TAL A44 Low Voltage Alternators - 4 pole Installation and maintenance Three-phase 6 and 12-wire Dedicated single-phase 4-wire LEROY-SOMER™ Aide —AIl for dreamsElectric Power Generation Installation and maintenance 52250n-2017.08%% TAL A44 Low Voltage Alternators - 4 pole This manual concerns the alternator which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. SAFETY MEASURES Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual, All necessary operations and interventions on this machine must be performed by a qualified technician. Our technical support service will be pleased to provide any additional information you may require The various operations described in this manual are accompanied by recommenda- tions or symbols to alert the user to the po- tential risk of accidents. Itis vital that you understand and take notice of the different warning symbols used. Warning symbol for an operation capable of damaging or destroying the machine or surrounding equipment. AN 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. Aset of self-adhesive stickers depicting the various waming 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 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 its products at any time in order to incorporate the latest technological developments. The information contained in this document may therefore be changed without notice. This document may not be reproduced in any form without prior authorization Allbrands and models have been registered and patents applied for. 2 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole CONTENTS 1- RECEIPT. 1.1 -Standards and safety measures. 1.2 - Inspection. = Identification... 1.4 St0TAGE oeesnennnnnnnnnnnnsiennnnnnnnn 1.5 Applications 1.6 - Usage restrictions. Baan aah 2- TECHNICAL CHARACTERISTICS... semneneanennennnaennnnssnes 5 2.1 - Electrical characteristics... . 25 2.2 - Mechanical characteristics......n:sssnemnnnnnannnnnnsnnntnnnnanenennaesnnense® 3 - INSTALLATION. 10 3.1 -Assembly, nnn 110 3.2 - Cheoks prior to frst USE. nso” 3.3 - Terminal connection diagrams. .....nnnnnmninmnnnnnnnnnnnnnnnnnennnsnne A 3.4 - Commissioning 14 3.5 - Setting up. 14 4- SERVICING - MAINTENANCE. 15 4.1 - Safety MeASUPeS...nnsnninnnnnnnnnninnninnnninnnnnnninnnnnnnnnnnns 1S 4.2 - Routine MAINtEMANCE.........essessossssesseesersseeseeeeesneesennsenssnnnnsuneeessnssareeneseesenessesssnssassassaseaesse 1D, 4.3 - Bearings 16 4.4 - Mechanical defects. 16 4.5 - Electrical fAUIS......nnnnnnnninnntnnnnnnninnninnnnnnnnnnnnnnnnnsnncetT 4.6 - Dismantling, reassembly.......rnmnininnninnnnnnnnnnnnnnnnnnnnnnsnns 1D - Installation & maintenance of the PMG... saseeseeseennennnsonsnssnssnnsnsiananesesseesnesaneanennensennsans 2O, 4.8 - Table of characteristics. 21 5 - SPARE PARTS. 23 5.1 - First maintenance patts....nn.0nsnmnnnnnninnnninnnnnnnnnnnnnnnnninnsnne BB 5.2 - Technical support service. 23 5.3 - Accessories. 23 5.4- Exploded view, parts list and tightening torqUe......s0sn:nnennnnnnnnnsnnses 24 Disposal and recycling instructions EC declaration of incorporation LERoY-SOMER™ 3Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 1-RECEIPT 1.1- Standards and safety measures Our alternators comply with most international standards. See the EC Declaration of Incorporation on the last page. 1.2-Inspection On receipt of your alternator, check that it has not suffered any damage in transit. If there are obvious signs of knocks, contact the transporter (you may be able to claim on their insurance) and after a visual check, turn the machine by hand to detect any malfunction 1.3 - Identification The alternator is identified by means of a nameplate fixed on the machine (see drawing), Make sure that the nameplate on the machine conforms to your order. So that you can identify your altemator quickly and accurately, we suggest you fil in its specifications on the nameplate below 1.4 - Storage Prior to commissioning, machines should be stored : - away from humidity (< 90%); after a long period of storage, check the machine insulation. To prevent the bearings from becoming marked, do not store in an environment with significant vibration. 1.5 Application These altemators are mainly designed to produce electricity in the context of applications involving the use of generators. 