User and maintenance manual for generating sets R340U 33504081101NE_0_1
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. If this product contains a gasoline engine WARNING The engine from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm The state of California requires the above two warnings.
1. Preface ............................................................................................................................................................................................ 3 1.1. General recommendations ................................................................................................................................................. 3 1.2. Pictograms and their meanings ..................................................................................................
6.3. Generator set with KERYS control panel .......................................................................................................................... 53 6.3.1 Presentation of the KERYS............................................................................................................................................... 53 6.3.1.1. Operating conditions ......................................................................................................................................
1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.
1.2. Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of identification by the operator. Replace any notice that is missing or illegible.
WARNING: DANGER This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions and precautions for use. Important: Carefully read the instructions supplied with the generating set before using or servicing the equipment. WARNING: DANGER Risk of electrocution Do not touch the cables or connections when the generating set is in operation. Switch off the generating set for maintenance operations. DANGER Use diesel fuel only.
WARNING: DANGER Hot coolant can cause serious burns. Switch off the engine. Do not remove the filler cap until it is completely cold. Do not open the radiator when it is hot. DANGER Rotating parts can cause serious injury. Do not operate the generating set with the doors open. Do not remove the enclosures. Shut down the generating set before any maintenance or servicing operation. DANGER Avoid any contact with the exhaust pipes, turbochargers and silencers. Keep flammable materials away from hot parts.
WARNING: DANGER A poor earth connection can lead to serious injuries or death. Always connect the earth terminal of the generating set to an external earth terminal. WARNING Voltage selector This function should be used by qualified persons only. WARNING Adjust the output voltage correctly before connecting a load. WARNING The voltage selector must not be used when the generating set is operating. Figure 1.
1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.
Environment The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained in a good state of cleanliness. The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products and dust.
1.3.3 Risks related to toxic products Warning Glycol is a toxic product and dangerous if absorbed. The corrosion inhibitor contains alkali. Avoid all contact with the skin and eyes. Read the Do not swallow it. instructions on the packaging. This substance should not come into contact with the eyes. In the event of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Avoid prolonged or repeated contact with the skin.
1.3.5 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of the countries in question. The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutral system sold. Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the supply use.
1.4. Identifying sets Generating sets and their components are identified by means of identification plates. The precise rules for identifying each major component (engine, alternator etc.) are set out in each manufacturer's documents contained in this manual. Examples of identification plates Generating set Engines Figure 1.
Alternator Cabinet Figure 1.
2. General description 2.1. Description Overview 1 2 3 4 5 6 1 2 3 Control unit External emergency stop Expansion bottle 4 5 6 Protective grilles Chassis Circuit breakers Figure 2.
7 8 7 Battery charge alternator 8 Starter batteries Figure 2.1 (continued): General description of the generating set 9 11 13 10 12 9 10 11 Coolant filter Filling with fuel Oil filters 12 13 14 External fuel supply combined tap (optional) Circuit breaker Interchangeable fuel pre-filters Figure 2.
Sockets ( voltage 208/120V ) 16/285
2.2. Technical specifications RENTAL POWER / R340U Range / Generating set type Weights and Dimensions Dimensions with standard tank Dimensions l x w x h: 4475 mm x 1410 mm x 2690 mm Weight: 3830 kg dry weight 4300 kg in operating configuration Hood: M228C Noise level: 80 dB à 1 m (0.70) 70 dB à 7 m (0.70) Dimensions with high autonomy tank Dimensions l x w x h: 4527 mm x 1410 mm x 2780 mm Weight: 4520 kg dry weight 5888 kg in operating configuration Hood: M228C-DW Noise level: 80 dB à 1 m (0.
Fuel Fuel type Standard fuel tank High autonomy fuel tank Diesel 470 L 1368 L Lubrication Oil capacity with filter Min. Oil pressure Nominal oil pressure Oil consumption (100 % load) Oil sump capacity Type of lubricant 35 L 0.7 bar 6 bar 0,06 L/h 28 L Genlub Cooling Engine capacity with radiator Max coolant temperature Fan power Ventilator air flow Refrigerant type Thermostat 41 L 103 °C 17.8 kW 7.2 m3/s Gencool 82-92°C Alternator data ● Compliant with NEMA MG21 standards, UTE NF C51.
2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section. 2.3.1 Specifications 2.3.1.1.
2.3.1.2. Specifications of coolants Engine Coolants Make John Deere Type All MITSUBISHI All Volvo All Make GenPARTS Mitsubishi GenPARTS GenPARTS Type GENCOOL PC -26°C LLC GENCOOL PC -26°C GENCOOL PC -26°C GenCOOL PC -26 High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers. It is made from antifreeze and G 48 inhibitors. It protects up to -26°C.
RECOMMENDATIONS FOR USE: Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid. UNITS SPECIFIED VALUES TRIAL METHODS kg/m3 1,059 +/- 3 R 15-602-1 pH pH 7.5 to 8.5 NF T 78-103 Alkalinity reserve ml >=10 NF T 78-101 Boiling point °C 105 +/- 2 R 15-602-4 Freezing point: Glassware corrosion : (test with antifreeze) °C -26 +/- 2 NF T 78-102 SPECIFICATIONS Density at 20°C mg/test piece R 15-602-7 - Copper +/- 2.
3.1.2.2. Fork lift truck Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position the forklift arms in these pockets), making sure that only its cross-members are resting on the arms. Lift the equipment, handling it gently. Set down the generating set in its unloading position. Figure 3.1: Transporting a generating set using a forklift truck 3.2.
Figure 3.3: Offset fluid retention container underneath the generating set chassis. Figure 3.4: Offset fluid retention container integrated into the chassis and tank. Generating sets fitted with the offset tank option (DW) above also have a high level indicator in the retention container. In all cases, the retention containers must be regularly checked to ensure they contain no fluid (fuel, oil and coolant, or rainwater or condensation).
3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these gases and the noises emitted should be taken into account.
3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country. b) Power cables These can be unipolar or multipolar according to the power of the generating set.
d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector "factory" set to trigger instantly, with a sensitivity of 30 mA. Important Any modification to this setting could endanger personnel. Any modification would render the user liable, and must only be performed by qualified and authorised personnel.
4. Trailer 4.1. Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly. Warning Trying to tow a trailer with a non-matching device (bar, wires, cords, etc.) could lead to serious accidents. Also check: - no incipient fractures or excessive wear on the hitching system. - locking system is operating properly.
