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High Frequency Alternators: Installation and Maintenance

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400Hz

High Frequency Alternators


Installation and maintenance
Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
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 b) Do not allow children younger than 14


to go near the air outlet guards.
Before using your machine for the first time,
it is important to read the whole of this A set of self-adhesive stickers depicting the
installation and maintenance manual. various warning symbols is included with
All necessary operations and interventions this maintenance manual. They should be
on this machine must be performed by a positioned as shown in the drawing below
qualified technician. once the machine has been fully installed.
Our technical support service will be pleased
to provide any additional information you WARNING
may require. The alternators must not be put into
The various operations described in this service until the machines in which they
manual are accompanied by are to be incorporated have been
recommendations or symbols to alert the declared compliant with EC Directives
user to potential risks of accidents. It is vital plus any other directives that may be
that you understand and take notice of the applicable.
following warning symbols. This manual is to be given to the end
user.
WARNING
The range of electric alternators and
Warning symbol for an operation capable their derivatives, manufactured by us or
of damaging or destroying the machine on our behalf, comply with the technical
or surrounding equipment. requirements of the customs Union
directives.
The alternator is a sub-assembly
delivered without a system of protection
against short-circuits. The protection
Warning symbol for general danger to must be provided by the circuit-breaker
personnel. of the generator, sized to interrupt the
fault current.

© 2023 Moteurs Leroy-Somer SAS


Share Capital: 32,239,235 €, RCS Angoulême
338 567 258.
Warning symbol for electrical danger to
personnel. We reserve the right to modify the characteristics
of this product at any time in order to incorporate
the latest technological developments. The
SAFETY INSTRUCTIONS information contained in this document may
We wish to draw your attention to the therefore be changed without notice.
This document may not be reproduced in any
following 2 safety measures which must be
form without prior authorization.
complied with: All brands and models have been registered and
a) During operation, do not allow anyone patents applied for.
to stand in front of the air outlet guards,
in case anything is ejected from them.

2
Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
CONTENTS

1 - RECEIPT..............................................4 6 - ASSEMBLY OF ALTERNATOR TO


1.1 - Standards and safety measures......... 4 PRIME MOVER....................................8
1.2 - Inspection............................................ 4 6.1 - Foundation.......................................... 8
1.3 - Storage............................................... 4 6.2 - Alternator mounting single bearing..... 8
1.4 - Applications......................................... 4 6.3 - Alternator mounting double bearing.... 8
1.5 - Usage restrictions............................... 4
1.6 - How to read a machine number.......... 4
7 - ELECTRICAL CHECKS......................9
7.1 - Insulation checks................................ 9
1.7 - Identification........................................ 4
7.2 - Connection checks.............................. 9
2 - TECHNICAL CHARACTERISTICS.....5 7.3 - Setting up.......................................... 10
2.1 - Electrical characteristics..................... 5 7.4 - Residual voltage checks................... 10
2.2 - Mechanical characteristics.................. 5 7.5 - Rated voltage and balanced voltage
2.3 - Schematic diagram............................. 5 checks....................................................... 10
7.6 - Connection diagram with D550
3 - OPERATING PERFORMANCE...........6 digital AVR................................................. 11
3.1 - Voltage accuracy and response time... 6
3.2 - Voltage adjustment............................. 6 8 - SERVICING - MAINTENANCE..........12
3.3 - Stability adjustment............................. 6 8.1 - Safety measures............................... 12
3.4 - Overload............................................. 6 8.2 - Routine maintenance........................ 12
3.5 - Short circuit......................................... 6 8.3 - Bearings............................................ 13
8.4 - Mechanical faults.............................. 13
4 - AUTOMATIC VOLTAGE 8.5 - Electrical faults.................................. 14
REGULATOR.......................................6 8.6 - Dismantling and assembly................ 16
8.7 - Rotating rectifier assembly................ 17
5 - INSTALLATION AND
8.8 - Table of characteristics..................... 17
COMMISSIONING.....................................7
5.1 - Delivery and storage........................... 7
9 - SPARE PARTS..................................18
5.2 - Location.............................................. 7
9.1 - Recommended spares...................... 18
5.3 - Foundation.......................................... 7
9.2 - Technical support service.................. 18
5.4 - Installation........................................... 7
9.3 - Exploded view, parts list and
5.5 - Alignment............................................ 8
tightening torque ...................................... 19
5.6 - Direction of rotation............................. 8
5.7 - Terminations and switchgear.............. 8 Disposal and recycling instructions