1.6 - Usage restrictions Use of the machine is restricted to operating conditions (environment, speed, voltage, power, etc) compatible with the characteri- stics indicated on the nameplate. Leroy-Somer ‘Weight i AVE Excit Ect waves |[lloas VIA [arose A) DE bearing INDE_ beanng 5 10015 Angoaitne Coder. LERoY-SOMER™Electric Power Generation 5250n-2017.087h Installation and maintenance TAL A44 Low Voltage Alternators - 4 pole 2-TECHNICAL CHARACTERISTICS 2.41 -Electrical characteristics This machine is an_altemator without sliprings and revolving field brushes, wound as ‘2/3 pitch”, 4, 6 and 12-wire, with class H insulation anda field excitation system available in either SHUNT, AREP or PMG 2.2 - Mechanical characteristics - Steel frame - End shields in aluminum - Greasable ball bearings - Mounting arrangement: single bearing with standard feet and SAE flanges/coupling discs - Drip-proof machine, self-cooled version. + Electrical options - Space heaters In order to conform to standard EN 61000- 6-3, EN 61000-6-2, EN 55011, the R791 interference suppression kit is needed + SHUNT dedicated single-phase 4-wire ROUE POLAIRE MAIN FIELD excrarrice EXTER Arms + t ine J? He] Pots an ong oes 2 2 Bane Taio 5 § 2 g eu te 2Konme Fégioge tern etereur ‘Esmal rence wotape ter Remove ink R-2 ose potentomotr y is ‘OPTIONAL RIStT Serie| Biack ef [71 Biack ef [Ta Bak et> [NC Blue pa | GreenYelow sf [AL 3h ‘OPEN FOR Gate LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole * SHUNT three-phase 6-wire STATOR: 6-wire (T1 to 76 identification) MAIN FIELD | " m2 | 13 EXCITER ui vi pom 3 | 5 | oe | 16 wl 3 va | wa 3 | 8 3 3 | g 8 yetow 5 ' 5 | green : "Data L blue a _! —_— yf “(putemiao ond cores ara. S OPTIONAL TPA © eo) R791T per | [ee Black | Tit] 4 ~ Black Ta [12] [12 Black 73 [73] [Nc Blue No Green/Yellow SE Consuit120manualref 5243 6 LERoY-SOMER™Electric Power Generation Installation and maintenance 522 0n 2017.08 Low Voltage Alternators - 4 pole + SHUNT three-phase 12-wire MAIN FIELD STATOR: 12:wira (T1 to T12 identification) exoren b 2 22% %% —— cE Is |k lz is +} — pr $1 Exctor fold ° Iz | Rotating rectors EE Ee ER Se SE BE ia 3 ° 3PH 1 PH o[aler |r blue tio} 13 | 12 | to low + 1 1 1 1 wiite ne} 12 | Ne. } Ne. . cl v2 | ne} ne. } ne. ort i E “For andFF connec, OPTIONAL 4 R791T SPH] [Fer 2) /[R120 jo yn | | U Black Tp] Ce a Black 72 [72] UU Black 73 [73] [w Blue WE 22 op bbb Greon/Yelow Consult 120manualret 5243 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole + AREP-three phase 6 or 12-wire EXCITATRICE EXCITER Bobs auxiiaires ‘Aux winging % 2 9 2 ROVE POLAIRE | ANN FIELD EF Ee EE ic Eis & oF | STATOR aero Jd « Els gE ER ieee 78 3 Fe ee & qe ¢ © 3] | 8 pton: TW pourTAL O44 sexi Sptonal Tf TALO¥S oly oft] gf Bees imaguoge man to T6 Wt on Hh PH] RH era | Fe ne wpe O | 3 TIO soc 2 | 12 1 = > Note: : sounlages At Sensing according fovttoge- ssid ‘vee 2 fis eaulemet Vi Werfigh votage @ao4aovy 20° 12's seulem Lin forlow volage ieoasavy Connection A BF See diagram S520 02554 y Be cate ON For anti clock wise rotation 8> 1,79 a Desexciaton - Deenesgizing [OPTION Ti pour TALOaA (OPTION. OPTIONAL OPTIONAL /! CT for TAL O44 R791T_ SPH IPH] | | Tod: insta CaF ow vy | (D) Staronly aa cee reyrz | “14 as]rs_ | a = NON FOURNIS PAR LS ] ‘tna aoa et a TY | LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole + PMG three-phase 6 or 12-wire ROVE POLAR s MAN FELD ze EE ¢ E EXCITATRICE E IS is EXCITER PMG — (a = | qT) STATOR —_—4 = l wey a + Indctue Enotes ° Ras Fonts ae Ei ee RE Pe FREE §§ ‘ipa aaa lars Option: TU! pour TAL 044 seul Showers vaageerner trees | Optional: ICT for TAL D4 cnly akc ‘STATOR 6 fewires: ‘marque /mank T1370 TS Til cron 74 fe 3H |IPH ~-L- ARR-D=F | FF RX 29 7 ETS 3 To 4 eu lor qo i socom 29 | 2 at Duecicostontenions ME ‘Sensing accordinatowotage: Se VW for high voltage (380-460) 216° 12 8 seslerner L12 fe low voltage (208-24 an Seeding Souder seat 8) wih 2 wees ony Be cet toate For anti clock wise rotation 83 01,79 @ Desexciaton - Deenergizing ‘atranes ans IN TW! pour TALO44 see OPTION - OPTIONAL | OPTIONAL 1! CT for TAL 044 rascal Trane SPH [IPH] || Twa:in/1A Rad T_ vous (©) Staronty —— EF own cot Naeack TPT Po ti Reo] BETH cen cor --- N10 oufor ne Nowiack mfr |. 