4.3. Operation "On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. So it is absolutely prohibited to exceed this speed. Nor are these trailers fitted with signalling lights. On-road use is prohibited. "On-road" trailer The driving speed must be suited to the condition of the road and the handling of the trailer.
4.5. Implementation for installation Operations to be carried out: Ensure that the ground is strong enough for the assembly not to sink into it. Unhitch the trailer. Immobilise the trailer by placing chocks under the wheels. Fully engage the parking brake (if fitted). Using the front wheel, position the generating set as close to horizontal as possible. Lower the stands (if fitted), and lock them. 4.6. Break transmission adjustment - The handbrake is used only as a parking brake.
Figure 4.3: Braking transmission Figure 4.4: Cross bar fitting Figure 4.
4.7.
4.8. Electrical connection diagram Figure 4.6 : Electrical connection diagram 4.9.
5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents. Danger 5.1. Installation checks Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.
• Coolant level, check Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be ejected. Warning Important The system must be filled up with liquid which has identical proportions to that already contained in the cooling system. Only open the filler cap (1). The coolant level must be between the MIN and MAX marks. Top up the oil if necessary. • Checking the air filter clogging indicator Special air filters must be used for extremely dusty conditions.
6.2. Generator set with TELYS control panel 6.2.1 Control panel presentation 6.2.1.1. View of the front panel 9 1 13 6 7 9 5 12 2 3 9 8 10 11 4 9 Figure 6.4 : View of the front panel 1 2 3 4 5 6 7 8 9 10 11 12 13 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage equipment. Key switch for switching the module on/off. Electronic board protection fuse.
1 2 3 Figure 6.5 : Description of the LEDs A lit LED indicates: 1 Alarm activated (flashing yellow). 2 Fault found (flashing red). 3 Module on (green, on continuously). 1 2 3 Figure 6.6: Close-up of USB ports 1 2 3 USB key connection (HOST): file transfer between USB key and TELYS and vice versa. Connection for microcomputer (DEVICE): file transfer between PC and TELYS and vice versa, main module power supply. Protective cover.
6.2.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones. SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS Figure 6.
6.2.1.3.
6.2.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised.
6.2.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples. Generating set stopped Screen no.
Generating set started Screen no.
Screen no. Pictograms Data displayed Single phase Alternator current indicator Two phase Alternator current indicator P8 Three phase Alternator current indicator Neutral Alternator current indicator Total Active Power Indicator Total Reactive Power Indicator P9 Total Effective Power Indicator Total Power Factor Indicator (lagging or leading) Fuel Level Indicator P10 Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on.
6.2.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows: Initialisation of TELYS Screen no. Screen Data displayed Initialisation of TELYS when the power is switched on and/or when loading a configuration G1 G2 Generating set serial no.
Generating set stopped Screen no.
Generating set started Screen no.
Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand) Screen no. G 12 Screen Data displayed Start Demand AUTO Do you wish to change to Auto Mode? WARNING Immediate start OK Operating mode - operation in Manual Mode AUTOMATIC start demand Esc Generating set stop request due to fault or by pressing STOP in Auto Mode Screen no.
6.2.2 Starting Check that the generating set circuit breaker has triggered.
6.2.3 Switching off Open the circuit breaker manually OR by selecting menu 12 "CONTROL LOAD" The following display will disappear (supply stopped) Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24/08/2005 13:12 Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position). 6.2.4 Alarms and faults 6.2.4.1.
In conjunction with this LED: a flashing pictogram appears on the LCD screen representing the circuit affected by the fault and the associated indicator, if present (example) message on graphic display (example) FAULT FAULT Oil Pressure 25/12/05 15:30 OK=HELP Faults have priority over alarms. Faults are displayed in the descending order of their appearance (from the most recent to the oldest). 6.2.4.2.
6.2.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes: The yellow and red LEDs to flash the related screen to be displayed (example below) FAULTS 1/2 FAULT Emergency Stop 25/12/05 15:30 Esc=RESET If several faults are present, the number of faults is displayed at the top of the screen.
6.2.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable). Terminology used by the SAE CAN J1939 standard SPN: Suspect Parameter Number This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.
In the event of a fault, the screen will display the following message: FAULT ALARM ENGINE GENERAL 110 18 25/12/2005 15:30 OK=HELP Engine fault code. Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the code. The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation.
6.3. Generator set with KERYS control panel 6.3.1 Presentation of the KERYS The MICS Kerys system consists of a set of electronic modules in which each module performs a specific function.. These modules are interconnected according to a very precise architecture and exchange data to allow the following: the command, control, regulation and protection of one or more generating sets according to multiple configurations.
6.3.1.2. Conformity to legal and regulatory requirements The various components of the system comply with the following standards: Requirements specific to programmable controllers: (Functional characteristics, immunity, robustness, safety, etc.) EN 61131-1/2/3 (IEC 1131-2, IEC 664), EN61326, CSA 22-2, UL508. Compliance with European directives (low voltage, electromagnetic compatibility, machinery).
6.3.2 Description of the KERYS 6.3.2.1. Identification of the hardware components KERYS Tactil MMI module MMI Module P/N: 31613391001 D346000/B1 S/N: 1800 BATCH No.
Regulation module Regulation module 31613391501 Module item reference A44Z1: manufacturer product reference A44Z1-G G: “main” module hardware upgrade index 04: week of manufacture (week 4) 08: year of manufacture (year 2008) A: “secondary” module hardware upgrade index 0408A519 519: serial number “related” with a batch number (*) (519 = the 519th module manufactured in week 04 of the year 2008) (*) i.e. a maximum of 999 modules that can be related with a batch number.
Logical inputs and outputs module Logical inputs and outputs module (ESTOR – Binary inputs and outputs) P/N : Module item reference 31613391201 D341000: manufacturer product reference D341000/B1 B1: module hardware upgrade index 0250: serial number “not related” with a batch number S/N: 0250 (0250 = le 250th module manufactured since the start) 06: year of manufacture (year 2006) Batch No.
6.3.2.2. Identification of the software components Only the components base module, MMI module, regulation module and protection module have embedded software. ”Software version” is referred to in order to identify a program implemented in one of the components. V: as software version 1.05 : is the revision, which is a combination of 3 digits c : main revision index 1 : secondary revision index used for specific projects Date of software version in English (year, month, day). V1.
6.3.3 Description of the Man Machine Interface (IHM/MMI) 6.3.3.1. The Man Machine Interface Signalling control keys Operating buttons of the generating set Navigation keys Alphanumeric keypad Backlit display with touch-sensitive keypad Display The display has the following specifications: 7-inch colour TFT display, 16/9, 65536 colours dimensions: 154 mm x 86 mm neon backlighting 480 x 234 resolution touch panel (8 columns x 8 rows). 59/285 M.M.I.
