LSAP 40 / 42.3 / 44.3 / 45 / 46.

2-4 POLE

Low Voltage Alternators - 4 pole

Installation and Maintenance

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Electric Power Generation INSTALLATION AND MAINTENANCE

LSAP 40 / 42.3 / 44.3 / 45 / 46.2-4 POLE

A.C. GENERATORS

1 - RECEIPT 6 - DISMANTLING, REASSEMBLY

1.1 Standards and safety measures.................3 6.1 Tools Required.................................................16

1.2 Inspection...................................................3 6.2 Screw Tightening Torque................................16
1.3 Identification..............................................3 6.3 Accessing, Checking and replacing diodes....16
1.4 Storage........................................................3 6.4 Replacing the NDE bearing on a single
bearing m/c......................................................17
6.5 Replacing the DE bearing on a two
2 - TECHNICAL CHARACTERISTICS bearing m/c......................................................17
6.6 Accessing the main field and stator...............17
2.1 Electrical Characteristics........................4
2.2 Mechanical Characteristics....................4
2.3 Options...................................................4
2.4 Shunt System with R201/R203 AVR......5 7 - SPARE PARTS

3 - INSTALLATION 7.1 First maintenance parts....................................18

7.2 Description of bearings....................................18
3.1 Assembly..................................................6
7.3 Product support................................................18
3.2 Inspection prior to first use....................6
3.3 Terminal connection diagrams...............7
8 - WARRANTY
3.4 Commissioning........................................9
3.5 Setting up................................................9 CERTIFICATE.....................................................21

9 - WARRANTY CLAUSE.......................................22
4 - AVR

4.1 R-120............................................................9 10 - AC GENERATOR REGISTRATION FORM (ARF)..23

4.2 AVR Connection Diagram.........................10
4.3 R201/203....................................................11 11 - SERVICE HISTORY CARD...............................24

5 - SERVICING, MAINTENANCE 12 - SPACE HEATERS............................................25

5.1 Safety measures............................................13

5.2 Electrical faults..............................................14
5.3 Checking the windings ................................15
5.4 Checking the diode bridge ..........................15
5.5 Checking the windings and rotating diodes
using separate excitation.............................15

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Electric Power Generation INSTALLATION AND MAINTENANCE

LSAP 40 / 42.3 / 44.3 / 45 / 46.2-4 POLE

A.C. GENERATORS

This manual Corresponds to the AC Generator We wish to draw your attention to the contents
which you have just purchased. of this maintenance manual. By following certain
important points during installation, and servicing
of your AC Generator, you can look forward to
The latest addition to a whole new generation many years of trouble-free operation.
of AC Generator, this range benefits from the
experience of the leading manufacturer worldwide,
using advanced technology and incorporating
strict quality control.
WARNING SYMBOLS
SAFETY MEASURES
Locations at which warning symbols shoud be
Before using your machine for the first time, it is positioned is shown in the sketch below. User may
important to read completelly this installation install these for safety purposes. (the stickers of
and maintenance manual. symbols are generally not supplied with the
machine).
All necessary operation and instructions 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 the manual

are accompanied by recommendations or symbols
to alert the user to potential risks of accidents. It
is vital that you understand and take notice of the
following warning symbols.

WARNING

Warning symbol for an operation capable of damaging

or destroying the machine or surrounding equipment.

Warning symbol for general danger to personnel.

Warning symbol for electrical danger to personnel.

Note: LEROY-SOMER reserves the right to modify the

characteristics to its products at any time in order to
incorporate the latest technological development.
The information contained in this document may
therefore be changed without notice.

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Electric Power Generation INSTALLATION AND MAINTENANCE