4 2a Nowbiack 13] 13] os [FT Bleulbiue == sire CONTACTS NON FOURNS PAR LS il Neat CONTACTS NOT SUBPUED BY LS LERoY-SOMER™ 9Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 3-INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate formechanicalandelectrical hazards. 3.1-Assembly A All mechanical handling operations must be undertaken using suitable equipment and the machine must be horizontal. Checkhowmuchthemachine weighs before choosing the lifting tool. During this operation, do not allow anyone to stand under the load. + Handling The generously-sized lifting eyes are for handling the alternator only. They must not be used to lift the genset. The choice of lifting hooks or handles should be determined by the shape of the lifting eyes. Choose a lifting system which respects the integrity and the environment of the machine. During this operation, do not allow anyone to stand under the load. The TAL A44 is equipped with two air deflectors that prevent access to the upper and lower holes of the flange. Coupling for this machine should be done with bolts in the eight accessible holes, disregarding the ones that cannot be accessed because of the deflectors. ingle-bearing coupling Before coupling, check the compatibility between the alternator and the engine by performing: = undertaking a torsional analysis of the transmission (alternators data are available on request), = checking the dimensions of the flywheel and its housing, the flange, coupling discs and offset. +Double-bearing coupling - Semi-flexible coupling Careful alignment of the machines is recommended, checking that the lack of concentricity and parallelism of both parts of the coupling do not exceed 0.1 mm. This alternator has been balanced with a 12 key. Location The room where the alternator is placed must be ventilated to ensure that the ambient temperature cannot exceed the data on the nameplate. 10 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 3.2-Checks prior to first use + Electrical checks A\ Under no circumstances should an alternator, new or otherwise, be operated if the insulation is less than 1 megohm for the stator and 100,000 ohms for the other windings. There are 2 possible methods for restoring the above minimum values. a) Dry out the machine for 24 hours in a drying oven at a temperature of 110 °C (without the regulator). b) Blow hot air into the air intake, having made sure that the machine is rotating with the exciter field disconnected. Note : Prolonged standstill In order to avoid these problems, we recommend the use of space heaters, as well as turning over the machine from time to time. Space heaters are only really effective if they are working continuously while the machine is stopped. Ensure that the alternator has the degree of protection matching the defined environmental conditions. + Mechanical checks Before starting the machine for the first time, check that: -all fixing bolts are tight, - the length of bolt and the tightening torque are correct, - the cooling air is drawn in freely, - the protective grills and housing are cor- rectly in place, - the standard direction of rotation is clock- wise as seen from the drive end (phase rotation in order 1 - 2-3). For anti-clockwise rotation, swap 2 and 3 - the winding connection corresponds to the site operating voltage (see section 3.3). 3.3 - Terminal connection diagrams To modify the connection, change the position ofthe stator cables onthe terminals. The winding code is specified on the nameplate. Any intervention on the alternator terminals during reconnection or checks should be performed with the machine stopped, In no case should the internal connections in the terminal box be subjected to stresses due to cables connected by the user. SHUNT single-phase dedicated 4-wire Connection Series connection 1 279 “ OQ), OF® blue O Br L lc Pet ae Ti Me LERoY-SOMER™ "5250n-2017.087h Electric Power Generation Installation and maintenance TAL A44 Low Voltage Alternators - 4 pole + SHUNT three-phase 6-wire Connection Let ‘OUTPUTS TOTHERIGHT wane 1 unas woe O}™ © om semi ourPuTs ToT ie Hb vera me Yop vat LM + AREP or PMG three-phase 6-wire Connectioncodes Vatiage/ Detection Factoryconnection Or 4p winding [ S0H2 | O0He | ouruTsToTHERGHT ‘OUTPUTS TOTHELEFT Ser my 6S [200-415] sa0-aa0] as = [s00-s16 ae ” N z os wong OF AREP: R190 ‘3 a wnt eS wan ty TH) ne ®) sen [vimana [sor | 6042 | carry ie ai aon |_8S__ [220-240] 720-200 + wf \ 2s | 200 [220-240|(1pm on (>) pn (1pm) wanes 5 wauis mn an aner:nivo [OO KC pen .20) es | Le TRILET wun gop) unum r mL wee Os NOE AX incase of reconnection, ensure that AVR voltage detectionis correct! 