The generating set operational keys 1 3 2 4 15 5 14 13 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 10 9 8 7 6 Manual mode selection. The illuminated led indicates that the mode is active Selecting stop mode. The illuminated led indicates that the mode is active Automatic mode selection. The illuminated led indicates that the mode is active Test in progress LED.
The navigation keys It is also possible to navigate through the menus using the keypad. Return to upper level or escape for the dialogue boxes Move up Move to the right Move to the left Confirm function of selected key Move down It is possible to gain direct access to a menu by pressing the numerical key corresponding to its name. The alphanumeric keys They allow alphanumeric input by successive pressing of the keys. The characters entered appear in the order they were typed on the keypad.
6.3.3.2. Navigation in the screens There are three types: the home screen, the navigation screens, the operation and configuration screens. Home screen This screen is the entry point to the system. It enables the main functions of the navigation to be accessed. 15/10/03 19:10 :00 GS 1 Home Auto Faults -1Operation Alarms -6System -2Fault finding -5Configuration -4Maintenance -3Archiving/Metering Navigation screens These screens enable the various sub-menus to be accessed.
The operating and configuration screens These screens bring up the information and commands relating to the active menu. They are divided into three zones: an upper band common to all types of screens. the central section in which the specific information on the selected menu appears. a lower band.
Controls Access to the “Alarms and Faults” screen Access to the regional parameters screen Access to the “Alarms and Faults” screen Access to the “Drive” or “TOR variables” screen Access to the regional parameters screen 15/07/09 19:10 :00 GS 1 Welcome When configured in power plant with switches, displays a dialogue box enabling you to select the generating set to which you want to be connected Auto 1st action: 2nd action: Faults Alarms access to the home screen return to the menu previously se
Entry of a text Name of the modified function Text to be modified or created Inserts a space to the left of the cursor Title configuration CDE AERO Insert Valid Copy Delete title Paste Delete a character Esc. Deletes the letter shown by the cursor Deletes the entire text Closes the menu without saving the changes Saves the changes and closes the dialogue box You move within the text using the “right” or “left” arrows on the keypad.
Selecting from a list The box heading indicates the parameter which will be assigned from your selection. Arrows for moving the cursor List indicating possible selections Type of fault (6000) Whithout General Alarm Valid Esc.
During saving, the following screen indicates that the operation in is progress: Saving in flash… 6.3.4 Configurations 6.3.4.1. Operating principle The operational modes are as follows: Without coupling to grid Without N/E switch (A612) - Operation of a single genset without coupling. - Normal/emergency switch (NES) not controlled by Kerys. With coupling to grid Temporary coupling (A651) - Automatic operation of a single genset. - Temporary coupling on grid return following interruption.
6.3.4.2. Legends M A Electrically controlled circuit breaker B Exchange of information from A to B and from B to A Transmission of information from A to B only 3 PH 3 PH + N 6.3.4.3. ”Current” information, 3 PH = 3 phases ”Voltage” information, 3 PH + N = 3 Phases + Neutral Configuration in solo generating set Without Normal/Emergency inverter (A612) This configuration is designed to provide: The generation of electricity for an installation from an external starting command (dry contact).
FORCED OPERATION (Kerys in “AUTO” mode) Start of FORCED OPERATION • Generating set start request (dry contact, switch, clock, etc.). • The speed and voltage of the generating set increase. • Generating set power unit switched off after voltage and frequency stabilisation. The installation is supplied by the generating set End of FORCED OPERATION • Dry contact, switch, clock, etc. switched on. • Generating set power unit switched on. • Cooling delay. • Generating set stopped and set to standby.
Automatic operation (Kerys in “AUTO” mode) (temporary “grid return” coupling) Loss of grid voltage • Adjustable grid loss acquisition delay (controlled by the Kerys or by a mains detection module). • Generating set start request. • The speed and voltage of the generating set increase. • Power unit switched on, grid side. • Generating set power unit switched off after voltage and frequency stabilisation.
6.3.4.4. Power plant configuration (Several generating sets in parallel) Without common part and without Normal/Emergency inverter (A632) This configuration is designed to provide: Emergency electricity supply to an installation following a grid loss (The grid loss is not controlled by Kerys). Return to the grid will be achieved by Normal / Emergency switchover by means of a self-driven inverter (not controlled by Kerys). FORCED OPERATION with a generating set.
Principle of coupling in normal operation Coupling in normal operation enables all the generating sets to be coupled (in voltage and frequency) to a busbar supplied by a generating set designed as master at the output. A number (1 to 15) is assigned to each Kerys. This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs. A second number (from 1 to 15) is also assigned to each Kerys and defines the priority.
The second GS thus coupled initiates its power on ramp (adjustable delay) and the distribution of power among the two generating sets takes place. Each generating set will then take 50% of the required power, i.e. 225 kW. When the power required for the application reaches 75% of the power of the two generating sets in operation (GSs at priority 01 and 02), i.e. 900 kW, the third GS (at priority 03) is then started and is synchronised with GS1 and GS2. Its flow is then closed.
FORCED OPERATION Start of FORCED OPERATION • Generating set power units switched off. • Generating set start request. • The generating sets increase in speed. • Speed stabilisation delay. • Order of excitation for each generating set at nominal speed; the voltage is then quickly established on the busbar. • Start of active power distribution. • Resumption of application at rated voltage and frequency.
Principle of coupling when stopped - all the generating set power units are switched off, - starting of all the generating sets, - when the speed reaches 1450 rpm, activated excitation command on all the generating sets, - the voltage generated by each generating set increases gradually and the voltage is therefore the same in all generating sets, - the generating sets therefore reach 1500 rpm at 400 V 50 Hz.
Wattmetric control The wattmetric control is used when two generating sets are coupled. It provides optimum management of the number of generating sets operating by constantly analysing the power required by the user. Let us take the example of a power plant of 4 x 600 kW generating sets.
Wattmetric control This wattmetric control will be activated after a global operation delay. This global operation enables the application to be resumed after power is restored to the different outputs, and ensures stability of the load before the wattmetric control is started. Depending on the power for the application, the number of generating sets in production may vary in order to optimise the production to consumption. The procedure is as follows: • End of the global operation delay.
6.3.5 Connections of the generating sets 6.3.5.1. Recommendations before the connections Disconnect the battery cables before carrying out any work on the generating set. To disconnect the battery disconnect the negative cable (-) first.