3
Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
1 - RECEIPT a long period of storage, check the machine
1.1 - Standards and safety insulation. To prevent the bearings from
measures becoming marked, do not store in an
environment with significant vibration.
Our alternators comply with most
international standards. 1.4 - Applications
1.2 - Inspection This alternator is mainly designed to produce
On receipt of your alternator, check that it electricity in the context of applications
has not suffered any damage in transit. If involving the use of generators.
there are obvious signs of knocks, contact 1.5 - Usage restrictions
the transporter (you may be able to claim on Use of the machine is restricted to operating
their insurance) and after a visual check, conditions (environment, speed, voltage,
turn the machine by hand to detect any power, etc) compatible with the characteri-
malfunction. stics indicated on the nameplate.
1.3 - Storage
Prior to commissioning, machines should
be stored: away from humidity (< 90%); after

1.6 - How to read a machine number


It is extremely important to properly identify the machine when requesting parts or service.
Always have the alternator model number and serial number when requesting information
from the factory. We cannot help you witout this information.
For example machine no: TGS3L23A 40436-HF
TG S 3 L 2 3 A 4 0 4 3 6 HF

FRAME SIZE

S-SINGLE/ 3/1 PHASE RATING YEAR MONTH SERIAL NUMBER HIGH


D-DOUBLE FREQUENCY
BEARING

1.7 - Identification
The alternator is identified by means of a nameplate fixed on the machine. Make sure that the
nameplate on the machine conforms to your order. So that you can identify your alternator
quickly and accurately, we suggest you fill in its specifications on the nameplate below.

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
2 - TECHNICAL - The automatic voltage regulator (AVR) will
CHARACTERISTICS sense this low voltage and compare it with
the set reference voltage level and provides
2.1 - Electrical characteristics such power as is available from the main
All standard products have 2/3 pitch main stator winding in order to establish the
windings to eliminate the third harmonic. exciter field.
This serves to lower operating tempera- - The power from the main output winding is
tures, give lower harmonic content and rectified in the AVR and added to residual
better waveform, and extend the overall life voltage level of exciter to produce a greater
of the alternator. magnetic field strength. This in turn
increases output voltage from the exciter
2.2 - Mechanical characteristics rotor and so on.
- Degree of protection: IP23 - The output from the exciter rotor is rectified
- Type of mounting: single-bearing IM2005 by the rotating diodes which adds to the field
and two-bearing IM2001 strength and increase the output voltage
- Other types of protection and mounting from the main stator.
can also be offered on request - The AVR senses this increases, compares
2.3 - Schematic diagram it with the set reference and uses the
increased power from the main stator to
- Here the excitation power is derived from further increase the exciter field excitation
the main output winding. as required. ln this way the main stator
Referring to the schema below, initially the voltage is progressively built up until the
machine builds up voltage with the help of sensed voltage is the same as the set
residual magnetism. reference voltage.
TO LOAD
U V W N

A.V.R.
OUTPUT

Main Stator Exciter


Stator
ROTATING RECTIFIER
ASSEMBLY

Exciter
Main Field (Rotor) Rotor
(Armature)