12 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole += SHUNT, AREP or PMG three-phase 12-wire Us>THV=>T2IN aA AREP/ PMG : R’ w TH Connection codes Voltage Detection Factory connection @srn up winding | SOHz | 60Hz DE Paokisr | “I” 6 _ | 190-208 | 190-240 meas wy ‘ 8 - | 190-208] 34 ur wens SHUNT: R120 np >THINI=>T2/N=>T3/V=>ne. + von2 = THiNt=>T2/N=>T3/V: nit 4 AREP/ PMG: R180, t gps A scones nf On, ww)“ mM) Noe Orn ew winds | 50Hz | 60Hz swiesser 6 | 260-415 | 380-480 8 =| 80-416 SHUNT: R120 um aw) ® tw) BH winding [| S0H2 | 6OHz DE swfososta THA gp 6 | 220-240 | 220-240 8 200 | 220-240 rel rol D Celie var SHUNT: R120 lu rslrap |} O OSD Us>TLINT=>T2/N=>T3/V=>ne. OQ 7 ral ae uot DY ABer PM: Rien i Lemus Noe “counterclockwise, LeandLsinverted winding | S0Hz | 60HZ pF 6 _| 220-240 | 220-240 MH ~240 | Tl tal | See 8 200 220-240 T+ = >. vs SHUNT: R120 nro On” U=>T10/N=>T1/N=>N1/V=>nc. | 112/73) id L AN eripua: nian Oo OF Leste Tio i VorapsL=2voage LL NDE AM incase otreconnection, ensure that AVR voltage detectionis corect! LERoY-SOMER™ 13Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole + Connection checks A\ Electrical installations must comply with the current legislation in force in the country of use. Check that: - The residual circuit-breaker conforms to legislation on protection of personnel, in force in the country of use, and has been correctly installed on the alternator power output as close as possible to the altemator. (In this case, disconnect the wire of the interference suppression module linking the neutral) - Any protection devices in place have not been tripped. - Ifthere is an external AVR, the connections between the alternator and the cabinet are made in accordance with the connection diagram - There is no short-circuit phase-phase or phase-neutral between the alternator output terminals and the generator set control cabinet (part of the circuit not protected by circuitbreakers or relays in the cabinet) ~The machine should be connected with the busbar separating the terminals as shown in the terminal connection diagram - The alternator earth terminal inside the terminal box is connected to the electrical earth circuit - The earth terminal is connected to the frame. The connections inside the terminal box must never be subjected to stress due to cables connected by the user. = 3.4-Commissioning A The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual. The machine is tested and set up at the factory. When first used with no load, make sure that the drive speed is correct and stable (see the nameplate). ‘On application of the load, the machine should achieve its rated speed and voltage; however, in the event of abnormal operation, the machine setting can be altered (follow the adjustment procedure in section 3.5). If the machine still operates incorrectly, the cause of the malfunction must be located (see section 4.5), 3.5 «Setting up AS The various adjustments dui must be made by a qual . Ensure that the drive speed specified on the nameplate is reached before commencingadjustment. After operational testing, replace all access panels or covers. TheAVRisused to make any adjustments tothe machine. 14 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 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 inal state. All such operations performed on the alternator should be undertaken by personnel trained in the commissioning, servicing and maintenance of electrical and mechanical components, who must wear personal protective equipment appropriate for mechanical and electrical hazards. Before any intervention on the machine, ensure that it cannot be started by a manual or automatic system and that you have understood the operating principles of the system. : During and after running, the alternator will reach temperatures hot enough to cause injury, such as burns. 