6.3.5.3. • Earthing system (Standard only) The ground of the generating set must be connected to earth. To do so, use a copper cable (Green / Yellow), 25 mm² minimum for a bare cable and 16 mm² for an insulated cable, connected to the earth of the generating set, and to a ground rod of galvanised steel pushed vertically into the ground. For a fault voltage of 25 V and a fault current of 30 mA.
Earthing system: TNS Interconnection bar between genset grounds Neutral connected to grounds CIRCUIT DISJONCTEUR Current transformer BREAKER Ground N R S T Ground rod Earthing system: TT Active differential circuit breaker Interconnection bar between genset grounds Neutral CIRCUIT BREAKER DISJONCTEUR Current transformer Ground N R S T Ground rod Type of earthing system: EDF application (On rental generating set only) Active differential circuit breaker Interconnection bar between gen
Power plant Connection of the generating sets to the box Genset 2 Genset x Neutral GSX current transformer link GS2 current transformer link GS1 current transformer link Genset 1 1 current transformer per GS Earth junction box Ground rod Genset 1 Genset 2 One ground rod for one generating set power plant Important 81/285 Genset x
Earthing system: IT Isolated neutral CIRCUIT DISJONCTEUR BREAKER Current transformer Ground R N S T Ground rod Earthing system: TNS Neutral connected to grounds CIRCUIT DISJONCTEUR Current transformer BREAKER Ground R N S T Ground rod Earthing system: TT Neutral CIRCUIT Current transformer Ground DISJONCTEUR BREAKER N R S T If equipped Ground rod Junction box 82/285
7 Xcbc3 Xcbc3 Connection of generating sets to client terminal boards 28 30 32 34 36 38 40 42 44 46 48 29 31 33 35 37 39 41 43 45 47 7 28 30 32 34 36 38 40 42 44 46 48 29 31 33 35 37 39 41 43 45 47 Junction box Remove the shunts at terminals 45-48 and 46-47 Reinsert the shunts of terminals 45 and 46 after having disconnected the current transformer from the junction box. Important 6.3.5.4.
6.3.5.5.
6.3.5.6. Power 1. Pass the power cables through the access hatch to the power box of the generating set (AIPR or console, depending on the generating set). 2. Connect the power cables to the busbars. 3. Connect the power cables to the application. N GENERATING SET R APPLICATION S T N R S T Check that the direction of rotation of the phases between the generating set and the application is the same. Important Type of cables: 6.3.5.7.
6.3.6 Operation and setting menus 6.3.6.1. Layout of the menus The diagram below shows the layout of the main menus. -0Home -1Operation -2Fault finding -3Archiving & Metering -4Maintenance -5Configurations -6System - 1.1 Operation - 2.1 Digital Variables - 3.1 Events archives - 4.1 Provider - 5.1 Equipment - 6.1 Regional parameters - 1.2 Function keys - 2.2 Analog variables - 3.2 Electrical archives - 4.2 Emails - 5.2 Applications - 6.2 Application identification - 1.3 Synchro.
6.3.6.2. Setting of regional parameters Without an input access code this screen allows: input of the display language setting of date and time Navigation reference: 6.1 15/07/09 19 :10 :00 GS 1 Regional parameters Stop Faults Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Alarms Inhibit the keys -1– Identification application -2Software versions -3Printing To clean the touch screen (dust, hydrocarbons, etc.
When an access code of a sufficient level is validated this screen also allows: Setting of the module synchronisation time Selection of the logo displayed on the Kerys home screen. When the time setting by the SNTP protocol is not active the screen looks like this.
In the second case the screen has this appearance. 15/07/09 6.3.6.3. 19 :10 :00 GS 1 Regional parameters Stop Faults Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Inhibit the keys SDMO welcome logo KOHLER welcome logo -1Identification application -2Software versions -3Printing Alarms Information on the KERYS Indication of the application Navigation reference: 6.
Software version Navigation reference: 6.3 The information relating to the software versions installed in the different modules is accessible from this menu. Only the lines corresponding to the installed equipment appear 15/07/09 19 :10 :00 GS 1 Software versions Stop Faults Module Software versions Software version dates IHM 0.00 00/00/00 Base 0.00 00/00/00 Resident logic 0.00 00/00/00 Regulation 0.00 Protection 0.00 Engine 0.
6.3.6.4. Operating menus Operation This main screen displays all the main electrical parameters of the generating set. It is the general operating and monitoring screen for the generating set. This screen can also be displayed by pressing the indicator displaying the operation mode of the generating set. The frequency, U23 voltage, active and reactive power indicators, can be displayed in analog or digital form. Switching from one mode to another is performed by pressing the desired indicator.
Navigation reference: 1.6 15/07/09 19 :10 :00 GS 1 Date Time Status @ Title 26/11/03 11:11:12’55 1 6131 HT LOW COOLANT LEVEL FAULT 26/11/03 10:35:16’28 0 6017 INSULATION 1 ALARM 26/11/03 10:10:10’10 0 60C3 CIRCUIT BREAKER FAULT ON GENERATING SET OUTPUT -1Function keys Active line Alarms & Faults -2Synchro. column Stop Faults Alarms -3Central unit measure. summary Keys for scrolling when the list is longer than the number of lines possible on the screen, i.e.
6.3.7 Rental configurations 6.3.7.1. Choice of application configuration Solo generating set Without inverter (A612) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button on the KERYS. 4. Turn the changeover switch to position 1.
5. Select the configuration of the mains detection of the generating set by clicking directly on the touch screen. For a mains detection by means of the regulation card you must select the configuration “Mains supply detection using the adjustment card” and connect the voltage reference to the terminals Xcbc1 - 1-2-3. For mains detection by an external switch you must select the configuration “Mains supply detection using an external contact” and connect the external switch to the terminals Xcbc3 - 34-35.
Back-up to perform GS 1 Rental application Stop Faults Alarms A612: Single Genset without N/E Mains supply detection using the adjustment card Validation … Saving in flash Mains supply detection using an external contact 7. The KERYS saves your new configuration. 8. After return to the KERYS home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch.
After changeover, the screen below appears. 15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms A651: Temporary power grid single Genset coupling Validation Grid CT ratio 20.0 5. To enter the value of the grid current transformer ratio: press the “GRID CT RATIO” button on the touch screen. Using the alphanumeric keys of the MICS KERYS: enter the value of the CT ratio in tenths. Example: CT = 100A/5A (calculation: 100/5 =20; 20x10=200) value to be entered 200.