LSAP 40 / 42.3 / 44.3 / 45 / 46.2-4 POLE

A.C. GENERATORS
1- RECEIPT 1.3 Identification
The ac generator is identified by means of a
1.1.Standards and safety measures nameplate fixed on the frame.
Our ac generators comply with most international Make sure that the nameplate on the machine
standards and are compatible with IS 4722 and’ conforms to your order.
the recommendations of the
1.3.1 Nameplate
International Electrotechnical Commission.
IEC 34-1 You can identify your machine quickly and accurately,
we suggest you fill in its specifications on the nameplate
Before using your generator for the first time, below.
read carefully the contensts of this installation and Mention name plate details on all your
maintenance manual, supplied with the machine. correspondence.
All operations performed on the generator should
be undertaken by qualified personnel with specialist 1.4 Storage
traini ng in the com missioning, servi cing and
maintenance of electrical and mechanical machinery. Prior to commissioning, machines should be stored
This maintenance manual should be retained for the away from humidity ; In case of relative humidity of
whole of the machine’s life and be handed over with more than 90%, the machine insulation resistance
the contractual file. The various operations described (IR) can drop very rapidly, just above zero at around
in the manual are accompanied by recommendations 100% humidity Monitor the state of the anti-rust
or symbols to alert the user to potential risks of protection on unpainted parts. For storage over an
aciddents. It is vital that you understand and take extended period, the machine can be placed in a
notice of the different warning symbols. sealed enclosure (heatshrunk plastic) with dehydrating
sachets inside, away from significant and frequent
1.2 Inspection variations in temperature to avoid the risk of
condensation during storage. If the area is affected
On receipt of your alternator, check that it has not by vibration, try to reduce the effect of these vibration
suffered any damage I transit. If there are obvious signs by placing the generator on a damper support
of knocks, contact the transporter (you may able to claim (rubber disc or similar) and turn the rotor a fraction
on their insurance) and after a visual check, turn machine of a turn once a fortnight to avoid marking on
by hand to detect any malfunction (double bearing). bearing rings.

TM

BRUSHLESS SYNCHRONOUS GENERATOR

Type M/CNo.
kVA Insul.Class Encl. Conn.
kW Direction DE Hz Altitude
Volts Ambient C P.F. RPM
AMPS. SAE / Disc Duty Wt. Kg.
Phase Excitation VOLTS AMPS.
AVR Bearing DE. NDE. IEC 34.1 / IS: 13364/4722

NIDEC INDUSTRIAL AUTOMATION INDIA PRIVATE LTD.

BENGALURU - 562 162. INDIA

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS

2 - TECHNICAL CHARACTERISTICS

2.1 Electrical characteristics

The LSAP alternator is a machine without sliprings and

revolving field brushes, will have”2/3 pitch”, 6-wire, with
class ‘H’ insulati on and a field excitati on system
available in either “SHUNT” or “AREP” version.

R-120

STATOR : 2 wires (U N)

R121
2.1.1 Options
- Stator temperature detection probes. Two-bearing with SAE flange and standard
- Space heaters. cylindrical shaft extension.
- Machine, self-cooled
2.2 Mechanical Characteristics - Degree of protection; IP 23
- Steel frame 2.3 Options
- End shields in cast iron
- Protection against harsh environment.
- Greased ball bearings
- Air input filter, air output labyrinth cowling.
- Mounting arrangement
Alternators fitted with air inlet filters should be
Md35;
derated by 5% (power)
Single bearing with standard feet and SAE - To prevent excessive temperature rise caused by
flages/coupling discs. clogged filters, it is advisable to fit the stator winding
B34 with thermal sensors (PTC or PT 100).

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS

2.4 - SHUNT system with R201/R203 AVR

R201 AVR for LSAP42/43/44: R203 AVR for LSAP40

LSAP42/43/44 SHUNT version

STATOR : 6 wires (markedT1 to T6)

5+ 6-
SERIES
Connection

R 201 Power supply and voltage reference

LSAP40 SHUNT version

STATOR : 6 wires (marked T1 to T6)

T1 T2 T3

5+ 6- T4 T5 T6
SERIES
Connection

R 203 Power supply and voltage reference

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS
3 -INSTALLATION Tighten the coupling discs screws to the recommended
3.1 Assembly torque and check that there is lateral play on the
crankshaft.
3.1.2.2 Double bearing ac generator
-Semi-flexible coupling
All mechanical handling operations must be Careful alignment of the machines by measuring
undertaken using approved equipment. the concentricity and parallelism of the two parts
While being handled, the machine should of the coupling is recommended, the difference
remain horizontal. between the readings should not exceed the
pecified values (say 0.1 mm)
3.1.1 Handling