4.2 - Routine maintenance + Checks after start-up After approximately 20 hours of operation, check that all fixing bolts on the machine are still tight, plus the general state of the machine and the various electrical connections in the installation. + Electrical servicing Commercially-available volatile degreasing agents can be used. Do not use: trichlorethylene, perchlo- rethylene, trichloroethane or any alkaline products. These operations must be performed ata cleaning station, equipped witha vacuum system that collects and flushes out the products used. The insulating components and the impregnation system are not at tisk of damage from solvents. Avoid letting the cleaning product run into the slots. Apply the product with a brush, sponging frequently to avoid accumulation in the housing. Dry the winding with a dry cloth. Let, any traces evaporate before reassembling the machine. + Mechanical servicing Cleaning the machine using water or a highpressure washer is strictly prohi- bited. Any problems arising from such treatment are not covered by our warranty. Degreasing: Use a brush and detergent (suitable for paintwork). Dusting: Use an air gun. Ifthe machine is fitted with air inlet and outlet filters, the maintenance personnel should clean them routinely at regular intervals. In the case of dry dust, the filter can be cleaned using compressed air and/or replaced if tis clogged. After cleaning the alternator, itis essential to check the winding insulation (see sections 3.2and 4.5). LERoY-SOMER™ 15Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 4.3 - Bearings The bearings are permanently greased | Approximate ife ofthe grease (depending on use) = 20,000 hours or 3 years 4.4 - Mechanical defects Fault Action Bearing [both bearings the ambient temperature) (bearing temperature 80°C above] - Bearing not Excessive overheating of one or|- If the bearing has tumed blue or if the grease has tumed black, change the bearing lully locked (abnormal play in the bearing cage) ~ End shields incorrectly aligned Excessive overheating of [Abnormal _|altemator frame (more than temperature |40° C above the ambient ltemperature) Air flow (inlet-outlet) partially clogged or hot air is being recycled from the altemator or engine Alternator operating at too high a voltage (>105% of Un on load) ~ Alternator overloaded !Too much vibration - Misalignment (coupling) - Defective mounting or play in coupling }- Rotor balancing fault (Engine - Alternator) humming and vibration Vibrations, Excessive vibration and humming |- Phase imbalance noise coming from the machine _ |- Stator short-circuit - System short-circuit - Misparalleling [Alternator damaged by a Possible consequences Abnormal | siqnfcant impact, followed by | Broken or damaged coupling noise ~ Broken or bent shaft end - Shifting and short-circuit of main field - Fan fractured or coming loose on shaft - Irreparable damage to rotating diodes/AVR, surge suppressor 16 LERoY-SOMER™Elects Power Generatio A Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 4.5 - Electrical faults Fault Action Effect CheckiCause Connect a new Battery of to 12 Meetno [vl to tem eae. atno nals F4 and F2 ae oR — lespectng the polanty. for 2 to 3 seconds The alterator builds up and lwhen the battery is removed its voltage is stil correct. _|- Lack of residual magnetism its voltage does notreach | to the AVR The alterator builds up but |- Check the connection of the voltage reference The altemator builds up but its voltage disappears when the battery is removed resistance) the rated value when the —_|- Faulty diode battery is removed }- Armature short-circuit - Faulty AVR Field windings open circuit (check winding) - Main field winding open circuit (check the Voltage |Check the drive too low speed resistance) [Check the AVR connections (possible AVR failure) - Field windings short-circuited Comect speed - Rotating diodes bumt out }- Main field winding short-circuited (check the ‘Speed too low Increase the drive speed (do not touch the AVR voltage pot. before running at the correct speed) Votage [Adjust AVR volt- too high age potentiometer Adjustment ineffective Faulty AVR = Check the speed : possibilty of cyclic regularity Voltage |the surge disap- | suppressor. the pears [rotating diodes. during and replace any Joperation defective [components Wollage | adjust AVR stabi - Loose connections escila- ity potentiometer Faulty AVR }- Speed too low when on load