Machine Sr. No.

Alternators
Installation and Maintenance Instructions
LSC 86-4 POLE
2150KVA - 3125KVA
Double bearing
 CONTENTS
Sl.No. Description Page Sl.No. Description Page No.
1.0 OPERATING & MAINTENANCE No.
INSTRUCTIONS

1.1 Checking for damage 3 1.13 Drying out of machine 6

incurred during transit 1.13.1 Drying our with integral 6
Ventilation system
1.2 Transport and storage 3 1.13.2 Drying out with short 6
circuiting
1.3 Setting up the machine 3
1.14 Automatic Voltage 6
Regulator
1.4 Cooling of Machine
1.4.1 Ambient Temperature 3 2.0 SPARE PARTS LISTS 7
1.4.2 Direction of cooling 3
3.0 TROUBLE SHOOTING CHART 7
1.5 Preparation for starting up 3
4.0 GENERAL 8
1.6 Machine Drive 4
1.6.1 Coupling Drive 4 4.1 Rectifier Diode check 9
1.6.2 Aligning the machine 4 4.2 Winding check 9
4.3 Varsitor check 9
1.7 Electrical Connections 4 4.4 AREP winding check 9
4.5 Recommended metering 9
1.8 Things to Remember instruments for check
4
4.6 Recommended Tools 9
1.9 Starting Up 5 5.0 GA Drawing 10
1.9.1 Insulation Resistance 5
1.9.2 Operating Speed 5

1.10 Operation 5

1.11 Maintenance 5

1.12 Bearings 5
1.12.1 Type of Bearing 5
1.12.2 Regreasable Bearing 6

Description Principle of Operation

“LEROY SOMER” (LSC) brushless alternators When starting, the residual magnetism creates a
are of salient pole, self excited and self current in the Exciter armature . This current is
regulated type. The rotor consists of an exciter rectified by the Rotating diode Assembly and feeds
armature, main rotor and rotating diode the main field .the induced voltage is then used to
assembly. This arrangement eliminates the increase the excitation power via AVR to the
sliprings and brush gear arrangements of exciter field to ensure a fast and smooth build up of
conventional alternators. The alternators are self the out put voltage in the main stator winding .
regulated through an automatic voltage regulator
which in turn controls the excitation of the exciter The sensing voltage for the AVR is taken from U &
field to maintain the desired voltage within the V phase of the output leads.
limits.

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1.0 OPERATING AND MAINTENANCE outlet on the machine and any nearby
INSTRUCTIONS wall must not be less than the dimension
stated below, otherwise ventilation will
1.1 Checking for damage incurred during be obstructed.
transit Minimum distance ( guide value ) : 1 x diameter
of machine

Immediately after receiving the machine,

inspect it for damage incurred during transit. 1.4 Cooling the machine
The transport or delivering company must
be notified of possible complaints 1.4.1 Ambient temperature
immediately.
The machine is normally built to run at a
1.2 Transport and storage
ambient temperature of up to 40°C and an
installation height of up to 1000 meters
During transit and storage, the machine
above mean sea level. For Ambient
must not be supported on the terminal box
temperature higher than 40°C the out put
or air entry hood, or exposed to any
should be derated by the factor given
sources of damages.
below.
Store preferably at a constant temperature
Ambient Temperature Max. available
in a dry, well-ventilated room where the
Power
machine will be protected against sudden
impact of environmental changes.
45°C 96 %
If the alternator is stored for a long period (3 50°C 93 %
months & above) it is necessary to rotate
the rotor at periodic intervals to avoid 1.4.2 Direction of cooling air
solidification of grease and lubrication of
bearing. In case if a machine is stored for a The machine is cooled by a unidirectional
year or more complete regreasing of fan, mounted on the shaft. It draws cooling
bearing is required. air from the non drive end and expels it at
the drive end.
1.3 Setting up the machine
1.5 Preparation for starting up
The installation site must comply with the
machine’s enclosure rating and be Pull the protective lacquer coating off the
sufficiently large for cooling and end of the shaft and the flange, or remove it
maintenance purposes. with solvent. Never clean it off with emery
cloth. Comply with the relevant
When setting up the machine, make sure regulations on environmental protection
that and safety.

