Nidec LEROY-SOMER LSA 52.2 MHV Instruction Manual

LSA 52.2 MHV
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Industrial Range Alternators - 4 pole
Installation and maintenance

TABLE OF CONTENTS
1. GENERAL INFORMATION 4
1.1 INTRODUCTION 4
1.1.0 General points 4
1.1.1 Safety notes 4
1.1.2 Conditions of use 4
1.1.2.1 Generalities 4
1.1.2.2 Vibratory analysis 4
1.1.2.3 Risk of blasting object 4
1.2 GENERAL DESCRIPTION 5
1.2.1 Generator (arep) 5
1.2.2 Excitation system 5
2. DESCRIPTION OF SUB-ASSEMBLIES 6
2.1 STATOR 6
2.1.1 Electric machine armature 6
2.1.2 Excitation field winding 6
2.1.3 Stator protection 6
2.1.3.1 Heating resistor 6
2.1.3.2 Stator winding temperature sensor 6
2.1.3.3 Stator air sensor 6
2.1.3.4 Bearing vibration sensor 7
2.2 ROTOR 7
2.2.1 Revolving field-coil 7
2.2.2 Excitation armature 7
2.2.3 Fan (machines: IC 0 A1) 7
2.2.4 Rotating diode bridge 7
2.2.5 Balancing 8
2.3 TERMINAL BOX 8
2.3.0 Description 8
2.3.1 Automatic voltage regulator (AVR) 8
2.4 NAMEPLATES 8
2.4.1. Main nameplate 8
2.4.2. Lubrication nameplate 8
2.4.3. Rotation direction nameplate 8
2.5 ANTI FRICTION BEARING 9
2.5.0 Description of antifriction bearings 9
2.5.1 Antifriction bearing protection devices 9
9
9
9
9
9
2.6 Not applicable
2.7 Not applicable
2.8 Not applicable
2.9 Not applicable
2.10 Not applicable
2.11 Not applicable 9
2.12 TRANSPORT LOCKING SYSTEM 9
3. INSTALLATION 10
3.1 TRANSPORT AND STORAGE 10
3.1.1 Transport 10
3.1.2 Storage warehouse 10
3.1.3 Maritime packing 10
3.1.4 Unpacking and installation 10
3.1.5 Storage measures of antifriction bearings10
3.1.6 Not applicable 10
3.1.7 Not applicable 10
3.1.8 Storage measures of open drip proof
machines 10
3.2 INSTALLATION OF THE MACHINE 11
3.2.1 Fitting the coupling (double-bearing
machine only) 11
3.2.2 Fitting the stator 11
3.3 MACHINE ALIGNMENT 11
3.3.1 Alignment general points 11
3.3.1.1 General points 11
3.3.1.2 Shaft elevation caused by Thermal
elevation 12
3.3.1.3 Not applicable 12
3.3.1.4 Shaft elevation of Anti-friction bearing
machine 12
3.3.1.5 Generator check before alignment 12
3.3.1.6 Alignment procedure"Double concentricity"
alignment method 12
3.3.2 Two bearings machine alignment (flanged)
13
3.3.2.1 Machines without axial end play (standard)
13
3.4 ELECTRICAL CONNECTIONS 14
3.4.0. General points 14
3.4.1 Phase-sequence 14
3.4.1.1 Standard units ; IEC 34-8 14
3.4.1.2 On request ; NEMA 15
3.4.2 Insulating distances 15
3.4.3 Added products in the terminal box 15
4. START-UP 16
4.1 ELECTRICAL START-UP INSPECTION 16
4.1.0 General points 16
4.1.1 Winding Insulation 16
4.1.2 Electrical connections 16
4.1.3 Parallel operation 16
4.1.3.1 Definition of parallel operation 16
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
2

4.1.3.2 Possibility of parallel operation 16
4.1.3.3 Parallel coupling 16
4.2 MECHANICAL START-UP INSPECTION 16
4.2.0 General points 16
4.2.0.1 Alignment ; fixing ; prime mover 16
4.2.0.2 Cooling 16
4.2.0.3 Lubrication 16
4.2.1 Anti friction bearing machines start up 16
4.2.2 Not applicable 17
4.2.3 Not applicable 17
4.2.4 Vibrations 17
4.3 START-UP SEQUENCE 17
4.3.1 Static checks 17
4.3.2 Rotating checks 17
4.3.2.0 Rotor speed rate of rise (Standard unit) 17
4.3.2.1 Rotating checks not excited 17
4.3.2.2 Rotating checks at no load excited 17
4.3.2.3 Generator and site safety parameters 17
4.3.2.4 Rotating checks at full load 17
4.3.3 Generator start up check list 19
5. MAINTENANCE AND SERVICING 21
5.0 GENERAL 21
5.1 MAINTENANCE SCHEDULE 22
5.1.0 General 22
5.1.1 Stator 22
5.1.2 Rotor 22
5.1.3 Terminal box 22
5.1.4 Not applicable 23
5.1.5 Anti friction bearing 23
5.1.6 Not applicable 23
5.1.7 Rubber dampers 23
5.1.8 Not applicable 23
5.1.9 Not applicable 23
5.1.10 Protection devices 23
5.2 AIR GAP CHECK 24
5.2.1 General points 24
5.2.2 Double bearing machine 24
5.3 ANTI FRICTION-BEARINGS 24
5.3.1 General points 24
5.3.2 Cleaning bearings from old grease 24
5.3.3 Cleaning bearings assembly area 25
5.3.4 Bearing removal 25
5.3.5 Bearing re-assembly 26
5.4 Not applicable 26
5.5 LUBRICANTS 26
5.5.1 Greases 26
5.5.2 Oils 27
5.5.2.1 General 27
5.5.2.2 Synthetic oils 27
5.5.2.3 Mineral oils 28
5.5.2.4 Oil filtering and pollution 28
5.6 Not applicable 28
5.7 Not applicable 28
5.8 BOLT TIGHTENING 28
5.8.0 General 28
5.8.1 Steel screw in steel tapping 28
5.8.2 Plugs 28
5.8.3 Electrical contact 29
5.8.4 Rotating diodes 29
5.8.5 Synthetic parts 29
5.9 ELECTRICAL MEASURING
INSTRUMENTS 29
5.9.1 Instruments used 29
5.10 WINDINGS INSULATION CHECK 29
5.10.0 General 29
5.10.1 Insulation measure 29
5.10.2 Polarization index 30
5.11 ROTATING DIODE BRIDGE TEST 31
5.12 CLEANING THE WINDINGS 31
5.12.0 General points 31
5.12.1 Coil-cleaning products 31
5.12.2 Cleaning operation 31
5.13 DRYING THE WINDING 32
5.13.0 General points 32
5.13.1 Drying method 32
5.13.1.1 General points 32
5.13.1.2 Drying generator in a stopped position 32
5.13.1.3 Drying generator in rotation 32
5.14 RE-VARNISHING 33
10. TYPICAL ASSEMBLIES AND DRAWINGS
34
10.1 MACHINE CUT VIEWS 34
10.1.1 Machine type A52 34
10.2 ANTI FRICTION BEARING ASSEMBLY35
10.2.1 Machine type A52.2 35
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
3