Main Stator Exciter


Stator

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400Hz
High Frequency Alternators
3 - OPERATING PERFORMANCE 4 - AUTOMATIC VOLTAGE
3.1 - Voltage accuracy and response REGULATOR
time The D550 is a digital automatic voltage
The steady state voltage accuracy will be regulator (AVR) for alternators with rated
±0.8% at 0.8 to unity p.f (lag) from no load to field current up to 7 A.
full load and this is independent of the It offers a vast array of regulation modes
temperature, voltage, load and power factor suitable for all power generation
within the limits specified. The voltage applications, including grid-connected
regulator will keep the alternator voltage configurations.
constant without undue overheating of its The D550 also integrates a visual interface
component and under consideration of through the EasyReg Advanced software,
speed drop to the extent of 4 % of rated which allows the user to read the
speed. The response time of regulation is configuration values and parameters. It
less than 75 milliseconds. can also be configured directly via USB
without external power supply.
3.2 - Voltage adjustment The D550 also includes several protections
A potentiometer is provided in the AVR for and functions to keep the alternator
voltage adjustment up to ±5% of rated running in full safe operation.
voltage. Provision is made for connecting The communication port is CANJ1939
external potentiometer in the AVR for any compatible.
remote adjustment. • Regulation modes:
Refer to the AVR manual ref. 5744 for - Voltage
details. - Field current (manual mode)
3.3 - Stability adjustment - Generator power factor
A potentiometer is provided to reduce the - Grid power factor
voltage hunting under no-load condition. - Generator kVAr
Procedure to set STAB pot is as follows: • Regulation features:
refer to the AVR manual ref. 5744 for details. - Voltage equalization
- Droop management
3.4 - Overload - Cross current compensation
The 400Hz alternators are designed to - Soft start
withstand 10 % overload for one hour in - Load Acceptance Module (L.A.M.) func-
every 12 hours of rated load operation and tion to assist during heavy load application
50% over load for 30 seconds as specified events
in relevant standards. - Negative field forcing
3.5 - Short circuit • kW, kVAr, kVA & PF calculation
The alternators are designed to withstand • Protections & Limitations:
the short circuit current of three times the - Under and over field current limitation
rated current for three seconds. The exciter - Loss of field sensing
is liberally designed to cater ta the excitation - Generator under/over voltage
requirement under such conditions. - Loss of sensing
- V /Hz regulation mode

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
5 - INSTALLATION AND 5.3 - Foundation
COMMISSIONING For mounting the alternator with the prime
Personnel undertaking the various mover, it will be necessary to mount the
operations indicated in this section must alternator on a bedplate or base frame but
wear personal protective equipment not directly over the cast foundation.
appropriate for mechanical and electrical The holes that take up the foundation or
hazards. anchor bolts must be grouted with concrete
of a composition equal to that of the
5.1 - Delivery and storage foundation itself.
Upon receipt of the alternator, it is The nuts of the bolts shall be tightened only
recommended that it should be carefully after the concrete has properly cured.
examined for possible damage in shipment. 5.4 - Installation
The alternator was given to the Freight
Company in good condition, and they are WARNING
responsible for the product from our dock to
yours. Any damage should be noted on the All mechanical handling operations
freight bill before accepting the shipment. must be undertaken using suitable
Claims for damages must be promptly filed equipment and the machine must be
with the Freight Company. horizontal. Check how much the machine
weighs before choosing the lifting tool.
WARNING During this operation, do not allow
anyone to stand under the load.
The alternator must be stored in a clean The machine can only be started up and
and dry place to avoid entry of moisture used if the installation is in accordance
and the harmful dusts as otherwise the with the regulations and instructions
insulation resistance of the windings will defined in this manual.
get affected. In order to prevent
Make sure that the air inlet and outlet
compression pits in the bearings, the
openings are clear without any
alterntor should be stored in vibration
obstruction.
free premises.
The alternators are intended for
5.2 - Location horizontal mounting and direct drive
- The alternator shall be installed where through flexible coupling in case of
there is sufficient circulation of fresh-air. i.e. double bearing machine and with
ambient temperature never exceeds 40°C coupling disc in single bearing machine;
for the normal rating. the tapped holes provided in the shaft
- For higher temperature, a deration factor end/hub can be used for fitting coupling.
should be applied. CRANE CRANE
- Further the room must be dry and the
machine must be easily accessible.
- Vibration of the alternator should be with in
values specified in IEC60034. If vibration is
more, then the levels of the alternator feet
should be checked with the help of dial
indicator and corrected.
- Care should be taken exhaust of diesel
engine does not get mixed with the air inlet
of the alternator.
GROUND LEVEL