The generously- sized lifting rings are for handling WARNING

the AC Generator alone, They must not be used to This ac generator has been balanced with a ½key.
lift the genset. Choose a lifting system which
respects the positioning of the rings. 3.1.3 Location
Ensure that the ambient temperature in the room where
the ac generator is place cannot exceed 40o C for standard
power ratings (for temperatures above 40o C, apply a
derating coefficient). Fresh air, free from damp and
dust, must be able to circulate freely around the air
input louvers on the opposite side from the coupling, It
is essential to prevent not only the recycling of hot air
from the machine or engine, but also exhaustfumes.
3.2 Inspection prior to first use
0.2.1 Electrical checks

Under no circumstances should an ac generator, new

or otherwise, be operated if the insulation value is less
than 1 megohm for the stator and 100,000 ohms for the
other windings.
There are two possible methods for restoring the
above minimum values.
a) Dry out the machine for 24 hours in a drying oven
3.1.2 Coupling at a temperature of approximately 1100C.
b) Blow hot air into the air input, having made sure
3.1.2.1 Single bearing ac generator
that the machine is rotating with the exciter field
Before coupling to the prime mover, check that both disconnected.
are compatible by: c) Run in short-circuit mode (disconnect the AVR)
- Undertaking a torsional analysis of the transmission. - Short-circuit the output phases using connections
- Checking the dimensions of the flywheel and its capable of supporting the rated current (try not to
exceed) 6A/mm2)
housing, the flange, coupling discs and offset.
- Insert a clamp ammeter to monitor the current
WARNING passing through the short-circuit connections.
- Connect a 48 Volt battery in series with a rheostat
When coupling with ac generator to the prime mover, of approzimately 10 ohms (50 Watts), to the exciter
the holes of the coupling discs should be aligned with field terminals, respecting the polarity.
the flywheel holes by cranking the engine. Do not use - Open fully all the ac generator louvers.
the alternator fan to turn the rotor. - Run the ac generator a rated speed. Adjust the
exciter field current using the rheostat to obtain the
rated output cuttent in the short-circuit connections.

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 Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS

Note: Prolonged standstill: In our order to avoid these 3.3 Terminal Connection diagrams
problems, we recommend the use of space heaters, as
well as turning over the machine from time to time. To modify the connection, change the position of
Space heaters are only effective if they are working the terminal cables, Consult the factory for this.

continuously while the machine is stopped.

3.2.2 Physical and visual checks

Before starting the machine for the first time, check that:
- the fixing bolts onthe feet are tight
- the cooling air is drawn in freely
- the protective louvres and housing are correctly in place
- the standard direction of rotation is clockwise as seen Any intervention on the ac generators terminals
from the shaft and (Phase rotation in order 1 - 2 - 3). durin reconnection or checks should be performed,
For anticlockwise rotation, swap 2 and 3. with the machine stopped.
- the winding connection corresponds to the
site operation voltage.

T3 T1 I I

U
T2 I I

V
T1 T4 T3 I I

W
T6
T5
T4
I I
T5 N
T6
T2

Dedicated Single phase Wiring diagram.

T1 (U) T 4 (N)

Note : Above connections Diagrams are for explanation only

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Electric Power Generation INSTALLATION AND MAINTENANCE

LSAP 40 / 42.3 / 44.3 / 45 / 46.2-4 POLE

A.C. GENERATORS
3.3.1 - Mechanical checks
Before starting the machine for the first time check that :
- the fixing bolts on the feett are tight.
- the cooling air is drawn in freely.
- the protective grilles and housing are correctly in place.
- the standard direction of rotation is clockwise as seen from the shaft end
(phase rotation in order 1-2-3). For anti-clockwise rotation swap 2 and 3.
- the winding connection corresponds to the site operation
voltage (see section 3.3)

3.3.2 - Terminal connection: 6 wire

Connection codes Voltage L.L Factory connection
L1(U) Winding 50 Hz 60 Hz
D T1 T4 T5 T6
3-phase
6 380-415 480 N
NDE

L3(W)
T4 N
T3

T5 L2(V)
R201/ voltage sensing:
T6 T2
T3 T2 U=>(T1) / V=>(T2) L1(U)
N =>N T1
L3(W) L2(V)
R203/ voltage sensing:
0=>(T1) / 200V=>N

L1(U)
Winding 50 Hz 60 Hz
F 240
6 220-240 L3(W)
Single-phase
T3T5
T6 T1 L2(V)
T2 T4
L1(U)
T3 T4
T1 T6
R201/203 voltage sensing:
T5 T2 0 => (T3) / 220 V => (T2)
L3(W) L2(V) Operating phases :L2(V), L3 (W) single phase

In case of reconnecting, ensure that AVR voltage sensing is correct!