15/07/09 19:10 :00 GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A651: Temporary power grid single Genset coupling Validation Grid CT ratio 20.0 7. Press the “Validation” button on the touch screen. 15/07/09 19:10 :00 GS 1 Rental application A651: Temporary power grid single Genset coupling Saving in flash … Validation Grid CT ratio 20.0 8. The KERYS saves your new configuration.
9. After return to the KERYS home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch. Important Power plant Without common part and without inverter (A632-A633) 1. Turn off the battery isolator switch. 2. Check that the emergency stop buttons are activated. 3. Press the “STOP” button on the KERYS. 4. Turn the changeover switch to position 2.
Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 6. Press the generating set number on the touch screen.
Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 9. Press the generating set number on the touch screen.
Back-up to perform GS 1 Rental application Stop Faults Alarms Stop Faults Alarms A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation 12. Press “Validation" on the touch screen. Back-up to perform GS 1 Rental application A633: Power plant without shared switching unit without Normal/Emergency Digital Bus Number of gen sets in power plant 2 Genset number 1 Validation Saving in flash … 13.
14. After returning to the Kerys home screen, The configuration will only be taken into account if the following operations are carried out: Turn on the battery isolator switch. Wait 5 seconds. Turn off the battery isolator switch. Important Operations to be carried out on each generating set of the power plant. Important 6.3.8 Use 6.3.8.1.
15/07/09 19:10 :00 GS 1 Welcome Stop Faults Alarms -0Welcome -1Operation 2. -2Function keys -7User adjustments -3Synchro. column -6Alarms & Faults -4Central unit measure. summary -5Measurements Press “User settings” on the touch screen. 15/07/09 19:10 :00 GS 1 User adjustments -0Operation -1Set point -2Output threshold -3Wattmetric Control -4User parameters (1/2) 3. Press “User parameters (1/2)” on the touch screen.
15/07/09 19:10 :00 Power return Confirmation request User parameters (1/2) GS 1 Stop No load test time delay (sec) : Without Faults Alarms 600 Power 1 Power loss time delay (sec) : 3 Power return time delay (sec) : 180 Inversion in non-coupl. In emergency mode Whithout Inversion in non-coupl. In normal mode Whithout -1Set point 4. -2Wattmetric COntrol -3Generating set priority Press “Generating set priority” on the touch screen.
15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 02 Return to the previous priorities Valid Display GS 1 2 PRI 02 01 -1General parameters 6. -2Thresholds Press the selection arrows on the touch screen to select the priority of the generating set selected. 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Modification GS select.
Back-up to perform Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 Valid 02 Return to the previous priorities Display GS 1 2 PRI 02 01 -1General parameters 8. -2Thresholds Press “Save" on the touch screen. Back-up to perform Generating set priority GS 1 Stop Faults Modification GS select. Priority select 01 Save in flash Valid Valid GS 1 2 PRI 02 01 -1General parameters 9.
Back-up to perform Generating set priority GS 1 Stop Faults Alarms Modification GS select. Priority select 01 02 Return to the previous priorities Valid Saving in flash … Display GS 1 2 PRI 02 01 -1General parameters -2Thresholds 10. The Kerys saves your new configuration. 15/07/09 19:10 :00 Generating set priority GS 1 Stop Faults Alarms Modification GS select.
6.3.8.2. Starting, tests and stop In manual mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset. Refer to the section “Alarms and Faults” in the “Operating menus” to eliminate the faults. If no faults are present, manual mode can be activated by pressing Manu.
The manual start-up phase will begin once key 1 in the test keypad is pressed. The start-up request is maintained until the generating set starts (it is not necessary to keep key 1 pressed). This method may not, under any circumstances, be used to turn the engine over manually. During the start-up phase and until the alternator voltage and speed of the generating set stabilise, the green LED under the generating set symbol flashes and then lights up permanently once the phase is complete.
Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1 I1(A) Operation 2701 Manu F.
At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad. Important Pressing Stop may interrupt the power supply, depending on its status when the key is pressed (e.g. isolated grid operation). The generating set will stop after a cooling delay (180 seconds by default). The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped.
In automatic mode Starting Check there are no faults: grey: no fault. red: fault present. grey: no alarm. orange: alarm present. If faults are present, the fault management screen can be accessed by pressing Reset. Refer to the section “Alarms and Faults” in the Operating menus” to eliminate the faults. If no faults are present, manual mode can be activated by pressing Auto.
The installation is then controlled via the automatic systems in accordance with the configuration of the application: inversion of normal/emergency source grid coupling etc. Tests If no faults are present, automatic mode can be activated by pressing Auto. The test starting phase is then initiated after pressing 1 on the test keypad. Pressing 1 on the test keypad brings up the following window for selecting the test type. 15/07/09 19 : 10 :00 GS 1 I1(A) Operation 2701 Manu F.
After validation of the test, the orange LED on the test keypad lights up steady. During the start-up phase, and until the alternator voltage and generating set speed stabilise, the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase. The installation is then controlled via the programmable controller in accordance with the configuration of the application: normal/emergency source switchover grid coupling etc.
Switching off The generating set may be stopped at any time by pressing 0 on the test keypad. Pressing Stop may cause an interruption in the power supply depending on its status when the button is pressed (e.g. isolated grid operation). The generating set will stop after the cooling delay (180 seconds by default). Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped. 6.3.8.3.
Air preheating (Optional) Turn the switch to “ON” to initiate preheating of the generating set. AIR PREHEATING OFF ON In the case of a power plant, the position of the air preheating switches must NECESSARILY be the same on all the switches of the generating sets in the power plant. Important Bi-frequency (Optional) Turn the switch to the desired frequency and voltage. FREQUENCY 50Hz 400V 50Hz 440V 60Hz 480V Earthing system Turn the switch to the desired earthing system.
7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule.
Every 4 000 hours Belt tensioner Drive belt Coolant (green) 48 At least every (month) 12 24 48 I R R Every 8 000 hours Coolant VCS (yellow) 7.3. At least every (month) 12 24 R Alternator After 20 hours in operation, check the tightness of all the mounting bolts, the general condition of the machine and the various electrical connections of the installation.
8. Battery Fit the battery so that it is properly ventilated. Maintenance should only be carried out by qualified personnel. If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire. Only use insulated tools (the operator should not be wearing a watch, chain or any metal object). Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid. Batteries release oxygen and hydrogen gas, which are flammable.