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
5.5 - Alignment 6.2 - Alternator mounting single
Measuring the concentricity and parallelism bearing
of the coupling shall carefully align the Single bearing alternators are provided with
alternator and the prime mover. an SAE flywheel adapter and flexible drive/
The difference between the two coupling discs. Very close tolerances are maintained
haIves shall not exceed 0.1 mm. in the manufacture of the alternator so that
5.6 - Direction of rotation the alignment procedure is extremely
The alternator can be driven in either simple. A coupling hub is shrunk on the shaft
and special steel drive discs are bolted to
direction of rotation. For the standard phase
the hub. Holes are provided in the periphery
sequence U-V-W, the rotation is clockwise
of the coupling disc, which correspond to
looking from the drive end of the alternator,
tapped holes in the flywheel. The outside
for anticlockwise rotation; transpose phases
diameter of the discs fits in a rabbet in the
V and W to get U-W-V phase sequence. flywheel so that concentricity is ensured in
5.7 - Terminations and switchgear all cases. Ensure endplay available.
Standard termination consists of four The SAE adapter and the flywheel housing
terminals, three-phase and a neutral. are designed to match each other with no
Correct size of cable glands should be further alignment necessary. Shims may be
chosen. The switchgear should include all necessary under the feet of the alternator to
those required for the operation of the ensure a solid mounting.
alternator and the same is not in the scope
of supply of alternator manufacturer as WARNING
such. Adequate protection system has to be When coupling the alternator to the
provided to protect and to isolate the prime mover, do not use the fan to turn
alternator during any malfunction. the alternator or rotor.
For the optimum performance, the current in The holes of the coupling discs should
the three lines should be equal. However be aligned with the flywheel holes by
unbalance of up to 25% may be allowed for cranking the engine.
short period without exceeding the rated Make sure the machine is securely
current. Voltage regulation and other bedded in position during coupling.
performance characteristics are not
guaranteed for unbalance and non-linear 6.3 - Alternator mounting double
loads. bearing
6 - ASSEMBLY OF ALTERNATOR Two bearing alternators are provided with a
shaft extension and key way. For direct
TO PRIME MOVER coupled sets the assembler furnishes a
6.1 - Foundation flexible coupling which is installed between
The machine should be mounted on a the driver and the alternator shaft.
foundation / base frame, which may be of
steel structure or concrete platform. WARNING
The foundation / base frame must be well
designed for adequate rigidity and long life, Aligning the two machines as accurately
taking into consideration the dynamic as possible will reduce vibration,
loading under abnormal running of the increase-bearing life, and ensures
machine, vibration resulting from running minimum coupling wear. lt may be
machinery and other relevant factors. necessary to shim the alternator feet for
Care must be taken to ensure that the proper support and alignment.
surface to which the machine is bolted down Consult us for alignment specifications
is aligned and leveled in all directions prior and procedures.
to mounting the machine.

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400Hz
High Frequency Alternators
7 - ELECTRICAL CHECKS Another method of improving IR value of
winding is to circulate the hot air through the
WARNING machine.
Ensure that the alternator has the degree Placing heaters inside or near the machine
of protection matching the defined may do it. Care should be taken to see that
environmental conditions. temperature of no part of the winding
exceeds 90°C (194°F) total temperature by
7.1 - Insulation checks thermometer.
If the machine is stored for long period or is 7.2 - Connection checks
suspected to be damp, the insulation Most of the problems that arise during
resistance of the winding should be checked. operation are due to wrong, loose or
While checking the insulation resistance of snapped connections from AVR/ switchgear
the winding it must be ensured that all the to the machine. Hence, it is important to
connections to the AVR and rotating rectifier check these connections thoroughly.
assembly are removed. The connection between AVR and the
The insulation resistances of all windings alternator terminal should be checked as
are to be checked using a 500V megger per the connection diagram.
before the alternator is put into operation.
The insulation resistance of the winding
and earth should be greater than 2 Mega
ohm. If the resistance is less than this value, Any intervention on the alternator
connect 230V, single phase supply to space terminals during reconnection or checks
heater terminals provided inside the should be performed with the machine
terminal box for 1 or 2 hours. Again recheck stopped. In no case should the internal
for IR value. connections in the terminal box be
Alternative methods to improve IR Value subjected to stresses due to cables
are as follows: connected by the user.
- Disconnect the AVR from the terminals, WARNING
short circuit the three stator output terminals
through a cable capable of carrying the Electrical installations must comply with
the current legislation in force in the
rated current and also provide an ammeter country of use.
to monitor the current flowing in the short
circuit terminals. Connect a 24V battery to Check that:
- The residual circuit-breaker conforms to
the field winding (F1 & F2) terminals of the
legislation on protection of personnel, in
exciter stator with respect to the polarities in
force in the country of use, and has been
series with a rheostat of about 10 ohms and correctly installed on the alternator power
250W. output as close as possible to the alternator.
- Run the alternator to its rated speed and (In this case, disconnect the wire of the
adjust its excitation through the rheostat in interference suppression module linking the
order to obtain the rated current in the short- neutral).
circuited terminals. After getting heated up - Any protection devices in place have not
stop the prime mover, disconnect the exciter been tripped.
field connection from the 24 V battery and - If there is an external AVR, the connections
again measure the insulation resistance between the alternator and the cabinet are
value. made in accordance with the connection
diagram.