3.3.3 - connection diagram for options

Anti condensation heater Thermistor (PTC) temperature

130°C
103
Ph1 Blue
101
150°C
Ph2
102 Black
Ph3 180°C
104 Red/white

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 Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS

3.3.4 Connection checks 3.5 Setting up

Electrical installations must comply with the current

legislation in force in the country of use.
The various adjustments during tests must be
Check that: made by a qualified engineer. Take care that the
-the differential circuit-breaker confirms to legislation
drive speed specified on the nameplate is reached
on protection of personnel, in force in the country of
before commencing adjustment. After operational
use, and has been correctly installed on the ac generator testing. Replace all access panels or covers.
power output as close possible to the ac generator.

- any protective devices in place should not be tripped. 4. AVR

- if there is an external regulator, the connections
between the ac generator. and the cubicle are made in 4.1 R -120
accordance with the connection diagram.
- there is no short-circuit between phases or phase
neutral between the alternator output terminals and
the generator set control cabinet (part of the circuit
not protected by circuit-breakers or cubicle relays)
The machine should be connected with the terminal
lugs on top of one another as shown in the terminal
connection diagrams.

3.4 Commissioning

The machine can only be started up and used if the

installation is in accordance with the instructions
and advice defined in this manual.

The machine is tested and set 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 maintain its rated speed
and voltage however, in the event of abnormal
operation, the machine setting can be altered. If the
machine still operates incorrectly, the cause of the
malfunction must be located.

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS
4.2 AVR CONNECTION DIAGRAM
The AVR or Automatic Voltage Regulator type R-120 is state - of the -art advanced electronic voltage
regulator which ensures high voltage regulation within ±1%. It has an excellent dynamic response and
the recovery time of 1sec. on application of full load. The AVR is potted so that it can operate even in
humid and corrosive atmosphere. It provides factory set under-speed protection for the ac generator by
U/f function. The AVR is mounted on anti-vibration dampers for long life.

ROTOR ST ATOR

R - 120

WARRANTY VOID
IF BREAK OPEN
TO LOAD
OPEN FOR 60Hz
UF S V

Note : For 1 Phase connection connect, between U & N Put short link between N & N1

4.2a AVR PARAMETER

Characteristics
SL. NO. PARAMETER R - 120
- Voltage regulation: ± 1 %
1 Voltage adjustment
- Supply range/voltage detection 230V (50HZ)
2 Stability adjustment - Response time (1sec.) for a transient voltage
3 Under frequency roll off variation amplitude of ± 20%
adjustment - Voltage setting: V
4 Remote voltage adjustment - Stability setting : Sealed

5 Over Excitation adjustment

6 Accessory (DC input)

7 Quadrature Droop
8 Sense Loss indication
9 Under excitation indication
10 Under frequency roll off
11 Frequency roll of indicator

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS
4.3 - R201 & 203
4.3.1 AVR introduction
Sensing Input Thermal Drift
Voltage 170~260 VAC or 370~460VAC, 0.03% per ºC change in AVR ambient
1 phase 2 wire jumper selectable External Volts Adjustment
Frequency 50 / 60 Hz, Jumper selectable ± 8% with 1K ohm 1 watt trimmer
Power Input Unit Power Dissipation
80 ~ 260 VAC, 1 phase 2 wire Max. 10 watt
Voltage
Output Under Frequency Protection (Factory Setting)
Voltage Max. 90 VDC @ 240 VAC input 60 Hz system presets knee point at 57 Hz
Current Continuous 5A 50 Hz system presets knee point at 47 Hz
Soft Start Ramp Time
Intermittent 10A for 10 sec
2 sec.
Resistance Min. 9 ohm Dimensions
Voltage Regulation 138mm Lx 103mm W x 53mm H
< ±1% ( with 4% engine governing )
Voltage Build-up
Residual voltage at AVR terminal > 5 VAC
12 3 4 5 6 7
138
116

