 - 45 45 420
GT3 - 50 50 420
GT3 - 55 55 420
GT3 - 66 66 420
GEARLEC
Three-phase 60 Hz
Emergency power
KVA
Power take-off shaft speed
(min-1)
GT3 - 16.5 21 514
GT3 - 20 24 514
GT3 - 27.5 34.5 514
GT3 - 30 37.5 514
GT3 - 35 44 514
GT3 - 40 48.5 504
GT3 - 45 55 504
GT3 - 50 62 504
GT3 - 55 69 504
GT3 - 66 82.5 504
2.4 - Voltage regulation with electronic regulator
The R120 is specially adjusted for use with the GEARLEC/TRACTELEC. If the regulator
needs to be changed, follow the adjustment procedure below.

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GT3 / TF3 / TM3
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Setting up the R120
- For a 50 Hz application :
• Check that the strap U / F (marked
Frequency) is in position 50 Hz
• Rotate the TRACTELEC so as to obtain a
speed of 1500 min-1 / 50 Hz
• Adjust the voltage to 400V with
potentiometer V
- For a 60 Hz application :
• Check that the strap U / F (marked
Frequency) is in position 60 Hz
• Rotate the TRACTELEC so as to obtain a
speed of 1800 min-1 / 60 Hz
• Adjust the voltage to 480V with
potentiometer V
For other characteristics of the regulator,
see manual ref. 5243.
5+ 6-
SL
UF
OE
V S UF OPEN IN 60Hz OE UF SL
V N1 U N F1 F2
94 mm
104 mm
52 mm
82 mm
S
U/F
50 Hz
60 Hz
V
Exciter field
Voltage
Detection loss
Over-excitation
2 x holes Ø 5.5
x 83 mm
Voltage
Stability
Fuse 4A
240V
Under
frequency
Frequency
Supply

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GEARLEC - TRACTELEC
GT3 / TF3 / TM3
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3 - INSTALLATION AND
COMMISSIONING
Staff undertaking the various operations
indicated in this section must wear per-
sonal protective equipment appropriate
for mechanical and electrical hazards.
3.1 - Assembly
All mechanical handling and lifting
operations must be undertaken using
approved equipment and the machine
must be horizontal. Check how much the
alternator weighs before choosing the
lifting tool.
3.1.1 - Coupling
The GEARLEC or TRACTELEC is coupled
to the agricultural tractor by means of a
universal joint (not supplied). A housing
protects the splined shaft extension at the
alternator end. The universal joint must
incorporate a protective device.
Unsuitable or incorrectly or damaged
tted universal joint protection can
cause serious accidents.
It is prohibited to park near the alternator
while it is running as the charge demand
may cause the alternator and chassis to
jerk and move.
3.1.2 - TF3 version: TRACTELEC
without 3-point chassis
Fix the TRACTELEC securely onto a raised
baseplate for optimum alignment of the
universal joint link with the tractor power
take-off shaft.
3.1.3 - TFM3 version: TRACTELEC with
3-point chassis
The chassis is used to x the TRACTELEC
to the tractor’s 3-point linkage. Ideally, the
TRACTELEC should be placed on the
ground, raising it sufciently to align the
universal joint link with the tractor power
take-off shaft.
The TRACTELEC should be xed to the
tractor’s 3-point linkage during
operation. If transporting a Mobile
Tractelec mounted onto a tractor's
"3-point" xing, wedge the reversing
rods at the side to minimise vibrations.
3.2 - Inspection prior to rst use
3.2.1 - Mechanical checks
Before starting the maching for the rst time,
check that:
- the xing bolts on the feet are tight,
- the coupling is correct, and the universal
joint link is aligned as closely as possible
with the tractor power take-off shaft,
- cooling air is able to enter and exit freely
through the machine vents,
- the protective grilles and housing are
positioned correctly,
- the breather plug pin on the gearbox has
been removed,
- the bearings have been inspected and the
oil level of the gearbox is correct
(see section 4.2).
3.2.2 - Electrical checks
Isolation measures and dielectric tests: see
the alternator’s maintenance manual.
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.
WARNING

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GT3 / TF3 / TM3
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Connection checks
Check that:
- the TRACTELEC/GEARLEC is earthed
(earthing rod),
- the residual circuit-breaker conforms to
legislation on protection of staff 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 blue wire of the R 791
interference suppression module linking the
neutral),
- the machine has been connected to the
mains supply, according to the connection
diagram,
- the connection of any cables and links
conforms to the diagram included with the
machine,
- any protection devices in place have not
been tripped,
- the equipment to be supplied has its own
switchgear or starter system for motors.
The earth must meet electrical standards
and safety regulations in force in the
country concerned.
The GEARLEC version must also be
tted with a control and protection unit
enclosing all electrical accessories.
With conguration GEARLEC, in no case
should the internal connections in the
terminal box be subjected to stresses
due to cables connected by the user.
3.3 - Settings
Your machine is preset and tested in the
factory.
3.4 - Electrical diagram
The electrical diagram for the alternator, as
well as terminal connections, is dened in
the maintenance manual. With the
TRACTELEC, the electrical connection
must conform to the diagram below.
Electrical installations must comply with the
current legislation in force in the country of
use.
A current reversing switch must without
fail be placed between the mains supply
and the GEARLEC tted with a panel, or
the TRACTELEC.
DISJONCTEUR
DIFFERENTIEL
COMPTEUR
001254836
1
2
3
N
T
V
R 791
001254836
1
2
3
N
T
V
R 791
RCD
METER
MAINS SUPPLY
INTERNAL SUPPLY
4-POLE REVERSING SWITCH (OPTIONAL)
TRACTELEC INTERNAL CONNECTIONS
Blue
Green/Yellow
Blue
Brown
Brown
Brown

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GT3 / TF3 / TM3
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3.5 - Commissioning
Before starting up, check that all
preparations and safety procedures
already mentioned in this manual have
been observed.
Select a site which is sheltered from dripping
water and dust, and is free from humidity;
- check that the switch is in the
"TRACTELEC" position (standby),
- after engaging the power take-off shaft,
accelerate gradually whilst keeping an eye
on the voltmeter. The voltage must be 400V
(50Hz) or 480V (60Hz), see section 2.3,
- start up a motor and check its direction of
rotation. If necessary, reverse two phase
wires on the "TRACTELEC" switch to obtain
the opposite direction of rotation,
- switch on the various motors, start them in
decreasing order of power, then start the
other equipment to be used, and monitor the
voltage reading on the voltmeter. This
should be approximately 400V at 50Hz or
480V at 60Hz. If not, increase the tractor
speed. If the voltage does not increase
sufciently, the "TRACTELEC" or tractor
power is insufcient,
- in the case of a star-delta starter, wait for a
clear motor start-up before switching to
delta position. The voltmeter should return
to approximately 400V at 50Hz or 480V at
60Hz. If not, increase the tractor speed,
- to break the "TRACTELEC" general power
supply, switch off the electrical circuit and
set the reversing switch to the mains
"NORMAL" position. Stop the tractor motor.
Please note that the power may be
supplied to the electronic switchgear on
condition that its current consumption
does not exceed 40% of the rated current
between phase and neutral.
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 condition.
All such operations performed on the
alternator should be undertaken by staff
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 work is carried out 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