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400Hz
High Frequency Alternators
- There is no short-circuit phase-phase or If the machine does not build up due to low
phase-neutral between the alternator output or loss of residual magnetism, the following
terminals and the generator set control procedure is applied to recharge the
cabinet (part of the circuit not protected by alternator:
circuitbreakers or relays in the cabinet). - Stop the engine and disconnect the AVR
- The machine should be connected with the connections.
busbar separating the terminals as shown in - Flash the exciter field by connecting
the terminal connection diagram. 12/24V battery with F1 connected to
positive and F2 to negative terminal of the
battery for 10 - 15 seconds.
- The alternator earth terminal inside the Failures to build up voltage (see section
terminal box is connected to the electrical 8.5).
earth circuit
- The earth terminal is connected to the
frame.
The connections inside the terminal box Do not megger or flash test the alternator
must never be subjected to stress due to windings unless all leads to the AVR
cables connected by the user. have been disconnected.

7.5 - Rated voltage and balanced


voltage checks
The alternator is started and run at its rated
Diameter M6 M8 M10 M12 speed. Whenever ma nuai contrai of voltage
Torque 4 Nm 10 Nm 20 Nm 35 Nm is provided as a feature, the alternator
Tolerance ± 15% should be excited on no load manually, till
the rated voltage is developed between line
to line. The voltage balance on the three
7.3 - Setting up lines of the alternator should be checked.

The various adjustments during tests


must be made by a qualified engineer. Do not start the alternator with load on.
Ensure that the drive speed specified on Removal of pot sealing in AVR warranty
the nameplate is reached before void.
commencing adjustment.
After operational testing, replace all
access panels or covers.
The AVR is used to make any adjustments
to the machine.

7.4 - Residual voltage checks


The minimum residual voltage at the
alternator terminals required for positive
buildup is about 2.5V between line to
neutral with the alternator running at rated
speed.

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
7.6 - Connection diagram with D550 digital AVR
• SHUNT three-phase

ROTOR STATOR

EXCITER EXCITER 3-PHASE


STATOR ARMATURE BRIDGE RECTIFIER
MAIN STATOR WINDING
F1
U W

MAIN FIELD
F2

EXCITER FIELD
V
Bat+

Bat-
X2

X1

F+
Z1

Z2

L1
L2

W
F-

U
V

U V W N
S1 S2 S1 S2 S1 S2
U
V

OUTPUT
TERMINALS
W
D550
RT01
DI01
DI02

DI03
DI04

DI05
DI06

DI07
DI08
0V

0V

0V

TO LOAD

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400Hz
High Frequency Alternators
8 - SERVICING - MAINTENANCE
WARNING
8.1 - Safety measures
Do not use: trichlorethylene, perchlo-
Servicing or troubleshooting must be
rethylene, trichloroethane or any alkaline
carried out strictly in accordance with
products.
instructions so as to avoid the risk of
accidents and to maintain the machine in These operations must be performed at a
its original state. cleaning station, equipped with a
vacuum system that collects and flushes
out the products used.
The insulating components and the
All such operations performed on the impregnation system are not at risk of
alternator should be undertaken by damage from solvents. Avoid letting the
personnel trained in the commissioning, cleaning product run into the slots.
servicing and maintenance of electrical Apply the product with a brush, sponging
and mechanical components, who must frequently to avoid accumulation in the
wear personal protective equipment housing. Dry the winding with a dry cloth. Let
appropriate for mechanical and electrical any traces evaporate before reassembling
hazards. the machine.
Before any intervention on the machine,
ensure that it cannot be started by a manual • Mechanical servicing
or automatic system and that you have
WARNING
understood the operating principles of the
system. Cleaning the machine using water or a
highpressure washer is strictly prohi-
bited. Any problems arising from such
treatment are not covered by our
Warning : During and after running, the warranty.
alternator will reach temperatures hot Degreasing: use a brush and detergent
enough to cause injury, such as burns. (suitable for paintwork).
Dusting: use an air gun.
If the machine is fitted with air inlet and outlet
8.2 - Routine maintenance filters, the maintenance personnel should
• Checks after start-up clean them routinely at regular intervals. In
After approximately 20 hours of operation, the case of dry dust, the filter can be cleaned
check that all fixing bolts on the machine are using compressed air and/or replaced if it is
still tight, plus the general state of the clogged.
machine and the various electrical After cleaning the alternator, it is essential to
connections in the installation. check the winding insulation (see section
8.5).
• Electrical servicing
Commercially-available volatile degreasing
agents can be used.