1. GENERAL INFORMATION
1.1 INTRODUCTION
1.1.0 General points
This manual provides installation, operating and
maintenance instructions for synchronous machines. It also
describes the basic construction of these machines. This
manual is general ; it applies to an entire group of
synchronous generators. Additionally, in order to make
information-finding easier, Section 1, "Characteristics and
Performance", has been included, describing the machine
completely (type of construction, type of bearing, protection
index, and so forth...); this will enable you to determine
exactly the chapters which apply to your machine.
This synchronous machine has been designed for a
maximum length of service. To achieve this, it is necessary
to pay special attention to the chapter concerning the
periodic maintenance schedule for the machines.
1.1.1 Safety notes
The warnings "DANGER, CAUTION, NOTE" are used to
draw the user’s attention to different points:
DANGER :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE PERSONAL
INJURY OR LOSS OF LIFE
CAUTION :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR
DESTRUCTION OF EQUIPMENT
NOTE :
This warning is used when an operation, procedure, or
delicate installation requires clarification.
1.1.2 Conditions of use
1.1.2.1 Generalities
A machine must only be installed, operated, by qualified
and trained persons.
Any technical engineer operating, maintaining this machine
must be allowed to practice in regard with local working
laws (eg: to be certified to operate on high voltage
devices…)
Operation which require handling must be done by
qualified persons (Slinging technics; use of lifting devices
…) Local procedures must be scrupulously respected
Any product (sealing compound; cleaning product…) used
during any maintenance or servicing must be in
accordance with local regulation and environmental
standard
Waste disposal issued from servicing the machine must be
managed in respect with local regulation and
environmental standard
The main data of this machine are summarized in "Section
1" of this manual
Any operating condition other than those specified by the
original tender must receive a Leroy Somer agreement
Any modification of the machine structure must receive a
Leroy Somer agreement
1.1.2.2 Vibratory analysis
It is the responsibility of the gen set manufacturer to ensure
that the different assembled system will be vibratory
compatible.(ISO 8528-9 and BS5000-3)
It is the responsibility of the gen set manufacturer to ensure
that the shaft line torsional analysis has been done and
accepted by the different parties (ISO 3046)
CAUTION :
EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
THE STANDARD ISO 8528-9 & BS5000-3 MAY CREATE
HEAVY DAMAGES (BEARING DAMAGE, STRUCURE
CRACKS …).
EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
THE SHAFT LINE (ex: ABS, LLOYD …) MAY CREATE
HEAVY DAMAGES (CRANKSHAFT FAILURE ,
GENERATOR SHAFT FAILURE, …)
Refer to chapter 2.1.3.4 for further information about the
accepted vibration level of the standard ISO 8528-9 and
BS5000-3
1.1.2.3 Risk of blasting object
DANGER :
IN CASE OF MAJOR ACCIDENT, FLYING DEBRIS CAN
BE EJECT FROM THE MACHINE THROUGH THE AIR
INLET OR AIR OUTLET. THESE DEBRIS MAY CAUSE
INJURY OR LOSS OF LIFE. DO NOT ENTER INTO THE
HAZARDOUS AREA WHILE THE MACHINE IS
OPERATING
NOTE :
This risk has to be considered in the site risk
assessment.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
4

1.2 GENERAL DESCRIPTION
1.2.1 Generator (arep)
The synchronous generator is an alternating-current
machine, without ring or brush. The machine is cooled by
the flow of air through the machine.
For a better comprehension, use the drawings of chapter
10.
The Automatic Voltage Regulator (item 6) supplies the
exciter field (static part ; item 1) in DC current.
The Exciter works as a reversed alternator.
The Exciter armature (rotating part ; item 2) generate a
three-phase current which supplies the Rotating diodes
bridge (rotating part ; item 3)
The Rotating diodes bridge (rotating part ; item 3) rectifies
the three phases current in DC current which supplies the
Revolving field (rotating part ; item 4)
The revolving field (rotating part ; item 4) excites the
alternator armature (static part ; item 5) which generates a
three phases current
5
4
3
1
2
6
H1
H3
1- Excitation field winding
2- Excitation armature
3- Rotating diodes bridge
4- Revolving field
5- Alternator armature
6- Automatic Voltage Regulator
H1- AREP winding detect harmonic 1
H3- AREP winding detect harmonic 3
1.2.2 Excitation system
The excitation system is fitted at the Non Drive End side
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
5