f
4
.
5

U V N F+ F

81 12.5
103 6 51

4.3.2 Notice of use

The R201 AVR can be mounted in various place, like generator control panel, switchgear cabinets, etc. But
prevent high temperature, high moisture, or severe vibration places. See figure 1 for mounting dimensions.
The R201 AVR surface temperature will be over 60ºC when operations. Do not touch the heat sink.
Startup Procedure
1. Ensure all the wire of the regulator are correctly connected and the proper fuse (5A250V) is installed.
2. Turn voltage potentiometer full anticlockwise ( lowest voltage level).
3. If used, turn external voltage potentiometer to the middle position.
4. Turn stability potentiometer full clockwise (highest stability level).
5. Connect a 110VDC meter across the field F+, F- terminals.
6. Connect a 500VAC meter across line U to line V of generator.
7. Start and run the generator at no load and rated speed. The generator output voltage should build
up to a minimum level, If the voltage does not build up, it may be caused by low residual voltage of
generator. Refer to field flashing section in generator manual.
8. Slowly adjust voltage potentiometer clockwise until the generator voltage reach the proper value.
9. Turn stability trimmer clockwise until the output voltage is not stable, carefully turn stability trimmer
anticlockwise until rated stable voltage is reached. That is the match point between AVR and generator.

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS

4.3.3 AVR DIAGRAM

R201 3 Phase R201 1 Phase

ROTATING RECTIFIER
EXCITER ROTOR

EXCITER STATOR
N
TYPIC MAIN STATOR
W U
TYPIC MAIN STATOR

U V

F+ F - N V U 1 200V
F+ F - N V U 1 2 400V
2 200V 3
3
R201 4
400V R201 4 50/60Hz
50/60Hz 5 HAND TRIMMER (OPTIONAL)
5 6
6 HAND TRIMMER (OPTIONAL) REMOVE LINK R1-R2 BEFORE CONNECTING
REMOVE LINK R1-R2 BEFORE CONNECTING 7
7 UES TOW-CORE TWISTED-PAIR SCREENED
UES TOW-CORE TWISTED-PAIR SCREENED VR CABLE(RETED 250VAC/1A)
VR CABLE(RETED 250VAC/1A)

4.3.4 AVR PARAMETER

4.3.4(a) Frequency Roll-Off Adjustment

Connect a jumper from 4 to the 5 terminal for 50Hz operation, or leave the two terminals unconnected
for 60Hz operation. To reset the frequency roll-off, proceed as follow :
1. Startup engine and build voltage
2. Adjust the prime mover RPM to the desired frequency compensation (corner frequency roll-off ) point.
3. Adjust the front panel FREQ control until the output voltage low about 5V than nominal voltage.
( For 50Hz application, the frequency “roll-off” is factory preset to 47Hz, for 60Hz operation, the frequency
is 57hZ).

4.3.4(b) Voltage Adjustment

1. Adjust the front panel VOLT to vary the generator nominal voltage.
2. If used, a 1kW 1watt potentiometer may be connected to terminals VR and VR, refer to Figure4,5.

4.3.4(c)-Stability Adjustment

1. Adjust the front panel STAB control the system stable.

2. Rotation of the front panel STAB control in the counter-clockwise (CCW) direction will speed response
time, F rotated too for CCW, the generator voltage may oscillate (shunt)
3. Rotated the front STAB control CCW until the system start oscillating and then rotate cw just past the
point where oscillation occurred.

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 Electric Power Generation INSTALLATION AND MAINTENANCE

LSAP 40 / 42.3 / 44.3 / 45 / 46.2-4 POLE

A.C. GENERATORS
5 - SERVICING, MAINTENANCE

These instructions apply to the alternator of which you have just taken possession. We would
like to draw your attention to the contents of this maintenance manual.

5.1 SAFETY MEASURES A) During operation, prohibit the parking

Before operating your machine, you must of any person in front of the air outlet grills
have read this installation and maintenance due to a possible risk of material projection.
manual completely.

All operations this interventions to be carried B) Do not allow children under the age of
out to operate this machine will be carried 14 to be approached by air outlets A sticker
out by qualified personnel. sheet of the various safety instruction is
attached to this mai ntenance man ual.
Our technical support service is at your disposal
for all the information you need. They will be positioned according to the
drawing and when the machine is completely
The various operations described in this manual installed
are accompanied by recommendations or
symbols to make the user aware of the risks of WARNING
accidents. It is imperative that you understand
The alternators shall not be put into service
and respect the various
until the machinery in which they are to be
incorporated has been declared in conformity
ATTENTION with the EC Directives and any other applicable
di rectives. The se ins truc tion s mus t be
Safety note for an intervention that can damage
transmitted to the end user the range of
or destroy the machine or the surrounding
equipment. electrical alternators and related products
manufactured by us or on our behalf comply
with the technical requirements of the Customs
Union (EAC) Directives.