• the relevant operation and maintenance

safety regulations are observed.
• cooling air can enter and exit freely.
• exhaust gas and heated cooling air
cannot be drawn in by the machine.
• Feet fixing bolts of the alternator are
tightened .
• Correct Coupling is used.
• Protection covers are properly secured .
and free from any blockage. 3
The distance between the air inlet or
 • Local electricity supplier’s guidelines
1.6 Machine drive regarding protective measures.
• Phase sequence and direction of
1.6.1 Coupling drive rotation of the machine as stated on
rating plate.
All the rotors are dynamically balanced . • Ensure that a suitable electrical
Double bearing alternator is balanced with a protection device is fitted in the output
half key. The coupling must be dynamically circuit.
balance to an accuracy of ≤ G2.5. • Before starting, ensure that all the
terminal nuts are properly tightened and
The sensitive anti-friction bearing requires outgoing cables are properly crimped.
the couplings, belt pulley etc. to be • The control panel protection equipments
tightened by special devices. If this is not are correctly set as per the requirement .
possible, shrink fit the parts suitably so that • There is no short circuit due to wrong
they can be pushed on easily. Ensure that connections either between line-to-line
the drive elements are securely located or line-to-neutral at the alternator
after tightening. They must be securely terminals, or in the power switch .
clamped against their mechanical stops. • Ensure that alternator is properly
earthed.
If the hub of the drive elements is shorter • In such a large machine outgoing
than the shaft end, this difference must be connection with bus bar is
compensated by a space bushing to recommended.Use flexible bus bars at
prevent imbalance and uneven running. joints of bus bar of terminal box and Bus
bar of outgoing connections.
1.6.2 Aligning the machine

Precise, careful alignment of the machine When connecting the cable, make sure that
ensures that it runs with minimum vibration, no mechanical forces acts on the
this extends the service life of the machine machine’s connecting terminals, i.e.
and in particular of the bearings. Only outgoing cables are properly supported.
flexible coupling of low radial rigidity should
be used. If current surges or vibrations are to be
expected, secure the cables with cable clips
Even slight errors of alignment can or racks. If the plant is set up on flexible
rapidly result in damaged bearings. mountings, ensure adequate slack in the
cables.
It is vital that all the feet are fully in contact
with surface . Uneven / under surfaces 1.8 Things to Remember
cause stresses in the bearings and must be
compensated for by attaching sheet metal • Load should be balanced in all the three
shims. Once the machine is aligned phases, current unbalance should not
correctly, secure it properly. be more than 20%, with current not
exceeding the rated current in any of the
phases.
1.7 Electrical connections • Do not operate the machine at less than
The machine must be connected up 0.8 power-factor without deration.
• Isolate AVR during Meggar and High
according to the marking on the bus bar of Voltage tests.
the terminal box diagram. Installation is • Do not start the alternator on load.
permitted by a qualified electrician only.

Comply with the following points:

• Safety regulation of the local safety 4
authorities.
1.9 Starting up Irregular running will lead to deviation from
the nominal ratings.
1.9.1 Insulation resistance The machine voltage is regulated and
maintains a voltage accurate to ± 1.0 % for
After a long period out of use or in storage, the AVR R-449 from no load and full load
the machine’s insulation resistance must be for speed variation of +/- 4%.
measured.
1.10 Operation
Before starting up, measure the insulation
resistance of the winding between phases. During operation, current carrying
All parts not subjected to the measuring conductor and rotating parts must be sealed
voltage must be earthed. with the covers provided for this purpose.