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400Hz
High Frequency Alternators
8.3 - Bearings
The bearings are greased for life Approximate life of the grease (depending on use):
20,000 hours or 3 years
Monitor the temperature rise in the bearings, which should not exceed 90°C above the ambient
temperature. Should this value be exceeded, the alternator must be stopped and checks carried out.

8.4 - Mechanical faults


Fault Cause Rectification
Check the load and correct.
Alternator overload
To be in line with nameplate rating
Check ventilation and clean passage if
Blocking of ventilation passage
necessary
Over heating of Low speed on load Adjust prime mover speed
alternator
Low load power factor Reduce the load
Alternator operating at very high voltage Check voltage and adjust
High percentage of
Check and reduce nonlinear load
nonlinear load
Poor alignment Realign properly
Excessive vibration
Coupling and foundation bolts loose Tighten the bolts
and noise
Bearing defective Replace bearings
Over heating of Incorrect assembly of bearing Reassemble correctly
bearing Bearing damaged Replace bearing

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400Hz
High Frequency Alternators
8.5 - Electrical faults
Fault Cause Rectification
Defective voltmeter Check voltmeter and replace
Excitation circuit open Check for loose connection
Incorrect excitation circuit connection Check for proper connection
Check for residual voltage.
If residual voltage is less than 2.5 volts (L N),
field flashing required for few seconds
Low residual voltage Field flashing procedure:
No voltage from
- Disconnect regulator connections
alternator
- Connect 12/24V battery keeping F1 to
positive and F2 to negative terminal of
exciter stator
Grounded exciter field Check and correct
Rotating rectifier faulty Check rotating diodes
Fuses in AVR failed Replace fuses
AVR defective Replace AVR
Check rotating diodes and replace faulty
Voltage developed Rotating diode faulty diodes
but excitation Prime mover Adjust prime mover
current is high
Prime mover speed is low Adjust prime mover speed to rated speed
Low voltage build V Trim Pot incorrectly set Adjust voltage by V Trim Pot in AVR
up Low prime mover speed Adjust prime mover speed to rated speed
Loose or no connection to U terminals of the
Check and correct
AVR
Voltage - High Incorrect voltage setting Adjust voltage by V Trim Pot in AVR
AVR defective Replace AVR
Speed fluctuation of the prime mover Set the speed of the prime mover
Incorrect setting of stability Pot Adjust stability Pot in AVR
Voltage fluctuation Leading load power factor Correct the power factor
Load hunting, fluctuates rapidly Check and reduce the non linear load
High percentage of non linear load Rectification

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
• Checking the winding Assembly A: Connect a 12 V battery in
You can check the winding insulation by series with a rheostat of approximately
performing a high voltage test. In this case, 50 ohms - 300 W and a diode on both exciter
you must disconnect all AVR wires. field wires (5+) and (6-).

WARNING ASSEMBLY A
6 - Field 5+
Damage caused to the AVR in such
conditions is not covered by our 1A diode Rh. 50 -300W
warranty.
+
• Checking the diode bridge -

A diode in good working order should allow


the current to flow only in the anode-to- 12V battery
cathode direction.
A C Assembly B: Connect a “Variac” variable
Anode Cathode
power supply and a diode bridge on both
C C C
+ - exciter field wires (5+) and (6-).
Both these systems should have
characteristics which are compatible with
A A A A C the field excitation power of the machine
(see the nameplate).
~ ~ ~
+ +
3) Run the unit at its rated speed.
- ~ ~ ~ - + - 4) Gradually increase the exciter field
C C C current by adjusting the rheostat or the
variac and measure the output voltages on
A C L1 - L2 - L3, checking the excitation voltage
A A A 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
• Checking the windings and rotating and balanced within 1% for the rated
diodes using separate excitation excitation level, the machine is in good
working order. The fault therefore comes
from the AVR or its associated wiring (ie.
sensing, auxiliary windings).
During this procedure, make sure that ASSEMBLY B
the alternator is disconnected from any 6 - Field 5+
external load and inspect the terminal 40
50 60 +
box to check that the connections are
30

70

1A diode
fully tightened.
20

80
10

90

1) Stop the unit, disconnect and isolate the


0 100

AVR wires. Variac AC - DC


12V
2) There are two ways of creating an 220V
assembly with separate excitation.