© - We reserve the right to modify the

characteristics of this product at any time to
Safty instruction for general danger to
bring the latest technological developments.
personnel.
The information contained in this documents
is subject to change without this document
may not be reproduced in any form without
our prior authorization. Trademarks, models
and patents filed.
Safty instruction for electrical danger to
personnel.

SECURITY INSTRUCTIONS
We would like to draw your attention to the
following 2 safety measures:

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Electric Power Generation INSTALLATION AND MAINTENANCE

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A.C. GENERATORS
5.2 Electrical faults

Fault Action Effect Check/Cause

No Voltage Connect a new The alternator builds up - Lack of residual magnetism

at no load battery of 4 to 12 but its voltage does not - Check the connection of the
on start-up volts to terminal reach the rated value when voltage reference to the AVR
E- and E+. the battery is removed
- Faulty diode
respectively for a The alternator builds up - Armature short-circuit
time period for but its voltage disappears - Faulty AVR
2 to 3 seconds when the battery is - Field windings open circuit
removed. (check winding)
- Main field winding short-circuited

Voltage Check the drive The speed is corrected. - Check the AVR connections
too low speed (possible AVR failure
- Field windings short-circuited
- Rotating diodes burn out.
- Main field winding short
circuited - check the resistance
- Increase the drive speed

Voltage Adjust AVR voltage Speed too low (Do not touch the AVR voltage pot.
too High potentiometer (P2) before running
Ineffective adjustments. at the correct speed.)
Faulty AVR

Voltage Adjust AVR stability If not effect, try normal - Check the speed : Possibility of
oscillations potentiometer fast recovery modes (St2) cyclic irregularity
- Loose connections
- Faulty AVR

(*) Warning : During single-phase operation, check that the sensing wires from the AVR are connected to the
correct output terminals.

Check the AVR. The voltage does not return - Exciter winding open circuit
Voltage
surge suppressor, to the rated value. - Faulty exciter armature
disappear
rotating diodes and - Faulty AVR
during
replace any defective - Main field open circuit or
operation
components. short-circuited

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A.C. GENERATORS

5.3 Checking the winding

Assembly A : Connect a 12 V battery in series with
You can check the winding ins insulation by performing rheostat of approximately 50 ohms 300 W and a
high voltage test. In this case. You must disconnect all diode on both field wires (+) and (-).
AVR wires.

WARNING

Damage caused to the AVR in such conditions is not

covered by our warranty.

5.4 Checking the diode bridge

A diode in good working order must allow the current

to flow from the anode to the cathode.
Assembly B : Connect a “Variac” variable power supply
and diode bridge on both exciter field wires (+) and (-).
Both these systems should have characteristics which are
compatible with the machine field excitation power
(see the nameplate).

3) Run the unit at rated speeds.

4) Gradually increase the exciter field current by

adjusting the rheostat or the variac and measure
the output voltages on U,V, W checking the excitation
5.5 Checking the windings and rotating diodes voltage and current at no load and on load (see the
using separate excitation 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).

During this procedure, make sure that the ac generator

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 AVR wires.

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

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A.C. GENERATORS

6- DISMANTLING, REASSEMBLY 6.2. Screw tightening torque

IDENTIFICATION SCREWØ Torque N.m
During the warranty parlod, this operation should
Field term. block screw M4 4N.M
only be esrried out in an approved workshop or in
our factory, otherwise the warranty may be Field screw M6 10N.m
invalidated. Diode bridge screw M6 5N.m
Diode nut M5 4N.m
WARNING Assembly rod M8 20N.m
Earth screw (if installed) M6 5N.m
Whilst being handled, the machine should remain Balancing bolt M5 4N.m
norizontal Discs/shaft screw M10,12,16 66,110,250
Lifting screw M8 4N.m
Grill screw M6 5N.M
Cover screw M6 5N.m