When measuring the insulation resistance, Increased vibration may be observed due to
all connections (main connection, improper alignment, poorly fitted foundation
measuring connection and protection or or frame, or weak mountings. This must be
suppression circuit) must be disconnected corrected for trouble-free operation.
from the winding.
1.11 Maintenance
Measurement must be carried out using
500 V DC. Brushless machines are maintenance-
free apart from their regreasable
Due to the capacitive charge in the winding, bearings and the dust filters, if fitted.
the measurement unit indicates the correct
insulation resistance value only after Before starting work on the machine, make
several seconds have elapsed. Earth the sure that it is switched off and take action to
winding immediately after the measuring prevent it from being switched on again. All
has been switched off. work must be performed by qualified staff
only.
If the insulation values too low, first check
the terminal insulation for dirt and moisture. If there is moisture or dust in the terminal
Clean or dry them as the case may be, and box, it must be removed above all from the
repeat the measurement. Damp windings surface of the insulating parts. The reason
can lead to current leakage, flash-over or for the accumulation of moisture or dust
break down. must then be established and rectified.

If the insulation resistance on new, All windings must be cleaned with dry
cleaned or repaired windings is less compressed air at least once a month to
than that stated below, drying out is prevent accumulation of dust. It is important
needed (see item 1.13 drying out the to check the free flow of cooling air through
machine) the alternator from time to time. Any
blockage should be immediately removed.
4.0 MΩ at a winding temperature of 25°C Diodes should be checked for their
1.5 MΩ at a winding temperature of 80°C healthiness and the excitation current of the
alternator should be regularly monitored, if
1.9.2 Operating speed possible.

The machine’s speed must correspond to 1.12 Bearings

the value stated on its rating plate. The
machine must run smoothly both at no load 1.12.1 Type of Bearing
and when under load. The standard version of the alternator is

