Nidec Leroy-Somer Gearlec Series Instruction Manual

550 265
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547
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581 546
GEARLEC - TRACTELEC
GT3 / TF3 / TM3
Low Voltage Alternator - 4 pole
Installation and maintenance

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GT3 / TF3 / TM3
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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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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
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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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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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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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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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

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4.2 - Routine maintenance
4.2.1 - Inspection after start-up
After approximately 20 hours of operation,
check that all xing screws on the machine
are still tight, plus the condition of the
gearbox (traces of oil) and the various
electrical connections in the installation.
4.2.2 - Ventilation circuit
Ensure that the suction grilles are not
blocked by foreign bodies (straw, feathers,
wool, etc.).
4.2.3 - Bearings
The bearings are permanently greased (see
the alternator manual). A quick check of all
the generator bearings can be carried out by
turning the shaft end by hand; the assembly
should turn freely without sticking.
4.2.4 - Gearbox
The gearbox oil should be emptied and
replaced after 50 hours of operation, then
every 500 hours and in all cases, at least
once a year. Quality of oil to be used:
SAE 90 oil.
Quantity of oil for GT3,TF3,TM3 16.5 - 20 =
0.75 litre
Quantity of oil for GT3, TF3, TM3 27.5 - 66 =
1.5 litre
Before use, check the gearbox oil level
[552], and top up if necessary.
Monitor the temperature rise in the gearbox,
which should not exceed 60°C above the
ambient temperature. Should this value be
exceeded, the machine must be stopped
and checks carried out.
4.2.5 - Servicing and storage
Cleaning the machine using a water
spray or a high-pressure washer is
strictly prohibited.
Any problems arising from such
treatment will not be covered by our
warranty.
Store your machine in a dry, airtight place to
avoid condensation.
4.3 - Fault detection
If, when commissioned, the alternator does
not work normally, the source of the
malfunction should be identied.
To do this, check that :
-the protection devices are switched on;
- the connections comply with the diagrams
in the maintenance manuals supplied with
the machine,
- the generator speed is correct, see section
2.3 (use a frequency meter rather than a
revolution counter).
Repeat the operations dened in
section 3.
4.4 - Mechanical faults
See the alternator maintenance manual.
For the gearbox, follow the troubleshooting
guide below. Mechanical faults should be
noted with the machine disconnected from
the mains.
Fault Excessive gearbox
temperature rise
Action Check oil level
Source Lack of oil or incorrect oil level
Fault Abnormal gearbox noise
Action Change the bearings
Source Faulty lubrication
Fault Signicant gearbox vibration
Action Stop the machine
Source Faulty universal joint coupling
WARNING

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4.5 - Electrical faults
Electrical faults should be noted with the
machine disconnected from the mains.
See the alternator maintenance manual.
For the GEARLEC or TRACTELEC, follow
the troubleshooting guide below.
Fault Voltage too high or too low
Action Check the speed
Source Faulty voltmeter, speed
incorrectly set
Fault No voltage
Action Check the alternator
Source See the alternator maintenance
manual
Fault No voltage
Action Check protection devices
Source Circuit-breaker, reversing
switch, sockets
Fault No voltage
Action Check connections
Source Wire disconnected in the
terminal box
4.6 - Electronic faults
See the regulator maintenance manual,
reference 5243.
4.7 - Dismantling the gearbox
During the warranty period, this
operation should only be carried out in
an LEROY-SOMER approved workshop
or in our factory, otherwise the warranty
may be invalidated.

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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
closest 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 - SPARE PARTS
5.1 - Technical support service

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547
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575
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Installation and maintenance
GEARLEC - TRACTELEC
GT3 / TF3 / TM3
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5.2 - Exploded view and parts list GT3 / TF3 / TM3

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No. Nbr. Description No. Nbr. Description
265 1 Connecting ange 574 1 Electrical unit (Tractelec)
266 12 Assembly nut 575 1 Control module (Tractelec)
546 1 Chassis (Tractelec) 576 1 30 mA residual current protection
switch (3P+N) (Tractelec)
547 1 Universal joint protection 577 1 Three-phase male + female socket
(3P+N+E) (Tractelec)
548 4 Fixing bolt 578 1 Single-phase male + female socket
(2P+E) (Tractelec)
550 1 Gearbox 581 1 King pin (Tractelec)
551 1 Filling plug 586 1 Drain plug
552 1 Oil level 604 1 Two-pole circuit-breaker (1P+N)
(Tractelec)
557 1 Splined input shaft 605 1 Four-pole circuit-breaker (3P+N)
(Tractelec)

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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:
- electronic materials found in the terminal
box, including the automatic voltage
regulator (198), current transformers (176),
interference suppression module (199) and
other semi-conductors.
- diode bridge (343) and surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
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.

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Moteurs Leroy-Somer
Siege social : Boulevard Marcellin Leroy CS 10015 - 16915 Angoulême cedex 9 - France
SAS au capital de 65 800 512 €- RCS Angoulême 338 567 258
Declaration of EC compliance and incorporation
This Declaration applies to the generators designed to be incorporated into machines complying with the
Machinery Directive Nr 2006/42/EC dated 17 May 2006.
MOTEURS LEROY-SOMER MLS HOLICE STLO.SRO MOTEURS LEROY-SOMER DIVISION LEROY-SOMER
Boulevard Marcellin Leroy SLADKOVSKEHO 43 1, rue de la Burelle STREET EMERSON
16015 ANGOULEME 772 04 OLOMOUC Boite Postale 1517 Nr4 Parcul Industrial Tetarom 2
FRANCE CZECH REPUBLIC 45800 ST JEAN DE BRAYE 4000641 CLUJ NAPOCA
FRANCE ROMANIA
Declares hereby that the electric generators of the types:
LSA40, LSA42.3, LSA44.2, LSA44.3, LSA46.2, LSA46.3, LSA47.2, LSA49.1, LSA49.3, LSA50.1, LSA50.2,
LSA51.2, LSA52.2, LSA52.3, LSA53.1, LSA53, LSA53.2, LSA54, LSA54.2, TAL040, TAL042, TAL044,
TAL046, TAL047, TAL049, as well as their derivatives, manufactured by Leroy-Somer or on Leroy-Somer's
behalf, comply with the following International Standards and Directive:
- EN and IEC 60034-1, 60034-5 and 60034-22
- ISO 8528-3 “Reciprocating internal combustion engine driven alternating current generating sets.
Part 3. Alternating current generators for generating sets”
- Low Voltage Directive Nr 2014/35/UE dated 26 February 2014
Furthermore, these generators, designed in compliance with the Machine Directive Nr 2006/42, are therefore
able to be incorporated into Electrical Gen-Sets complying with the following International Directives:
- Machinery Directive Nr 2006/42/EC dated 17 May 2006
- EMC Directive Nr 2014/30/UE dated 26 February 2014, as intrinsic levels of emissions and immunity
are concerned
WARNING:
The here mentioned generators should not be commissioned until the corresponding Gen-Sets have been
declared in compliance with the Directives Nr 2006/42/EC and 2014/30/UE, as well as with the other relevant
Directives.
Leroy-Somer undertakes to transmit, in response to a reasoned request by the national authorities, relevant
information on the generator.
Technical Managers
J.P. CHARPENTIER Y. MESSIN
4152 en - 2017.05 / m
The contractual EC Declaration of Conformity and Incorporation can be obtained from your contact on
request.

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Electric Power Generation Installation and maintenance
GEARLEC - TRACTELEC
GT3 / TF3 / TM3
3472 en -

[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
- 2019.05 / j
www.leroy-somer.com/epg
3472 en
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