Volt FA F2 Votage VolzasbetveenF ad corect |Runatnoload SMUT <20V - Check the speed ato load [and check the |AREPIPMG<10V fand too {voltage between Foal wing does een Taya one [volage between Ft andF2 |” short-circuit inthe main field (check the er resistance) ( |AREPIPMG > 15V - Faulty exciter armature (check the resistance) () Warring: During single-phase operation. check that the sensing wires from the AVR are connected to the [correct output terminals. Check the AVR. to the rated value - Faulty AVR - Exciter winding open circuit ‘The voltage does not return |- Faulty exciter armature - Main field open circuit or short-circuited [(*) Waring : The AVR internal protection may cut in (overload lost connection, short circuit). LERoY-SOMER™ 7Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole + Checking the winding You can check the winding insulation by performing a high voltage test. In this case, you must disconnect all AVR wires. conditions is not covered by our warranty. + Checking the diode bridge A diode in good working order should allow the current to flow only in the anode-to- cathode direction. ° ° Anode @—pf—® Cathode Oy Oo Oy .0 + Checking the windings and rotating diodes using separate excitation As During this procedure, make sure that the alternator is disconnected from any external load and inspect the terminal box to check that the connections are fully tightened. 1) Stop the unit, disconnect and isolate the AVRwires. 2) There are two ways of creating an assembly with separate excitation Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W anda diode on both exciter field wires (5+) and (6-). ASSEMBLY A 6 - Field 5+ Rh, 50 -300W 12V battery Assembly B: Connect a “Variac” variable power supply and a diode bridge on both exciter field wires (5+) and (6-). Both these systems should have characteristics which are compatible with the field excitation power of the machine (see the nameplate) 3) Run the unit at its rated speed. 4) Gradually increase the exciter field current by adjusting the rheostat or the variac and measure the output voltages on L1-L2-L3, checking the excitation voltage and current at no load (see the machine nameplate or ask for the factory test report) When the output voltage is at its rated value and balanced within 1% for the rated excitation level, the machine is in good working order. The fault therefore comes from the AVR or its associated wiring (ie sensing, auxiliary windings). ASSEMBLY 8 6-_ Field Be 18 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 4.6 - Dismantling, reassembly During the warranty period, this operation should only be carried out in an approved workshop or in our factory, otherwise the warranty may be invalidated. Whilst being handled, the machine should remain horizontal (rotor not locked when moved). Check how much the machine weighs before choosing the lifting method. + Tools required To fully dismantle the machine, we recommend using the tools listed below: - 1 ratchet spanner + extension - 1 torque wrench - (set of flat spanners: 7, 8, 10, 12 mm = 1 socket set: 8, 10, 13, 16, 18, 21, 22, 24mm - 1Allen key: size 5 (eg. Facom: ETS), size 6 (ET6), size 10 (ET10, size 14 (ET14) - 1720 and T30 TORX bit ~1 puller (U35)/(U32/350) + Bolt tightening torque See section 5.4. + Access to diodes - Remove the air intake grille [51] - Check all 3 modules using an ohmmeter or a battery lamp. - Refit the modules, - Refit the air intake grille [51] + Access to connections and the regulation system The terminals are accessed directly by removing the terminal box lid [48] + Replacing the NDE bearing on single bearing machines Dismantling - Remove the terminal box lid [48] - Unscrew the fixing clamps on the power output cables, remove the connector from the exciter. - Remove the 4 nuts on the tie rods. - Remove the NDE shield [36] using a puller: eg. U.32 -350 (FACOM) - Remove the antifriction bearing [70] using a bolt puller. Reassembly - Heat the inner slipring of a new bearing by induction or in a drying oven at 80°C (do not use an oil-bath) and fit it to the machine. - Place the preloading wavy washer [79] in the shield and fita new O ring seal [349]. Refit the NDE shield and pass the bundle of wires between the top bars of the shield, - Refit the fixing clamps on the