2. DESCRIPTION OF SUB-ASSEMBLIES
2.1 STATOR
2.1.1 Electric machine armature
The alternator stator (armature) is a stacking of low losses
steel laminations assembled under pressure. The stator
coils are inserted and blocked in the slots, then
impregnated with varnish and polymerised (VPI system).
1
2
3
4
(a)
(c)
(b)
5
1 - Stator
2 - Rotor
3 - Exciter
4 - Rotating diodes
5 - Fan
a - Stator Air inlet (cold air)
b - Stator air exhaust (warmed air)
c – Rotating diodes air cooling
2.1.2 Excitation field winding
The excitation field winding comprises a wound solid
element.
The excitation is flanged on the rear end shield of the
machine.
2.1.3 Stator protection
2.1.3.1 Heating resistor
The heating element avoids internal condensation during
the shutdown periods. It is connected to the main terminal
box strip. The heating resistor is switched on as soon as
the machine is shut down.
The electrical characteristics are provided in Section 1
"Technical Characteristics".
2.1.3.2 Stator winding temperature sensor
The temperature sensors are located in the zone assumed
to be the hottest part of the machine. The sensors are
connected to a terminal box.
Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
of :
TEMP. RISE
class ALARM TRIP
Power (KVA) < 5000 > 5000 < 5000 > 5000
B
130 °C 125 °C 135 °C 130 °C
F
155 °C 150 °C 160 °C 155 °C
H 175 °C 170 °C 180 °C 175 °C
To improve the machine protection we recommend to set
the alarm point following effective site conditions:
Alarm temperature (*) = Highest recorded temp + 10°K
Trip temperature (*) = Alarm temperature + 5 °K
(*) do not pass over the values of the previous table.
(*)Highest recorded temp: Temperature measured at
the site in the worst temperature condition at the stator
temperature sensor
E.g.: a class B machine (3000 kVA) reached 110°C during
a factory heat run test. Set the alarm temperature to 120°C
instead of 130°C as indicated in the previous chart. Set the
emergency shutdown to 125°C instead of 135°C as
indicated in the previous chart.
2.1.3.3 Stator air sensor
As an option an RTD or thermostat can measure the stator
air inlet temperature (cold air)
Stator air inlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 5 K
• shutdown 80°C
Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
• shutdown Nominal air inlet stator + 40K
NOTE :
For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
temperature
NOTE :
If quickly restarting after a stop Inhibit the stator air sensor
safety "alarm" for few seconds (no more than 30 s) during
the machine start up;
NOTE:
For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
Tair entering stator = Twater entering cooler + 15°K
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
6

2.1.3.4 Bearing vibration sensor
This chapter concerns the setting of seismic probes. For
setting of proximity probes refer to chapter 2.2.6.1
The vibration level of the machines is directly linked to the
duty and to the site characteristics.
We propose the following adjustment:
Vibration Alarm (*) = Site Highest Vibration level + 50%
Vibration Trip = Vibration Alarm + 50%
(*) do not pass over the values of the following chart
The machines are engineered to be able to withstand the
vibration level specified by the standard ISO8528-9 and
BS5000-3
Maximum levels for : reciprocating Internal combustion
engines
Nominal speed
(rpm) kVA Generator vibration level
(nominal conditions)
Overall
(mm/s rms)
(2–1000 Hz)
Any harmonics
1300 à 2199 > 250 < 20 < 0.5 mm ; pp
(5 – 8 Hz)
< 9 mm/s ; rm
(8 – 200 Hz)
721 à 1299 ≥250 < 20
>
1250 < 18
≤720 >
1250 < 15
< 10 (*)
(*) generator on concrete base
Maximum levels for : Turbines
Turbines
(hydraulic ; gaz ; steam) Max advised : 4.5
(overall ; mm/s rms)
2.2 ROTOR
2.2.1 Revolving field-coil
The Revolving field is a salient pole type, without any fixing
device as dove tail, cap bolt …
The revolving field is heat-shrunk onto the shaft
2.2.2 Excitation armature
The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
held in place by rivets.
The excitation armature is keyed and heat-shrunk onto the
shaft.
The windings are enamelled copper wires, class "F"
insulation (or "H", depending on the customer's request or
size of the machine).
2.2.3 Fan (machines: IC 0 A1)
The synchronous machine is characterized by a self-
ventilation system. A centrifugal fan is mounted between
the revolving field coil and the front bearing.
Air intake is at the rear of the machine and the exhaust on
the drive end side.
The fan consists of a hub, which is keyed and heat-shrunk
onto the shaft. The flange is made of welded steel,
attached to the hub with hexagonal head-cap screws. The
ventilation effect is obtained through, inclined blades. The
air is exhausted by centrifugation. The air inlet and outlet
must remain free during operation.
2.2.4 Rotating diode bridge
The rectifier bridge, comprising six diodes, is placed at the
rear of the machine. The rotating bridge is made of fiber
glass with a printed circuit to connect the diodes together.
This bridge is supplied with alternating current by the
excitation armature and supplies direct current to the
revolving field-coil. The diodes are protected against over
voltage by rotating resistors, or by varistors. These
resistors (or varistors) are mounted in parallel with the
revolving field-coil.
+
-
1
2
3
1 - Field
2 - Rotating resistors / varistors
3 - Exciter armature
The inner and outer rings are connected to the revolving
field-coil
1
2
1 - Outer ring
2 - Inner ring
The diode fastening screws must be tightened to the
correct torque.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
7

CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST
BE TIGHTENED USING A TORQUE WRENCH
CALIBRATED TO THE RECOMMENDED TORQUE.
2.2.5 Balancing
The complete rotor has been balanced according to
ISO8221 standard in order to obtain a residual imbalance
less than :
Gen set : Class G2.5
Turbine : Class G1
The shaft end is cold-stamped to indicate the type of
balancing (as per ISO8221)
H : balancing with Half-key carried out as
standard
F : balancing with Full key (done on request)
N : balancing without key (done on request)
The balancing is carried out in two planes.
The first is on the fan. It is recommended, when the fan is
refitted (after servicing) to respect the initial indexing.
The second is at the Non Drive End side.
The coupling must be balanced to fit the generator rotor
balancing.
2.3 TERMINAL BOX
2.3.0 Description
Use the attached Terminal box drawing
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
order to avoid circulating currents.
If accessories not supplied by Leroy Somer have to be
installed in the terminal box (CT’s, VT’s, Shunt …) refer to
chapter.3.4.3
2.3.1 Automatic voltage regulator (AVR)
When the automatic voltage regulator is located in the
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampers. The operation of the
regulator is explained in Section 3.
CAUTION :
RUBBER DAMPERS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS
2.4 NAMEPLATES
2.4.1. Main nameplate
The main nameplate is fitted to the stator. It gives the
manufacturer's electrical characteristics, the type of
machine and its serial number. The serial number is
necessary for any contact with the factory
For machines with anti-friction bearings lubrication
parameters are indicated.
2.4.2. Lubrication nameplate
The machines with Sleeve bearings have a lubrication
plate attached to the bearing, indicating:
•Type of bearing
•Oil change frequency
•Oil capacity of bearing
•Oil viscosity.
The machines with anti-friction bearings have the
lubrication parameters indicated on the main nameplate
fixed on the stator, indicating :
•Type of bearing
•Grease-change frequency
•Quantity of grease
•Grease type
2.4.3. Rotation direction nameplate
Located on the stator an arrow indicates the direction of
rotation.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
8

2.5 ANTI FRICTION BEARING
2.5.0 Description of antifriction bearings
The bearings ensure the rotor rotation guiding and axial
location
The bearings are protected from ambiant dust by labyrinth
seals and are of replaceable type.
The bearings must be lubricated regularly. The old grease
is forced out at the lower part of the bearings by the force
of the new grease being injected.
2.5.1 Antifriction bearing protection devices
As an option, the bearing may be equipped with RTD or
PTC sensors to detect eventual overheating
For special use in warm surroundings where the
temperature of the bearings exceeds the authorised limit
(for a bearing known to be in good condition), contact us.
Bearing; Alarm points and shutdown:
• alarm 90°C (194°F)
• shutdown 95°C (203°F)
To improve the machine protection we recommend to set
the alarm point following effective site conditions:
Alarm temperature (*) = Highest recorded temp + 15°K
(*) do not pass over the values of the previous chart.
E.g. : At site the common bearing temperature is 60°C. Set
the alarm temperature to 75°C instead of 90°C as indicated
in the previous chart
NOTE:
Specific dedicated devices based on the analysis of the
vibration signal are able to monitor bearings behavior
2.6 Not applicable
2.7 Not applicable
2.8 Not applicable
2.9 Not applicable
2.10 Not applicable
2.11 Not applicable
2.12 TRANSPORT LOCKING SYSTEM
Certain type of Machines may have their rotor locked
during transport.
The locking systems are red painted
The locking systems must be removed just before the
alternator final installation and re install ifthe alternator is
later re transported.
CAUTION:
THE ROTOR LOCKING SYTEM MUST REMAIN IN
PLACE IF THE ALTERNATOR IS SUBJECT TO BE
TRANSPORTED.
In case the locking system has to be reused; the system
must be relocated taking care not to touch other part than
the shaft. If necessary turn the shaft to avoid contact of the
locking system with the rotor cables
CAUTION:
THE ROTOR LOCKING FIXING SCREW MUST BE
TIGHTENED TO THE NOMINAL RECOMMENDED
TORQUE.
The Locking system fixing screws must be correctly
tightened (torque noticed onto plate item "2"). A too low
torque can conduce to an insufficient locking effect
Non Drive End bearing; Locking system examples:
1
2
3
3
1
2
3
3
1 - Cable
2 – Red label out of the alternator indicating a Locking
system
3 – Rotor locking system
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
9