8.2. Battery setting into service Batteries filled with acid have a density of 1.28 g/ml and are charged. In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the battery rest for 20 minutes. Before fitting the battery, stop the engine and any power consumer, clean the terminals and give them a light coating of grease. When connecting, connect the positive terminal (+) first, and then the negative terminal (-). 8.3.
8.4. Load preconization Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard and insoluble to acid; this deposit reduce the active surface of the plates, and increases their internal resistance) can no longer regenerate or be charged in a generating set. A discharged battery should be recharged immediately, or else it will suffer irreparable damage.
8.5.
9. Appendix 9.1.
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User guide and maintenance manual LEROY SOMER Alternator LSA46.2 L6 - L9 LSA46.
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3856 en - 2011.01 / h 371 364 367 49 48 124 120 122 177 198 41 466 15 n ive be g o t s i ual d user man n This to the e 322 325 320 30 321 1 31 37 347 323 33 34 4 343 100 78 28 LSA 46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES 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 WARNING SYMBOLS Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS CONTENTS 1 - RECEIPT.............................................................................................................................4 1.1 - Standards and safety measures....................................................................................4 1.2 - Inspection......................................................................................................................4 1.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 1 - RECEIPT 1.1 - Standards and safety measures • C : excitation system (C : AREP / J : SHUNT or PMG / E : COMPOUND) • 6/4 : winding number / number of poles. 1.2 - Inspection 1.3.1 - Nameplate So that you can identify your machine quickly and accurately, we suggest you write its specifications on the nameplate below. On receipt of your alternator, check that it has not suffered any damage in transit.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 2 - TECHNICAL CHARACTERISTICS 1.1 - Electrical characteristics The LSA 46.2 alternator is a machine without sliprings or revolving armature brushes, wound as “2/3 pitch”, 6 or 12wire, with class H insulation and a field excitation system available in either SHUNT, AREP or «PMG» version (see diagrams and AVR manuals). 2.1.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3 - INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. 3.1 - Assembly 3.1.2 - Coupling 3.1.2.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 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.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Connection codes Voltage L.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.2 - Terminal connection: 6 wire (not possible with the R 250) Connection codes Voltage L.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.4 - Connection checks 3.4 - Commissioning 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 alternator.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4 - SERVICING - MAINTENANCE 4.1 - Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.5.1 - Checking the winding You can check the winding insulation by performing a high voltage test. In this case, you must disconnect all AVR wires. Assembly A: Connect a 12 V battery in series with a rheostat of approximately 50 ohms - 300 W and a diode on both exciter field wires (5+) and (6-). ASSEMBLY A WARNING Diode 1A Damage caused to the AVR in such conditions is not covered by our warranty.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.6 - Dismantling, reassembly (see sections 5.4.1. & 5.4.2.) WARNING During the warranty period, this operation should only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty may be invalidated. Whilst being handled, the machine should remain horizontal (rotor not locked in position). Check how much the machine weighs (see 4.8.3) before choosing the lifting method. 4.6.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). 4 78 36 Threaded rod Dowel Nut - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). - Tighten the bottom thrust bearing screws (78), remove the threaded rod and fit the other screws. - Tighten the 6 shield screws (31). - Refit the air outlet grille (33). 4.6.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS If using a single-bearing or double-bearing machine with the regreasable bearing option: - Mount the new preloading (wavy) washer (79) + the new “O” ring seal (349) in the shield (36). - Screw a threaded rod into the thrust bearing (78). - Refit the shield (36) on the machine using a dowel and nut in the shaft extension (see diagram).
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.8 - Table of characteristics Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. (400V for the excitation values) 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). 4.8.1 - LSA46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5 - SPARE PARTS 5.1 - First maintenance parts Emergency repair kits are available as an option.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5.4 - Exploded view, parts list and tightening torque 323 37 31 1 322 325 320 15 30 321 466 41 198 177 371 364 33 48 34 49 4 28 347 343 100 78 70 349 79 367 91 124 90 120 36 122 51 365 72 21 71 53 5.4.1 - LSA 46.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 34 37 62 30 33 284 60 22 1 31 466 41 198 177 371 364 68 48 15 49 4 28 343 347 100 70 349 79 367 91 124 90 120 36 122 51 365 71 53 21 5.4.2 - LSA 46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Screw Torque Screw Torque Ref. Qty Description Ø N.m Ø N.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006/42/CE dated 17 May 2006. MOTEURS LEROY-SOMER Boulevard Marcellin Leroy 16015 ANGOULEME France MLS HOLICE STLO.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.
LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME www.leroy-somer.
4067 en - 2009.05 / b STATOR : 12 wires (marking T1 to T12) MAIN FIELD T1 T7 T2 T8 T3 T4 T5 T11 T6 Varistor SHUNT SYSTEM 5+ Induced 6- Field T10 75 mm R 250 P1 Voltage ST4 Stability Option R250 A.V.R. Installation and maintenance 237/285 KNEE 65Hz LAM OFF KNEE 57Hz LAM OFF External potentiometrer for voltage adjusting 9 LAM OFF SPECIAL 8 7 50Hz o 901 6 1 23 P2 KNEE 47.5Hz 78 Slow fuse 250V 8 A 5 4 60Hz LAM OFF 2 3 13% 25% OFF 13% 25% LAM FREQ. & L.A.M.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. This manual concerns the alternator A.V.R. which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your A.V.R., you can look forward to many years of trouble-free operation.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. SUMMARY 1 - SUPPLY...............................................................................................................................4 1.1 - SHUNT excitation system.............................................................................................4 2 - R250 A.V.R..........................................................................................................................5 2.1 - Characteristics...
LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 1 - SUPPLY 1.1 - SHUNT excitation system The regulator controls the excitation current according to the alternator’s output voltage. With a very simple conception, the SHUNT excitation alternator does not have a short circuit capacity. The SHUNT excitation alternator is autoexcited with a R 250 voltage regulator.
Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2 - R250 A.V.R. 2.1 - Characteristics The threshhold position and LAM fonction settings are done with the jumper. - Storage: -55°C; +85°C - Operation: -40°C; +70°C - Voltage regulation: around ± 0,5 %. - Supply range/voltage detection 85 to 139 V (50/60Hz). - Rapid response time (500 ms) for a transient voltage variation amplitude of ± 20 %. - Voltage setting P1. - Stability setting P2.
LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2.3 - R250 A.V.R. option Potentiometer for voltage setting, 1000 W / 0,5 W min: setting range ± 5 %. - Remove the ST4 jumper. It is advised to use the “LAM” at 25% for load impacts > at 70% of the genset rated power. Voltage Voltage UN 0,85 UN For wiring up the external potentiometer; the “earth” wires must be isolated as well as the potentiometer terminals (wires at the same voltage as the power). 2.
Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2.5 - Typical effects of the LAM with a diesel engine or without a LAM (U/F only) 2.5.1 - Voltage Transient voltage drop UN 0,9 (U/f) without LAM with LAM 0,8 1s 0 Time 2s 3s 2.5.2 - Frequency Max speed drop fN with LAM 0,9 without LAM 0,8 1s 0 2s Time 3s 2.5.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3 - INSTALLATION COMMISSIONING 3.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check that the position of the jumper corresponds to the operating frequency. - Check whether the ST4 jumper or the remote adjustment potentiometer have been connected. 3.2.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3.3 - Electrical faults Fault Action Connect a new battery No voltage at of 4 to 12 volts to no load on terminals E- and E+ start-up respecting the polarity for 2 to 3 seconds Voltage too low Effect - Lack of residual magnetism The alternator starts up but its voltage disappears when the battery is removed - Faulty A.V.R. - Exciter field short-circuited - Short-circuit in the main field.
Installation and maintenance LEROY-SOMER R250 A.V.R. 4 - SPARE PARTS 4.1 - Designation Description A.V.R. Type R 250 Code AEM 110 RE 019 4.2 - Technical support service Our technical support service will be pleased to help you with any information needed. For replacement part orders, it is necessary to indicate the type and the code number of the A.V.R. Please contact your usual correspondant. An extensive network of service centres is available to rapidly supply any necessary parts.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R.
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME S.A. au capital de 62 779 000 ¤ www.leroy-somer.
3 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM STAB. I EXC 1 4 2 50Hz 0 90 1 23 6 4 56 VOLT. 7 8 EXT.FREQ. SET. 9 LAM ON LAM OFF KNEE ONLY FOR SPECIAL CONFIG. SERIES 0 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 LEDS FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE Installation and maintenance 5 MODE 2 65Hz LAM OFF 60Hz 1 PHASE SENSING 2 3 STAT. AVRs SERIES 3 7000/8000 2 SERIES 7000/8000 LSA 49.1/50.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs This manual concerns the alternator AVR which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your AVR, you can look forward to many years of trouble-free operation.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs CONTENTS 1 - GENERAL INFORMATION ................................................................................................4 1.1 - Description.................................................................................................................... 4 1.2 - Characteristic................................................................................................................ 4 2 - POWER SUPPLY................
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 1 - GENERAL INFORMATION 1.1 - Description 1.2 - Characteristic The connection is realised by “Faston” connectors and the voltage sensing is single - phase. The R450 AVR is supplied in a casing designed to be mounted on a panel with dampers. - Operating temperature: - 30°C to + 65° C. - Storage temperature: - 55°C to + 85°C. - Shocks on the base: 9 g depending on the 3 axes.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2 - POWER SUPPLY characteristic), the second one has a voltage proportional to the stator current (compound characteristic : Booster effect). The power supply voltage is rectified and filtered before being used by the AVR monitoring transistor. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s. The rotating switch should be in the AREP position (see 3.2.3).
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.2 - PMG excitation system The AVR monitors the alternator output voltage by adjusting the excitation current. The rotating switch should be in the PMG position (see 3.2.3). With PMG excitation, a permanent magnet generator (PMG) added to the alternator supplies the AVR with voltage which is independent of the main alternator winding. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.3 - SHUNT or separate excitation system With SHUNT excitation, the AVR is powered by the main winding (100V to 140V 50/60 Hz ) by using X1, X2 on the AVR. The rotating switch should be in the SHUNT/ AREP position (see 3.2.3).
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3 - TECHNICAL CHARACTERISTICS 3.1 - Electrical characteristics - maximum power supply: 150V - 50/60 Hz - Rated overload current: 10 A - 10 s - Electronic protection: - In the case of a short-circuit, the excitation current is reduced to a value less than 1A after 10 s - In the event of loss of voltage reference, the excitation current is reduced to a value less than 1A after 1s for AREP/SHUNT, 10 s for PMG.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs excitation current must be limited to 9 A ± 0.5 A. WARNING The limitation threshold must be adjustable between 1 and 5.5 A. The genset breaker must be open during the short circuit. If the genset is restarted in short circuit, there is a excitation build up during 10s again at the maximum value. Operation between 3 and 6 In when short-circuited: The excitation current ceiling during a short-circuit equals 2.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs I exc(A) 2.9x I threshold (max. 9.5 A) 9.5 Diagram 2 (Maximum current I exc) P3 I threshold (1...5.5A) Shutdown 0.5 ~ 0.7 t(s) Activation of 90 s. tempo 90 s.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs KNEE 65Hz LAM OFF 78 456 7 6 2 5 3 4 60Hz RAPIDE 3 FAST RAPIDE FAST 2 For Pavers and hydraulic applications, select positions 0 (50 Hz) or 3 (60 Hz). 0 NORMAL NORMAL PMG NORMAL 1 NORMAL 0: AREP excitation and normal time response. 3: AREP excitation and fast time response. 1: PMG excitation and normal time response. 2: PMG excitation and fast time response. For SHUNT applications, AREP excitation must be selected.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.3 - U/F and LAM function 3.3.1 - Frequency variation compared with voltage (without LAM) Bend Voltage 48 Hz 100 % U/UN 57.5 Hz 50 Hz 60 Hz Frequency 50 Hz 60 Hz Hz 3.3.2.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.4.3 - Power • Equalization of voltages before paralleling (3 F). • Possibility of coupling to the mains of alternators already running in parallel (4F). Load on the shaft (kW) LAM 0 - R729 module: same as R726 with additional functions. • Detection of a diode fault. • 4-20 mA input. • Possibility of kVAR regulation. Variation in the load Load shedding due to LAM 1s 2s Time 3s 3.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4-INSTALLATION-COMMISSIONING 4.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check the rotating switches selections - frequency, - type of alternator, - normal position (response time), - external potentiometer, - rated voltage, - secondary current of the CT used, - type of excitation. - R450 optional operating modes 4.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs i) Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage from that observed previously (~ 15%). j) Readjust the speed of the genset to its rated no-load value. Adjustments in parallel operation Before starting work on the alternator, make sure that the speed droop is identical for all engines. k) Preset for parallel operation (with C.T.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs When the excitation current is set to the rated value, a voltage dip is observed in excitation current limit when the limitation is activated and the current limit is reached. 4.2.3 - Special type of use WARNING The excitation circuit F+, F- must not be left open when the machine is running: this will irreparably damage the AVR.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4.