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400Hz
High Frequency Alternators
8.6 - Dismantling and assembly
WARNING
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 in position). Check how
much the machine weighs before choosing the lifting method.
• Rotor removal
- Remove NDE front cover.
- Remove the screws of NDE bearing cap.
- Disconnect exciter stator winding leads
from AVR.
- Unbolt the NDE end shield from the stator
body and jack the NDE end shield with the
help of suitable bolts.
- Take out the rotor towards the DE side
along with the fan and bearing from the
stator body. NDE end shield removal
- Reassemble the rotor in reverse order.
• Rotating rectifier assembly removal
- Disconnect the rotating rectifier assembly
connections from main rotor and exciter
rotor.
- Unbolt the rotating rectifier assembly from
the exciter rotor with the help of suitable
spanners.
- Withdraw the rotating rectifier assembly
towards the NDE side. Rotating rectifier assembly removal
- Refit the rotating rectifier assembly on
exciter rotor in reverse order.
• Exciter rotor removal
- Remove bearing from the shaft using
suitable bearing puller.
- Remove rotating rectifier assembly from
the exciter rotor.
- Fix suitable fixture ta studs provided in
exciter rotor.
- Pull out the exciter rotor from the shaft with Bearing removal
suitable puller towards the NDE side.
• Exciter stator removal
- Disconnect the exciter stator winding leads
from AVR.
- Unbolt the NDE shield from the stator body.
- Unbolt the exciter stator core from NDE
shield.
- Refit the exciter stator in reverse order.

Exciter rotor removal

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400Hz
High Frequency Alternators
8.7 - Rotating rectifier assembly
Ref 1
Description Qty “B”
No 2

1 Base plate 1
2 Aluminum bar 2 6
7
3 Forward diode 3 8
9
4 Reverse diode 3
5 Varistor 1
6 Hexagonal bolt 3
7 Hexagonal nut 3 “B”

8 Plain washer 3
9 Lock washer 3 3 4
Section “BB” 5

8.8 - Table of characteristics


Alternator:16/24/26 poles - 400 Hz. The voltage and current values are given for no-load
operation and operation at rated load with separate field excitation. All values are given to within
± 10% and may be changed without prior notification (for exact values, consult the test report).
• Average values for the LSA 180/225/280
Resistances at 20 °C (Ω), field excitation current & weights of the machine
Excitation Weight in kg
Type L/L stator Rotor
No load At rated load SB DB
LSA 180 A 0.1150 1.898 0.8 3.5 117 54
LSA 180 B 0.1150 1.898 0.8 3.7 117 54
LSA 180 C 0.1146 1.897 0.9 3.7 117 54
LSA 180 D 0.0408 2.883 0.9 3.8 137 86
LSA 180 E 0.0408 2.883 0.8 3.8 151 110
LSA 180 F 0.0408 2.883 0.9 3.9 165 134
LSA 180 G 0.0274 3.727 0.8 4.0 185 177
LSA 180 H 0.0274 3.730 0.8 4.2 185 177
LSA 180 I 0.0176 4.571 0.9 4.3 200 201
LSA 180 J 0.0176 4.571 1.0 4.5 214 225
LSA 225 A 0.1250 4.480 0.9 4.0 300 330
LSA 225 B 0.0736 5.460 0.9 4.2 310 340
LSA 225 C 0.0432 6.630 0.9 4.0 335 365
LSA 280 A 0.0230 2.700 0.9 4.2 570 600
LSA 280 B 0.0199 2.930 0.9 4.4 725 755
LSA 280 C 0.0168 3.160 0.9 4.7 740 770
LSA 280 D 0.0138 3.400 1.0 4.6 780 790
LSA 280 E 0.0107 3.620 0.9 4.8 800 830
LSA 280 F 0.0076 3.849 1.0 4.8 850 880

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400Hz
High Frequency Alternators
9 - SPARE PARTS
9.1 - Recommended spares

Description Qty Code After operational testing, it is essential to


replace all access panels or covers.
Automatic voltage
1 ALT550KC001B
regulator (AVR)
BG1100631010
Bearing NDE 1
BG1100631210
Rotating rectifier ESC035MD004B
1 set
assembly (RRA) 1RRBF0700200
1ERLB0400100
Wound exciter rotor 1
1ERLB0500200
1ESLB0400600
Wound exciter stator 1
1ESLC0500200
AG3030570000
Terminal bar 1
AG3040790000

9.2
5.2 -- Technical
Technical support
support service
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
service.epg@leroy-somer.com or your
nearest contact, whom you will find 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 identified 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.