3. INSTALLATION
3.1 TRANSPORT AND STORAGE
3.1.1 Transport
During the transport the intermittent shocks level applied to
the machines must remains below 30 m/s2
Machines equipped with anti friction bearing must have
their rotor locked during the transport to avoid "false
brineling" problem
Machine temperature must remains within the range -20°C
to +70°C. Stay down to -40°C during few hours is admitted.
The machine must be protected against bad weather
conditions and condensation.
3.1.2 Storage warehouse
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or
to high humidity (75% maximum)
CAUTION:
THE HEATING RESISTOR MUST BE CONTINUOUSLY
SWITCHED ON
Storage at an ambient temperature of +5 to +45° C is
recommended.
The machine must not be subject to vibrations higher than
1mm/s rms
3.1.3 Maritime packing
The synchronous machine is hermetically sealed then
packed in a wooden crate.
In any case the generator must be store in a warehouse
(refer to chapter 3.1.2)
This packing provides access to the dessicant for periodic
change (every 18 months)
CAUTION :
BREAKING THE HERMETIC PROTECTIVE FILM
DISCHARGES LEROY SOMER OF ITS LONG STORAGE
GUARANTEE
3.1.4 Unpacking and installation
DANGER :
THE DEDICATED LIFTING HOOKS MUST BE USED TO
LIFT THE MACHINE WITH SLINGS (ONE HOOK AT
EACH CORNER OF THE MACHINE)
Rotors of machines with Sleeve bearings and single-
bearing machines, are blocked during transportation so as
to avoid any movement. Withdraw the retaining bars. The
retaining bar is screwed to the end of the shaft and to the
front support.
CAUTION :
TRANSPORT LOCKING DEVICES PAINTED RED OR
WITH RED STICKER MUST BE REMOVED.
The end of the shaft is protected from corrosion. Clean it
before coupling.
The heating resistor must be switched on at all times.
Before starting the machine up again, it will be necessary
to carry out a start-up inspection.
3.1.5 Storage measures of antifriction bearings
This chapter must be taken in consideration if a machine is
stopped more than 6 months.
After 6 months of stop; grease by injecting two time the
grease volume used for a standard maintenance.
Then, each 3 months turn the machine shaft line of few
turns while injecting a standard grease volume
3.1.6 Not applicable
3.1.7 Not applicable
3.1.8 Storage measures of open drip proof machines
For an open machine, it is recommended that the air inlet
and outlet be closed.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
10

3.2 INSTALLATION OF THE MACHINE
3.2.1 Fitting the coupling (double-bearing machine
only)
The coupling must be balanced separately before
assembly on the machine shaft. Refer to the balancing
instructions in chapter 2.2.5.
The shrinking of the half coupling onto the electrical
machine shaft end must be chosen, by the gen-set
manufacturer, in such way as it should be removable for
maintenance (e.g.: bearing change)
3.2.2 Fitting the stator
Four plates on the frame enable the unit to be fitted to a
skid.
The fixing bolts must support the forces created by the
static and dynamic loads.
The machine may be positioned by means of 4 dowel pins.
The dowel pins make later realignment easier. (The use of
pins is optional).
The machine may be aligned through the use of 4 jacking-
screws. These jacking-screws allow the machine to be
positioned according to the various axes.
3.3 MACHINE ALIGNMENT
3.3.1 Alignment general points
3.3.1.1 General points
The alignment aims to obtain the driving shaft and the
driven shaft coaxial when operating at the nominal
conditions (machine rotating; at its operating temperature)
The machine must be aligned according to the Leroy
Somer standard and adhere to the manufacturer's
alignment standard for the drive machine
When heating the machine has its shaft line which grow up.
Between stop and rotation the shaft axis location inside its
bearing is different. The total axis height elevation is
composed of the thermal elevation and of the bearing
elevation.
CAUTION:
THE ALIGNMENT MUST BE DONE TAKING IN
CONSIDERATION OF THE SHAFT THERMAL GROWTH
CORRECTION
The correct locating of the parts must be obtained by
inserting shims under the machine feet.
The double-bearing machines are mounted with bearings
(ball or roller) or Sleeve bearings. The axial clearance of
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.
CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
ACCURATE THAN THOSE OF LEROY SOMER
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
11

3.3.1.2 Shaft elevation caused by Thermal elevation
H(m) = Height of the machine axis
∆T= frame temperature elevation = 30°C
λ= Coefficient of steel elongation = 0.012 °K-1
3.3.1.3 Not applicable
3.3.1.4 Shaft elevation of Anti-friction bearing machine
Caused by thermal growth of the anti friction bearing.itself
1 - cold, in rotation, or stopped
2 - hot, in rotation, or stopped
3.3.1.5 Generator check before alignment
Check the generator shaft end run out.
Total Indicator Reading must be within 0.04 mm
NOTE:
RUN OUT CHECK CAN BE NOT FEASABLE ON
SLEEVE BEARING MACHINE BECAUSE OF THE TOO
HIGH NECESSARY BREAK AWAY TORQUE NEEDED
TO TURN THE ROTOR
3.3.1.6 Alignment procedure"Double concentricity"
alignment method
NOTE:
LASER DEVICES CAN MAKE THE JOB EASIER THAN
WITH THE SHOWN PROCEDURE
This method is not sensitive to axial movements.(the
alignment methods using axial measure may often be
perturbed by small axial movement of the rotor)
It is possible to check the alignment with the coupling
installed.
Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
important.
Two micrometers
Implementation :
During the measures, both shafts must turn simultaneously
in the same direction. (For example : the coupling installed
with its screws untightened). By turning both shafts
simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.
C1
C2
A
B
3h
9h
12h
6h
L
The "C1" and "C2" micrometers are located at an angular
difference of 180°.
More the distance "L" is long better should be the
sensitivity to detect the angular error
The reading should be performed 4 times for the "C1" and
"C2" micrometers : at 12h, 3h, 6h, 9h
It is recommended to record the results and draw the axes
for better evaluation, as explained below. Interpretation of
measurements by means of an example.
Values given in millimeters. The reading is considered
positive (+) when the micrometer stylus is pushed inwards.
∆
H (mm) =λ
(°K-1)
.H
(m)
.
∆T(°K)
"2"
Y ° 0,01 mm
"1"
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
12