cables and the exciter connector. LERoY-SOMER™ 19Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole - Replace the terminal box lid [48] and also the earth continuity bolt [29]. NDE shield Rotor Threaded rod hth S B gj ‘= When dismantling the shields, you need to change the antifriction bearings, the “O” ring seal, the preloading (wavy) washer and adhesive paste. + Accessing the main field and stator Dismantling Follow the procedure for dismantling the bearings. - Remove the coupling disc (single bearing alternator) and insert a tube of the corresponding diameter on the shaft end. - Rest the rotor on one ofits poles, then slide it out. Use the tube as a lever arm to assist dismantling. - After extraction of the rotor, be careful not to damage the fan or dismantle it. - Remove the revolving field coil (rotor) and place on special V-shaped supports. NOTE: If intervention is required on the revolving field coil (rewinding, replacement of components), the rotor assembly must be rebalanced. Reassembling the revolving field coil -Follow the dismantling procedure in reverse order. Take care not to knock the windings when refitting the rotor in the stator. - Refit the fan with its fixing bolts on the hub. Follow the procedure for refitting the bearings. 4,7 - Installation and maintenance of the PMG The PMG reference is PMG 7. See the PMG manual ref: 4211 20 LERoY-SOMER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 4.8 - Table of characteristics Table of average values’ Alternator - 4 pole - 50 Hz - Winding no. 6S. (6-wire)-no. 6 (12-wire) The voltage and current values are given for no-load operation and operation at rated load with separate field excitation. All values are given at + 10% (for exact values, consult the test report) and are subject to change without prior warning. Dedicated single-phase M: 4-pole SHUNT excitation 4-wire Resistances at 20 °C (Q) - Series connection ‘Type [LIN stator [Rotor] Field coil [Armature c | 0024 [235] 1165 | 0423 Di | 001s [204 | 1294 | 0.459 JT [ 00 [3s] 1294 [0.459 Dedicated single-phase M1: 4-pole SHUNT excitation 4-wire Resistances at 20 °C (Q)— Series connection Type | UL stator [Rotor] Field coil [Armature] c | oo [2as| i165 | 0423 Di_| 012 [264] 12.94 | 0.459 E | 001s [2eo| 1294 | 0.459 K | 0008 [34s] i294 | 0459 LERoY-SOMER™ 21Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole + Three-phase: 4-pole AREP excitation 6 and 12-wire Resistances at 20°C (Q) + Table of weights (values given for information only) Three-phase: SHUNT/AREP 6 and 12-wire Type _[LINstator [Rotor [Field coil [Armature| Type | Totalweight (ka) | _ Rotor (kg) A_ | 0067 [207 | 7.26 | 0.423 A 262 708 B | 0067 [207 | 726 | 0.423 B 262 708 c | 0080 [235| 726 | 0423 c 295 721 D_ | o050 [235| 726 | 0423 D 295 721 E | 0034 [289| 807 | 0459 E 368 754 H_ | 0034 [289| 807 | 0459 H 368 754 J [0029 [315] 807 | 0.459 7 398 766 K [| 002 [343| 807 | 0459 K 433 781 Resistance of auxiliary windings at 20 °C (Q) Type | Xe X2auallany ] 27, 22 auxiliary Dedicated single-phase M: SHUNT 4-wire windings windings A 0.450 0.657 Type [UNstator [Rotor B 0.450 0.657 c 289) 721 c 0.436 0627 Dt 332 138 D 0.436 0.627 J 397 166 E 0.365 0575 H 0.365 0575 Dedicated single-phase M1: SHUNT 4- J 0.308 0.480 whe K oat o6tt Type [UNstator [Rotor c 289) 721 DT 332 739 E 361 14 K a5 787 After operational testing, it is essential to replace all access panels or covers. Don't forget the bolt (29) earth continuity. 22 LeRoy-SomER™Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 5-SPARE PARTS 5.1 - First maintenance parts Emergency repair kits are available as an option. They contain the following items: [Emergency kit SHUNT 4941330 AVR R120 (4, 6 and 12-wire) = Diode bridge assembly = [Emergency kit AREP/PMG 5080204 ‘AVR R438 (6 and 12-wire) = Diode bridge assembly = igle bearing Kit 4879454 Non drive end bearing = @Onring = Preloading (wavy) washer 5 5.2 - Technical support service Ourtechnical support service will be pleased to provide any additional information you may require. When ordering spare parts, you should indicate the complete machine type, its serial number and the information given on the nameplate. Address your enquiry to your usual contact. Part numbers should be identified from the ‘exploded views and their description from the parts list. Our extensive network of service centres can dispatch the necessary parts without delay. To ensure correct operation and the safety of our machines, we recommend the use of original manufacturer spare parts. In the event of failure to comply with this advice, the manufacturer cannot be held responsible for any damage. rN After operationaltesting, itis essentialto replace all access panels or covers. 