6.3 Accessing, checking and replacing

diodes

6.3.1 Dismantling
- Remove the terminal box cover
- Remove the air intake louver
- Unscrew the fixing clamps on the power output
cables, disconnect E+, E-on the exciter
- Remove the 4 nuts on the studs
- Remove the NDE bracket using an extractor.
- Remove the surge suppressor
- Remove the 4 fixing screws from the diode bridges
on the armature.
- Disconnect the diodes.
- Check the 6 diodes using either an ohmmeter or a
battery lamp
6.1 Tools required
6.3.2 Reassembly
- 1 ratchet spanner + extension - Replace the diodes, respecting the polarity
- 1 torque wrench - Replace the surge suppressor
- Insert a new O ring in the bearing housing.
- 17 mm flat spanner
- Refit the NDE shield and pass the bundle of
-18 mm flat spanner wire between the top bars of the flange.
-110 mm flat spanner - Refit the air intake louvre
- Refit the terminal box cover
-112 mm flat spanner
-18 mm socket
-110 mm socket
-113 mm socket
-15 mm Allen key
-16 mm Allen key
-1 puller

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6.4 Replacing the NDE bearing on a single

bearing machine

6.4.1 Dismantling

6.4.2 Reassembly
the corresponding diameter on the shaft end or an
- Heat the inner slipring of a new bearing by induction support made according the following bellow.
or in a drying oven at800c (do not use an oil bath) and
fit it to the machine. - Rest the rotor on one of its poles, then slide it out,
Use the tube as a lever arm to assist dismantling.
- Place the preloading wavy washer in the flang - After extraction, be careful with the fan. It is necessary
and fit a new O ring seal. to replace the fan in case of disassembling.
- Replace the NDE bracket
NOTE: If intervention is required on the main field
(rewinding, replacement of components), the rotor
6.5 Replacing the DE bearing on a two bearing assembly must be rebalanced.
machine
6.6.2 Reassembly
6.5.1 Dismantling - Follow the dismantling procedure in reverse order.
- Uncouple the alternator from the prime mover. Take care not to knock the windings when refitting
- Remove the 8 assembly screws. the rotor in the stator.
- Remove the DE flange.
- Remove the NDE shield. If you replace the fan, respect the assembly guide
- Remove both bearings using a puller. according the following bellow. Use a tube and a
screw.
6.5.2 Reassembly
- Fit new bearings after heating them by induction
or in a drying oven at 800C (do not use an oil bath).
- Check that both the preloading wavy washer and
new O ring seal have been fitted on the NDE shield
Replace the DE flange, and tighten the fixing screws.
- Check that the whole machine is correctly assembled
and that all screws are fully tightened.
Follow the procedure for reassembling the bearings
6.6 Accessing the main field and stator

6.6.1Dismantling
Follow the procedure for dismantling bearings.
- Remove the coupling dies (Single-breaing machine)
or the DE flange (two-bearing machine) and insert a
tube of After final adjustments, the access panels
or cover should be refitted

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7 - SPARE PARTS

7.1 First maintenance parts

Emergency repair kits are available as an option.

They contain the following items :

Description Qty.

Voltage regulator (R-120) 1

Diode bridge assembly 1

Surge suppressor 1

7.2 Description of bearings LSAP 40/42.2/42.3/43.2/44.2/44.3/46.2

(a) Single bearing (b) Double bearing

Sl. NDE Bearing Sl. NDE Bearing DE Bearing
Frame Qty. Frame Qty.
No. No No. No No
1 LSAP 40 6305 2RS C3 1 1 LSAP 40 6305 2RS C3 6309 2Z C3 2

2 LSAP 42.2 6305 2RS C3 1 2 LSAP 42.3 6306 2RS C3 6310 2Z C3 2

3 LSAP 42.3 6306 2RS C3 1 3 LSAP 44.3 6308 2RS C3 6314 2RS C3 2

4 LSAP 43.2 6307 2RS C3 1 4 LSAP 46.2 6315 2RS C3 6316 2RS C3 2

5 LSAP 44.2 6309 2RS C3 1

6 LSAP 44.3 6308 2RS C3 1

7 LSAP 46.2 6315 2RS C3 1

7.3 Product support

Product support group at our works will be happy

to provide any information required by you.

When ordering spare parts, you should indicate the

complete machine type, its serial number and the
information indicated on the nameplate.