LEROY-SOMER Installation and maintenance R 450 AVRs 5 - SPARE PARTS 5.1 - Designation Description Type Voltage regulator R 450 (AVR) Code AEM 110 RE 031 5.2 - Technical support service Our technical support service will be pleased to provide any additional information you may require. When ordering spare parts, you should indicate the AVR type and code number. Address your enquiry to your usual contact. Our extensive network of service centres can dispatch the necessary parts without delay.
LEROY-SOMER Installation and maintenance 4531 en - 2012.
www.leroy-somer.
Appendix C - Common spare parts R340U Rental Power GENLUB ENGINE VOLVO TAD941GE GENCOOL 9.3.
330560243 X1 330570109 + 330570110 X1 330510015 + 330560617 X1 330560551 X2 330560634 X1 ALTERNATOR LEROY-SOMER LSA462VL12 Note Diode bridge 330410126 X1 Varistor 330410109 X1 For all technical assistance or spare part requests, contact your nearest SDMO agent.
SID PID PPID FMI 28 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- Throttle #2 Position 3 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- 14 Throttle voltage out of range 2 Vehicle invalid or missing 31 Vehicle speed mismatch Vehicle speed 91 91 132 Accelerator pedal position 3 Throttle Voltage high, short to V+ 4 Throttle Voltage low, short to V- 7 Throttle calibration invalid 8
100 102 273 PID PPID FMI 100 Engine oil pressure extremely low 3 Oil pressure sensor input voltage high Short to V+ 4 Oil pressure sensor input voltage low Short to V- 5 Oil pressure sensor open circuit 17 Engine oil pressure low 18 Engine oil pressure moderately low 31 Oil pressure detected, motor stopped 0 Manifold air pressure above normal 1 15 Manifold air pressure below normal Incoherent measurement of the oil pressure Manifold air pressure sensor input Short to V+ voltage hig
274 PID PPID FMI 108 3 4 17 110 110 15 Coolant temperature high least severe 16 Coolant temperature moderately high 17 Water temperature very low 31 Coolant temperature high 111 0 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 0 1 Value above normal Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit Fuel pressure sensor in the common rail Fuel pressure too low 3
172 PID PPID FMI 172 4 5 15 16 174 0 15 16 Fuel temperature moderately high 31 Fuel temperature sensor faulty 4 175 Oil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor 9 189 190 228 Transmission oil temperature invalid Rated engine speed 190 0 Engine speed de rated 31 Engine speed de rated 190 Engine speed s
282 285 PID PPID FMI 3 Overspeed output open/short to B+ 4 Overspeed output short to ground 285 4 323 324 286 Oil pressure output open/short to B+ 4 Oil pressure output short to ground 5 Oil pressure output open circuit 323 Shutdown output status 3 Shutdown output open/short to B+ 4 Shutdown output short to ground 5 Shutdown output open circuit 324 Warning output status 3 Warning output open/short to B+ 4 Warning output short to ground 5 Warning output open circuit 0 15
626 PID PPID FMI 45 3 4 5 627 Perkins SID Volvo CID John Deere SPN Description Comment Start enable device (intake heater and ether) Start enable device output short to B+ Not used, the control panel Start enable device output short to is in charge of managing the ground start enable device Start enable device output open circuit Power supply 1 Injector supply voltage problem 4 For 6125HF070 only 628 240 ECU unswitched power missing For 6068HF275 VP44 only Battery voltage below the oper
639 247 231 PID PPID FMI 2 Bus Off error 9 Passive bus error 11 Data registers read back failure 12 Loss of message error 13 Bus CAN error Comment Engine shutdown vehicle status 11 Engine shutdown vehicle request invalid 31 Engine shutdown vehicle request Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low Error in communication between the ECU and the TGV actuator Error in position of the TGV Temperature of the actuator moderately high.
PID 653 3 3 653 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #3 circuit open 6 Cylinder #3 circuit shorted Cylinder #3 balancing error/mechanical failure Cylinder #3 unknown error/mechanical failure Cylinder #4 injector status 7 11 4 4 654 0 Injector outside the specifications 1 Injector outside the specifi
PID 656 6 6 656 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #6 circuit open 6 Cylinder #6 circuit shorted Cylinder #6 balancing error/mechanical failure Cylinder #6 unknown error/mechanical failure Glow plug relay status 7 11 39 677 678 39 3 Glow plug relay voltage high 5 Glow plug relay voltage low 3 3
PID PPID FMI 1069 Comment 2 Tire size error 9 Tire size invalid 31 Tire size error 5 6 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit Pump coil short to ground 12 Pump defective 1076 Not possible with Genset application Fuel Injection pump status 0 Pump control valve closure too long Injection DE10 1 Pump control valve closure too short Injection DE10 2 Pump detected defect Injection VP44 3 Pump solenoid current high Injection DE10 5
PID PPID FMI Perkins SID Volvo CID John Deere SPN 3 4 1180 0 Turbine temperature extremely high Short to V+ 16 Turbine temperature moderately high Short to V- 173 1239 Exhaust gas temperature sensor Status of the pressure system of the common rail 96 1347 Pump control valve status 3 Pump control valve current high 5 Pump control valve error/mismatch 7 Fuel rail pressure control error 10 Pump control valve fuel flow not detected 1348 Pump control valve #2 status 5 1485 5 Pu
PID PPID FMI 2630 Description Comment Air temperature at the air cooler outlet 0 Air temperature extremely high 3 Sensor input voltage high Short to V+ 4 Sensor input voltage low Short to V- 15 Air temperature high 16 Air temperature moderately high 2659 Flow level of the EGR valve 2 Calculated EGR flow not valid 15 Calculated EGR flow rather high 17 Calculated EGR flow rather low Air temperature at turbo compressor outlet Temperature at compressor outlet moderately high Statuses o
SAE J1939-73 : March 2004 FMI and Description FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition (Region e of the signal range definition) Broadcast of data values is continued as normal.
FMI=11—ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known. Broadcast of data value is substituted with the “error indicator” value. FMI=12—BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used here to mean the packaged unit that includes some microprocessor and its associated components and circuits.
FMI=20-30—RESERVED FOR SAE ASSIGNMENT FMI=31—CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in cases when the reported SPN name spells out the component and a non-standard failure mode. This type of fault may or may be directly associated with the value of general broadcast information.