5
fitted with deep- groove ball bearings and Initial greasing quantity and regreasing
roller bearing. The Driving end side has a quantity at each lubrication point in grams
floating bearing, the Non driving end side a (guide values only.)
floating bearing and fixed bearing. Size (LSC) 86
The deep-groove ball bearings are axially Initial greasing 350
pre-loaded in relation to each other by Regreasing 70
* Amount of grease required when renewing bearing
spring element; this ensures smoother
Type of anti- friction bearing grease
running and reduces the negative effects of
external sources of vibration on the
On delivery, the bearings are lubricated with
bearings.
high grade, lithium-soap grease of grade 3
consistency such as
1.12.2 Regreasable Bearing
Shell Alvania G3
The alternators of Frame size LSC86are
Castrol AP3
fitted with relubricted devices normally bear
IOC SERVOGEM 3
a plate on which the following information is
stated:
The grease channels between the
• Regreasing intervals in hours of
lubricating nipple and bearing are filled with
operation
above bearing grease before leaving the
• Type or specification of anti-friction
factory.
bearing grease
Before regreasing clean the nipple so
Recommendation
that dirt cannot enter the bearing
Always regrease the bearings with same
selected brand of grease
Using a medium sized manual grease gun
(approx. capacity 500 g).approx. 1 g of
grease can be fed in per stroke at the 1.13 Drying out the Machine
tapered lubrication nipple (AM 8 * 1 DIN If the insulation value is between winding
71427) and the core or between winding is less
than the stated in item 1.9.1, the machine
Where possible, apply grease when the needs drying.
machine is running, unless this represents a
hazard for operating personnel. 1.13.1 Drying out with internal ventilation
system
Regreasing Interval In many cases it can be dried suitably using
its own ventilation system, but it should not
Bearing must be regreased in accordance be live while this is being carried out.On the
with the regreasing interval stated on the Automatic Voltage Regulator (AVR) , the
alternator plate, but at least once in every connection V, W, X1 and Z1 must be
six months. opened.If no improvement in the installation
Relubricating quantity resistance is registered after a running
DE and NDE side bearing must be period of approx., two hours , the alternator
regreased with the amount of grease must be dried out by shorting.
stated.
After about three regreasing operations, 1.13.2 Drying out by short-circuiting
remove expelled grease.
After about five regreasing operations, keep a)Short the main terminals U, V and W via a
applying more grease until fresh grease is current transformer and current meter
visible at outlets. Then run the machine if (for approx. 1.2 X nominal current) while
possible at half speed for one hour and then the machine is at standstill.
at the nominal speed.Check the b)Disconnect terminals E + and E - as well
temperature of the bearings and compare as U and V on the Voltage regulator.
with those temperatures obtained before c)Use12/24 V battery and rheostat to feed
regreasing. in exciter current at terminals E+ and E -
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Important 0.5 A. If circuit breaker is tripped, the
Connect the positive pole to E + and alternator must be de-excited and stopped
the negative pole to E - . immediately.
The AVR should be assembled in such a
d)Run the alternator at its nominal speed way that there is a free flow of cooling air
and adjust the short circuit current at the around it, and the ambient temperature
rheostat to approx. 1.2 X nominal current must not exceed 65°C.
(see name plate). Continue to dry the
machine until its insulation resistance has 1.14.3 Self Excitation
risen to a sufficient level. We recommend
measuring at approx. 2-hour intervals. LSC alternators are provided with 6 Nos.
permanent magnets in the exciter stator for
TYPE OF AVR frame 86 in order to provide sufficient
Types kVA Rating Suitable for residual magnetism and in order to have
R-449 2150-3125 Solo & parellel smooth self excitation. However, problems
with excitation may be caused by
1.14 Automatic Voltage Regulator contaminated de-excitation contacts or a
(AVR R-449) field connection with the wrong polarity.
On alternators that have not been operated
The AVR R-449 or Automatic Voltage
for a long time, it may be necessary to
Regulator is a state- of-the-art advanced
introduce an external excitation voltage.
electronic voltage regulator which ensures
high voltage regulation of ±1%. It has an
excellent dynamic response and the
recovery time is 300 to 500 ms on To do this, briefly connect up a 4.5V or 6 V
application of full load. The AVR is potted battery (at nominal speed) with positive to
so that it can operate even in humid and E+ and negative to E-.
corrosive atmosphere. It provides factory
set under-speed- protection for the
alternator by U/f function. The AVR is
mounted on anti-vibration dampers for long
life. 2.0 Spares parts list
For details of AVR 449 Please refer manual Applicable
3219 GB-4.33/b-07.01 Item Code Description kVA
In case of Grid Parelling use of Module R726 Ratings
if necessary.For details please refer manual Above
2440-4.33/c-2.01 4448788 AVR- R-449
1250
Above
4626113 Varistor
Caution : 2000
Use 932 Taparia make screw driver for Above
4551759 Diode Module 2000
AVR pot adjustments!
Bearing (Regreasable) Above
4441274
16036 2000
1.14.2 External mounting of AVR Bearing (Regreasable) Above
4464634
1036 2000
The following protective measures must be Permanent Magnet for
4471362 All
exciter
taken if the AVR is installed externally in the
switching panel:
The sensing line U, V is to be laid using
short circuit proof cable (1.5 mm2) from the
alternator to the switching panel. we
recommends the installation of a three
phase Miniature Circuit Breaker (MCB) with
a thermal tripping current of approximately
7
3.0 Trouble shooting chart