MEASUREMENTS
C1
C2
A
B
3h
9h
12h
6h
+ 0.90
+ 1.04
+ 1.34
+ 1.00
+ 0.86
+ 0.164
+ 0.102
+ 0.70
L=400
Measurements referring to the vertical plane:
Considering the vertical plane "C1" : The vertical action
towards the top of shaft "A" on the micrometer is dominant.
In the plane "C1" the axis "A" is higher than axis "B”
( 0.9 – 0.1 ) / 2 = - 0.05 mm
In the vertical plane "C2", the vertical action towards the
top of shaft "B" on the micrometer is greater.
In the plane "C2" the axis "B" is higher than axis "A"
( 0.134 – 0.102 ) / 2 = 0.16 mm
The respective position of the axes is as follows:
A
B
C1
C2
0.05
0.16
Regarding the vertical plane the angular alignment error is:
( 0.16 + 0.05 ) *100 / 400 = 0.0525 mm/100mm (not
acceptable)
Measurements referring to the horizontal axis:
In the plane "C1" the axis "B" is further to the right than "A”
( 0.104 – 0.86 ) / 2 = 0.09 mm
In the plane "C2" the axis "B" is further to the left than "A”
( 0.70 - 1.64 ) / 2 = - 0.47 mm
The representation of the shafts is as follows:
A
B
C1
C2
0.09
0.47
Regarding the horizontal plane the angular error is:
( 0.47 + 0.09 ) *100/ 400 = 0.14 mm/100mm (not
acceptable)
In the both planes the parallelism error is:
mm103.095
22
=+
or
mm496.04716
22
=+
(not
acceptable)
3.3.2 Two bearings machine alignment (flanged)
3.3.2.1 Machines without axial end play (standard)
The alignment must take the tolerances of the coupling into
account.
CAUTION:
A MISALIGNMENT EVEN IF ACCEPTABLE BY THE
COUPLING MUST NOT CREATE STRESSES LEVEL
NOT ACCEPTABLE BY THE BEARING
Shafts alignment limits to follow:
0.01 mm
100 mm
0.08 mm
parallelism error
Angular error
To check the alignment, there are different methods: the
"double concentricity" method is described in the
"alignment procedure" chapter 3.3.1.6.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
13

3.4 ELECTRICAL CONNECTIONS
3.4.0. General points
The installation must comply with the electrical schematics
attached in Section 5
Check that all the protection devices are correctly
connected and in good working order.
The assembler has the responsibility to mechanically and
electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
(respect of capability curve ; overspeed …)
For low-voltage machines, power supply cables must be
connected directly to the machine terminals (without adding
washers)
For high-voltage machines, power supply cables should be
connected to separate terminals or to current transformer
terminals (without adding washers).
NOTE:
The gland plate is made of non magnetic material.
CAUTION
DO NOT ADD WASHERS TO THE POWER SUPPLY
CABLE TERMINALS OTHER THAN THOSE USED BY
THE MANUFACTURER OF THE ELECTRIC MACHINE
Check that the lugs are tightened.(refer to chapter 5.8)
CAUTION
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED
CAUTION
A VOLTAGE TRANSFORMER MUST NEVER BE
SHUNTED
CAUTION
THE INSTALLED POWER CABLES MUST BE FIXED
AND SUPPORTED IN SUCH A WAY AS TO BE ABLE
TO WITHSTAND THE VIBRATION LEVEL REACHED BY
THE GENERATOR IN OPERATION (refer to chapter
2.1.3.4)
The power cables must not stress (push, pull, bend ...) the
generator terminals
3.4.1 Phase-sequence
3.4.1.1 Standard units ; IEC 34-8
Except by special request of the customer, the phase-
sequence is carried out using the IEC 34-8 standard.
An arrow located on the stator indicates the direction of
rotation.
Inside the terminal box a specific marking plate indicates
the specific generator phase sequence.
Clockwise rotation viewed
from the shaft drive end Counter clockwise rotation
viewed from the shaft
drive end
The phases are marked:
U1, V1, W1. The phases are marked: U1, V1, W1.
Viewed when facing the
terminal box door the
terminals are :
U1, V1, W1
Viewed when facing the
terminal box door the
terminals are :
U1, V1, W1
The installer connects :
L1 --> U1
L2 --> V1
L3 --> W1
The installer connects :
L3 --> U1
L2 --> V1
L1 --> W1
U2
V2
W2
U1
V1
W1
L1
L2
L3
U2
U1
V1
W1
L3
L2
L1
V2
W2
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
14