5.3 - Accessories + Space heater for use when stopped The space heater must run as soon as the alternator stops. It is installed at the rear of the machine. Its standard power is 100W with 220V or 100W with 110V on request. Warning: the power supply is Present when the machine has stopped. LERoY-SOMER™ 23Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole 5.4- Exploded view, parts list and tightening torque + Single bearing, SHUNT or AREP 24Elect Power Generation Installation and maintenance Fetben D017 Dh Low Voltage Alternators - 4 pole Ref. | Qty Description Bolt |Teraue |Ref. | aty Description Bort )Foraue |. Preloading (wavy) _T 1 | 1. |Statorassembly 79 | 1 [Preload 4 | 1 |Rotorassembly - | = | 90] 1 lexcitertield (stator) | - | - 15| 1 |Fan - | = Jot] 4 [Fixing ports me | to 16| 6 |Fixingbolts me | 5 fr00] 1 | ixeter armature - - 28| 1 [Earth terminal me | 10 |107| 1 |Diodesupportring | M5 | 6 29| 1 |earthcontinitybots | M6 | 10 |124] 1 {Terminal block me | 5 30 | 1 |Driveend(DE)shied | - | - [144] 1 | Terminal box -|- 31 | 8. |Fixing bolts mi2| 69 |t98] 1 evage regulator ms | 36 Interference 32] 1 |SAE.adaptorring | - | - [199] 1 |suppressionmodule | m5} 6 (RFI Kit) 33 | 2. | Protective guard Me | 5 [320] 1 | Coupling sieeve -|- Non dive end (NDE) a6 | 1 /Nondiveend(NDE) | _ | _ [322] 2 |Coupiing discs -|- 37 | 4 |Tierod mia} 90 |323] 8 [Fixing botts mie | 320 40 | 2. |Plasticcover - | - 325] - [spacer shims -|- Diode bridge 48 | 1 | Terminal box id - | = [os] 3 [Bese bre ms | 3 51 | 2. |Airintake guard ms | 36 [349] 1 |Oringseal -|- INon drive end (NDE) 70 | 1 Ioearing | LeRoy-SomeR™ 25Electric Power Generation Installation and maintenance 5250n-2017.087h TAL A44 Low Voltage Alternators - 4 pole Disposal and recycling instructions Weare committed to limit the environmental impact of our activity. We continuously survey our production processes, material sourcing and products design to improve recyclability and diminish our footprint. These instructions are for information purposes only. It is the user responsibility to comply with local legislation regarding product disposal and recycling. Recyclable materials Our alternators are mainly built out of 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 depar- tment can provide detailed directions on products dismounting upon request. Waste & hazardous materials. The following components and materials heed a special treatment and need to 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 plastic type information. All materials listed above need special treatment to separate waste from reclaimable material and should be handed to specialized disposal companies. The oil and grease from the lubrication systemshouldbeconsideredasahazardous waste and has to be handled according to local legislation 26 LERoY-SOMER™Service & Support Our worldwide service network of over 80 facilities is at your service. This local presence is our guarantee for fast and efficient repair, support and maintenance services. Trust your alternator maintenance and support to electric power generation experts. Our field personnel are 100% qualified and fully trained to operate in all environments and on all machine types. We know alternators operation inside out, providing the best value service to optimize your cost of ownership. Where we can help: Conception + Consulting & sp Outed amis Tau) Bee) SO eun iet. fo) Optimization SN) eeuriiy Ley Tor lao) *Genuine spare parts Booed Contact us: ‘Americas: +1 (507) 6254011 Europe & International: +33 238 609 908 Asia Pacific: +65 6263 6334 China: +86 591 88373036 India: +91 806 726 4867 scantiecadeorgo to: & [email protected] www.Irsm.co/supportLEROY-SOMER™ TAR eRe Linkedin.com/companyfleroy-somer ‘witterconvEPG_Alternators Facebook com/LeroySomer EPG 8 a Gi oO YouTubo.canv/LeraySamerOfial Aide —All for dreams ‘s226en-2017.090,