Fault Action Symptoms Cause

No voltage at no Connect a battery of 4 to The alternator builds up -Lack of residual magnetism
load or start up 12 volts to terminals E+ and voltage is correct
or E- respecting the when the battery is
polarity on the AVR for 2 removed
to 3sec
The alternator builds up -Check the connection of the
but voltage does not sensing leads to the AVR
reach nominal value -Faulty rotating diodes
when the battery is -Short-circuit on rotor windings
removed
The alternator builds up - Faulty AVR
but voltage collapses -Exciter windings shorted or open
when the battery is circuit (check winding)
removed -Main field winding open circuit
(check resistance)
Voltage too low Check the prime mover Correct speed Check AVR connections (possible
speed AVR failure)
-Exciter field short-circuited
-Rotating diode(s) burnt out
-Main field rotor short-circuited -
Check the resistance
Speed too low Increase the speed of prime mover
(Do not touch the AVR voltage pot.
before running at the correct speed)
Voltage too high Adjust potentiometer No adjustment of AVR faulty
voltage voltage
Voltage Adjust the stability If no effect - Check speed for possible cyclic
oscillations potentiometer on AVR irregularity
- Loose connections
- Faulty AVR
- Speed below nominal
on load(or LAM set too high)
Voltage correct Run on no load and Voltage between E+ & - Check speed
on no load too check voltage between E- (DC) SHUNT< 20V
low on load (*) E+ & E-
Voltage between E+ & -Faulty rotating diodes
E- SHUNT>30V -Short circuit in the main field.
Check resistance.
-Faulty exciter armature. Check
resistance.
(*) Warning: During single-phase operation ,check that the sensing wires from the AVR are connected to the
correct output terminals.
Voltage collapses Check the AVR, the The output voltage does -Exciter winding open circuit
during normal surge suppressor, the not return the rated -Faulty exciter armature
operation (*) rotating diodes and value. -Faulty AVR
replace any defective -Main field rotor winding
part open circuit or short circuit
(*) Warning : The AVR internal protection may cut in ( overload lost connection, short circuit)

CAUTION:

If AVR is faulty. Disconnect AVR and connect 12 V DC supply between E+ and E- terminals
(at 2 point terminal block on NDE shield) of exciters stator (with +ve to E+ and -ve to E-), when
machine is running at 1500 rpm on no load. If output voltage is between 400 V to 460 V, it
indicates that AVR is faulty. Replace the AVR.

8
4.0 GENERAL 1500 rpm on no load. If the alternator
4.1 Rectifier Diodes Check terminal voltage is 400 to 460 volts and
AREP winding terminal voltage across X1-
The diodes on the rectifier assembly can be X2 & Z1 –Z2 is 70 to 100 volts; the
checked with a multimeter. The flexible alternator is healthy.
leads connected to each diode should be
disconnected at the terminal end, and the
forward and reverse resistance checked.
On an electronic digital multimeter a healthy 4.5 Recommended Metering Instruments
diode will give a low resistance in one for checks
direction, and a high resistance in the other, • Multimeter 0-500 Vac, 0-100 Vdc, 0-400
but a faulty diode will show high resistance ohms.
in both the direction. Replace the faulty • Digital low resistance micro / milli ohm
diode. meter.
• Clip-on Ammeter 0-500 amps.
4.2 Windings Checks • Frequency meter.
Winding Resistance should be with in ± • Meggar 500 Vdc
10% of given values at 20°C

Code Rating Main Main Ex. Ex. 4.6 Recommended Tools

S : S / Brg kVA Stator Rotor Stator Rotor
(ohm) (ohm) (ohm) (ohm)
• Ring and double end spanner sets.
L86-2150 2150 0.0018 0.40 10.2 0.031
• Allen Key set.
L86-2450 2450 0.0014 0.44 10.2 0.031 • Screw Driver set.
• 932 Taparia make Screw Driver for AVR
L86-2850 2850 0.00114 0.49 10.2 0.031 pot.
L86-3125 3125 0.00104 0.514 10.2 0.031

4.3 Varistor Check

The Varsitor is a metal-oxide surge

suppressor connected across the rectifier
output terminals to prevent high transient
reverse voltage in the field from damaging
the diodes. This device is not polarized and
will show a high resistance reading in both
direction with an electronic digital
multimeter.If defective, this will be visible by
inspection, since it will normally fail to short
circuit and show signs of disintegration
.Replace if faulty

4.4 AREP Winding Check

Check the AREP windings X1-X2 & Z1-Z2

for interruption using an ohm-meter, when
the alternator is in stand still, Rectify the
fault if necessary. Assuming rectifier diodes,
Varsitor ,alternator main stator, main rotor,
exciter stator and exciter rotor , windings
are ok then disconnect AVR and connect
12V DC supply between E+ and E-
terminals of Exciter stator (with +ve to E+ 9
and –ve to E-)when machine is running at
5.0 GA Drawing

Note: GA drawing for 2150KVA will be provided on

request

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