3.4.1.2 On request ; NEMA
An arrow located on the front bearing indicates the
direction of rotation.
In the terminal box a specific marking plate indicates the
specific generator phase sequence.
Counter clockwise rotation
viewed from the stator
connection (NEMA)
(Clockwise rotation viewed
from the shaft drive end
following IEC)
Clockwise rotation viewed
from the stator connection
(NEMA)
(Counter clockwise
rotation viewed from the
shaft drive end following
IEC)
The cables are marked:
U1, V1, W1.
The terminals are marked :
T3, T2, T1
The cables are marked:
U1, V1, W1.
The terminals are marked :
T3, T2, T1
Viewed when facing the
terminal box door the
terminals are :
U1, V1, W1
Viewed when facing the
terminal box door the
terminals are :
U1, V1, W1
The installer connects :
L1 --> (U1) T3
L2 --> (V1) T2
L3 --> (W1) T1
The installer connects :
L3 --> (U1) T3
L2 --> (V1) T2
L1 --> (W1) T1
3.4.2 Insulating distances
Products not delivered by Leroy Somer and then installed
in the terminal box must meet the electrical insulating
distances.
This applies to power cables and lugs, and to added
transformers, etc.
Nominal Voltage 500 V 1 KV 2 KV 3 KV
Phase-Phase in
the air (mm) 25 30 40 60
Phase-Earth in the
air (mm) 25 30 40 60
Phase-Phase
Creeping (mm) 25 30 40 70
Phase-Earth
Creeping (mm) 25 30 40 70
Nominal Voltage 5 KV 7,5KV 12,5KV 15 KV
Phase-Phase in
the air (mm) 120 180 190 190
Phase-Earth in the
air (mm) 90 120 125 125
Phase-Phase
Creeping (mm) 120 180 190 190
Phase-Earth
Creeping (mm) 120 180 190 190
3.4.3 Added products in the terminal box
This may apply to site added customer CTs ; VTs etc.
Leroy Somer must be informed if some appliances have to
be installed in the generator terminal box.
The products not delivered by Leroy Somer and then
installed in the terminal box must meet the electrical
insulating distances. Refer to chapter 3.4.2
The installed appliances must be able to withstand
vibration.
T6
T5
T4
T3
T2
T1
L1
L2
L3
U1
V1
W1
T6
T5
T4
T3
T2
T1
L3
L2
L1
U1
V1
W1
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
15

4. START-UP
4.1 ELECTRICAL START-UP INSPECTION
4.1.0 General points
Electrical connections (auxiliaries, safeties and power
connections) must comply with the schematics provided.
Refer to Section 5 to get the concerned schematics
DANGER:
Check that all safety equipment operates correctly.
4.1.1 Winding Insulation
The insulation and the polarization index must be
measured on start up and then as per chapter 5.1.0
recommendation.
To measure the insulation (refer to chapter 5.10)
4.1.2 Electrical connections
The phases must be connected directly to the machine
links (with no spacers or washers, etc).
Make sure that the lugs are sufficiently tightened.
CAUTION:
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED BEFORE START UP. IF CURRENT
TRANSFORMER NOT USED ITS OUTPUT MUST BE
SHORTED
4.1.3 Parallel operation
4.1.3.1 Definition of parallel operation
• Between machines
Operation mode named by Leroy Somer "1F"
At least two alternators are connected in parallel to supply
a load
The Automatic Voltage Regulator is in voltage regulation
mode
A droop Current Transformer is necessary to share the
reactive load
• With the mains
Operation mode named by Leroy Somer "3F"
At least one alternator is connected in parallel with the
mains (Public electricity network)
The Automatic Voltage Regulator is in Power Factor
regulation mode
4.1.3.2 Possibility of parallel operation
CAUTION:
PARALLEL OPERATION CAN ONLY BE USED FOR
ALTERNATOR ENGINEERED FOR SUCH OPERATION
4.1.3.3 Parallel coupling
CAUTION:
A WRONG SYNCHRONIZATION CAN LEAD TO MAIN
DAMAGES (HIGH MECHANICAL OVERTORQUE AND
OVER CURRENT)
During synchronization the following values must not be
overpass:
Max frequency shift : 0,1 Hz
Max phase offset : 10° (electrical angle)
Max voltage (phase - neutral) between machines :
(at phase offset =0) 5 % of the nominal voltage
In case of wrong synchronization, or mains micro
interruption inducing a fault over the indicated limits Leroy
Somer will not be considered as responsible of the
damages.
4.2 MECHANICAL START-UP INSPECTION
4.2.0 General points
4.2.0.1 Alignment ; fixing ; prime mover
The installation must comply with the manufacturer’s
installation rules for drive machine (alignment, mounting).
An arrow on the stator, indicates the direction of rotation.
4.2.0.2 Cooling
The air inlet and exhaust must be unobstructed.
The cooling auxiliaries (water circulation in the cooler, etc)
must be operating.
4.2.0.3 Lubrication
Lubrication must be carried out as per chapter 5. Lubricant
quantity and periodicity as per Section 1
4.2.1 Anti friction bearing machines start up
The bearings are pre-lubricated in the factory, but before
they are put into service, it is necessary to re grease in
order to fill the free spaces in the greasing circuit and to
evacuate the storage grease.
CAUTION
UPON START-UP, GREASE THE MACHINE WHILE IT IS
RUNNING.
Record the temperature of the bearings during the initial
operating hours. Poor lubrication can cause abnormal
heating.
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not operate
at normal temperature. This may occur if the weather is
very cold or when the machine is operating under abnormal
temperature conditions (start-up phase, for example). The
bearings will become quieter after having reached their
normal operating temperature.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
16