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Service Support
Our network of international service of more than 80 instllations is at
yourdisposal. This local presence guarantees fast, efficient tracking,
support and maintenance services
Trust the power generation experts for the maintenance and support of
your alternator. Our field staff is qualifed and perfectly trained to work
in most environments and on all types of machines.

Our in-depth knowledge of alternator operation ensures optimal service

to reduce your operating costs.
We are able to help you in the following areas

Design
• Tips & Specifications
• Maintenance contracts

Life Exctension Start - Up

• Refurbishment • Commissioning
• Upgrade • Training

Optimization Exploitation
• Surveillance • Original spare
• System audit parts
• Repair
Services

To Contact us:
Americas: +1 (507) 625 4011
Europe & International: +33 238 609 908
Asia-Pacific: +65 6250 8488
China: +86 591 88373036
India: +91 80 6726 4867
Scan the code or go to the page:
service.epg@leroy-somer.com www.lrsm.co/support

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Disposal and recycling instructions All the materials listed above must suitably
We are committed to limiting the processed to separate the waste from the
environm ental impact of our business. recoverable materials and must be entrusted
We constantly monitor our production to the valorization companies.
processes, our raw material supplies and The oil and grease used for bearing
the design of our products to improve the lubrication must be considered as
ability to recycle them and reduce our hazardous waste and treated in accordance
carbon footprint These instructions are with local legislation
provided for information purposes only.
It is the user’s responsibility to comply with
local waste disposal and recycling legislation

Recyclable Materials

Our alternators are mainly composed of

cast iron, steel and copper, which can be
upgraded by recycling. These materials can
be recovered via a set of dismantling,
mechanical separation and melting
processes. Our technical support can give
you detailed instructions on disassembling
products on request

Waste and hazardous materials

The folllowing components and materials

require suitable treatment and must be
removed from the alternator prior to the
recycling process the electronic materials in
the terminal box, including the automatic
voltage regulator (198), the current
transformers (176), the interference
suppression module (199) and the other
semiconductors.
- the diode bridge (343) and the varistor
(347), assembled on the rotor of the
alternator the main plastic components,
such as the structure of the terminal box
on certain products. These components
usually have a symbol indicating the type
of plastic used.

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8. WARRANTY CERTIFICATE

Ref No. Date:

This is to certify that the AC Generator mentioned here under is warranted against inherent manufacturing
defects under normal use and preventive maintenance. The AC Generator its components will be repaired
free of cost if failed due inherent manufacturing defects within a period of 12 calendar months from the
date commissioning or 18 calendar months from the date of dispatch whichever is earlier.

For Nidec Industrial Automation India Private Ltd.

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The period of warranty is for TWELVE calendar months from the date of commissioning or
EIGHTEEN calendar months from the date of dispatch whichever is earlier.

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Nidec Industrial Automation India Private Ltd.

#45, Nagarur, Huskur Road, Off Tumkur Road,
Bengaluru - 562 162, India
T: +91 80 6726 4800 / F: +91 80 23717808
www.leroy-somer.in

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CLIMATE AND ENVIRONMENT

1) Anti-Condensation heaters (SPACE HEATERS)

Space heaters are recommended in areas of high humidity. Condensation will form on all surfaces
which are cooler than ambient temperature. To avoid this, anti-condensation heaters can be fitted
which will ensure the winding temperature remains a few degrees above the ambient temperature
and hence no condensation will form. Note that the anti-condensation heaters should be on only
when the D.G Set is OFF, and they should be switched off while the D.G set is in use.

2) Air Filters

Under site conditions where the air may be heavily laden with fine dust or sand we strongly
recommend the fitting of inlet air filter. The sizing of these is important to avoid airflow
restrictions and advice should be sought from the works.

Recommended deration to be considered for machines fitted with air filters.

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www.leroy-somer.in

twitter.com/Leroy-SomerIndia
linkedin.com/Leroy-SomerIndia

Nidec Industrial Automation Nidec Industrial Automation

India Private Ltd. India Private Ltd.
#45, Nagarur, Huskur Road, # 64/A, Main Road,
Off Tumkur Road, Tarihal Industrial Area,
Bengaluru - 562 162, India Tarihal, Hubli - 580 026. India
T: +91 80 6726 4800 Tel. : 0836-2310408, 2310513/516/517
F: +91 80 2371 7808 Fax : 0836-2310349
www.leroy-somer.in www.leroy-somer.in

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