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400Hz
High Frequency Alternators
9.3 - Exploded view, parts list and tightening torque

23
22
20
32
19

24

26

25

21

27

31
18
29
30
17
16
15

14

13
12
11

3
1

4
2

5
10

6
28

7
9
8

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
180 frame 225 frame 280 frame
Ref. Qty Description Screw Torque Screw Torque Screw Torque
Ø N.m Ø N.m Ø N.m
1 1 Stator assembly - - - - - -
2 1 Rotor assembly - - - - - -
3 1 Fan with key - - - - - -
4 1 Circlip for fan - - - - - -
5 1 Hub with key - - - - - -
6 6 Shim - - - - - -
7 3 Disc coupling M10 50 M12 90 M12 90
8 3 Locking washer - - - - - -
9 1 Pressure plate - - - - - -
10 1 Fan key - - - - - -
11 1 DE adaptor SAE-3 M10 50 M10 50 M12 50
12 1 DE slotted surround SAE-3 M6 10 M6 10 M6 10
13 2 Feet - - - - - -
14 1 Earthing bolt M10 50 M10 50 M10 50
15 1 Bearing cap M6 10 M6 10 M6 10
16 1 Bearing - - - - - -
17 1 NDE shield M10 50 M10 50 M10 50
18 1 Exciter stator M8 25 M8 25 M8 25
19 1 Exciter rotor - - - - - -
20 1 Diode M6 10 M6 10 M6 10
21 1 Terminal box top cover M6 10 M6 10 M6 10
22 1 Gasket - - - - - -
23 1 NDE front cover M8 25 M8 25 M8 25
24 1 Platform - - - - - -
25 1 Terminal bar M8 10 M10 26 M12 46
26 1 AVR M6 10 M6 10 M6 10
27 4 Grommet - - - - - -
28 1 Extension key - - - - - -
29 1 O-ring - - - - - -
30 1 Exciter rotor locking plate - - - - - -
31 2 Terminal box with gasket M6 10 M6 10 M6 10
32 1 Varistor M6 10 M6 10 M6 10

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400Hz
High Frequency Alternators

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Electric Power Generation Installation and maintenance 6149 en - 2023.07 / a

400Hz
High Frequency Alternators
Disposal and recycling instructions All materials listed above need special
We are committed to limiting the treatment to separate waste from
environmental impact of our activity. We reclaimable materials and should be
continuously monitor our production entrusted to specialist recycling companies.
processes, material sourcing and product
design to improve recyclability and minimise The oil and grease from the lubrication
our environmental footprint. system should be treated as hazardous
These instructions are for information waste and must be treated in accordance
purposes only. It is the user’s responsibility with local legislation.
to comply with local legislation regarding
product disposal and recycling. Our alternators have a specified lifetime of
20 years. After this period, the operation of
Recyclable materials the product should be stopped, regardless
Our alternators are mainly constructed from of its condition. Any further operation after
iron, steel and copper materials, which can this period will be under the sole responsi-
be reclaimed for recycling purposes. bility of the user.
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 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.

22
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 have a deep understanding of alternator operation, providing the best value
service to optimise your cost of ownership.
Where we can help:
Design
•Consulting & specification
•Maintenance
contracts

Life Extension
•Reconditioning Start-up
•System upgrade
•Commissioning
•Training

Optimisation
•Monitoring Operation
•System audit •Genuine spare parts
•Repair services

Contact us:
Americas: +1 (507) 625 4011
EMEA: +33 238 609 908
Asia Pacific: +65 6250 8488
China: +86 591 8837 3010
India: +91 806 726 4867
Scan the code or go to:

service.epg@leroy-somer.com www.lrsm.co/support
www.emersonindustrial.com
www.leroy-somer.com/epg

Connect with us at:

6149 en - 2023.07 / a

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