4.2.2 Not applicable
4.2.3 Not applicable
4.2.4 Vibrations
The vibration measurement must be taken on each bearing
in the three directions. The measured levels must be lower
than the specified values indicated in the chapter 2.1.3.4
Adjust the sensor as per chapter 2.1.3.4
4.3 START-UP SEQUENCE
The generator start up (commissioning) must follow the
following sequences:
4.3.1 Static checks
Machine fixing as per chapter 4.2
Alignment as per chapter 3.3
Cooling as per chapter 4.2.0.2 & 4.2.3
Bearing lubrication as per chapter 4.2.2
Electrical connections as per chapter 4.1.2
Winding insulation as per chapter 5.10
4.3.2 Rotating checks
4.3.2.0 Rotor speed rate of rise (Standard unit)
There is no restriction regarding the rate of rise of the rotor
spin up from stop to nominal speed
There is no restriction regarding the load rate of rise
4.3.2.1 Rotating checks not excited
Run the generator without excitation by steps to verify the
bearings temperature as per chapter 2.5.1 or 2.6.2
At the nominal speed (not excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).
4.3.2.2 Rotating checks at no load excited
In AVR manual mode; Voltage adjustment; check the
excitation current value (refer to Section 4 for the AVR
manual and to Section 2 for the generator test report)
In AVR automatic mode; Voltage adjustments; Voltage
range; check the excitation current value value (refer to
Section 4 for the AVR manual and to Section 2 for the
generator test report)
At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).
4.3.2.3 Generator and site safety parameters
Proceed to the site safeties adjustment (over voltage relay,
over current relay, differential protection; negative
sequence relay...). The setting points are not in Leroy
Somer scope of supply.
The settings must comply with the generator data sheet
(eg: capability curve; thermal damage curve …)
Check the synchronizer setting following chapter 4.1.3.3
For any operation at a speed exceeding the nominal range
(generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical
schematics)
4.3.2.4 Rotating checks at full load
Operating In parallel with the mains
Adjust the Power Factor
Load the generator step by step. :
Check the excitation current at 25%of the rated load
Check the excitation current at 100%of the rated load
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
17

At the nominal speed (full load) measure the vibrations.
Check that the vibration level is in accordance with the
generator duty (as per chapter 2.1.3.4).
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
18

4.3.3 Generator start up check list
TYPE SERIAL N°
Voltage V Frequency Hz Speed rpm
Output Power kVA Power Factor
STATIC CHECKS
Mechanical checks
•Direction of Rotation (refer to Section1)Clock Wise or Anti-clock Wise
•Mechanical Fixing of the generator (refer to chapter 4.2)________________________________________
•Coupling - Alignment to the engine (refer to chapter 3.3)________________________________________
•Cooling :Coolant flow (refer to Section1 ; chapter 4.2.0.2 & 4.2.3) _________________________________
•Air inlet and exhaust free ___________________________________________________
•Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type) (refer to Section1 & chapter 4.2.2) __
Or Anti-friction Bearings Greasing (refer to Section1 & chapter 4.2.1)
Temperature sensors (correct readings) (refer to Section1 & chapter 2.5.1 & 2.6.2) __
•Space Heaters (refer to Section1)___________________________________________________
Type of AVR : 1F 3F
Electrical connections between alternator, AVR and main panel : (refer to Section 4 & drawing Section 5)
•Output power cables connections following phase order (refer to chapter 3.4.1) ______________________
•Terminal box connections ________________________________________
•AVR detection voltage ________________________________________
•Supply power and excitation terminals ________________________________________
•Network detection (3F only) ________________________________________
•Command signals (equalisation and synchronisation for 3F) ________________________________
•Excitation polarity and booster ________________________________________
•Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) ______________________
•External accessories (e.g.. remote potentiometer) ________________________________________
ALL CURRENT TRANSFORMERS MUST BE CONNECTED
Windings insulation
Winding temp:…….°C
Voltage
1 minute
(MΩ)
10 minutes
(MΩ)
Polarisation
index
Static parts
3 Phases / Ground
"U" /Ground
"V" /Ground
"W" /Ground
"U" / "V"
"U" / "W"
Exciter field / Ground
Rotatin
g parts
Rotor / Ground
≤ 500 V
Exciter armature / Ground
≤ 500 V
Rotating resistances
≤ 500 V
Rotating diodes
≤ 500 V
All works must be carried out by a qualified and authorized person.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
19

ROTATING CHECKS
WITH EXCITATION - AT NO LOAD CONDITIONS
•Verification of the bearings temperature (refer to chapter 2.5.1 or 2.6.2) °C ______________
•In manual mode :Voltage adjustment ___________________________________
Excitation current check ___________________________________
•In automatic mode :Voltage Setting (referring to nominal voltage) ________________________
Excitation current check ________________________
•Parallel coupling : Adjustment to parallel operation (3F) ________________________
A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVER-
TORQUE)
•Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift 0,1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________
Control / Adjustment of the site safety Parameters
•Over-voltage, _____________________________________________________________
•Over-current (by short-circuit on stator in separate excitation mode), _________________________
•Negative sequence relay, _____________________________________________________________
•Over-speed, _____________________________________________________________
•Differential protection (in static conditions), _____________________________________
•Other protective device. _____________________________________________________________
CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY
WITH EXCITATION - LOADED
Take the load gradually from 0 to 100% in steps of 25%
Record for each step (refer to Section 1):
•Electrical output (KW)
•POWER FACTOR
•Voltage (V)
•Current (A)
•Excitation Current / voltage
•Winding temperature
Time
KW
pf
Volts
I (A)
I (ex)
U1 (°C)
V1 (°C)
W1 (°C)
•Bearings temperature (if thrust sensor available, please record its value)
Time
DE Thrust (°C)
DE Radial (°C)
NDE Radial (°C)
•Oil inlet temperature (if applicable ; refer to Section 1)
•Oil flows (if applicable ; refer to Section 1)
•Bearings vibrations (mm/s) (refer to chapter 2.1.3.4)
DE-V
DE-H
DE-A
DE-V
DE-H
DE-A
All works must be carried out by a qualified and authorized person.
Electric Power Generation Installation and maintenance 5654 en - 2017.10/ a
LSA 52.2 MHV
Industrial Range Alternators - 4 pole
20