Emerson - Overview - 4-16-15 Final - Vietnam PDF

1
2015 - Celebrating Our 125th Anniversary

We take tremendous pride in our
125-year legacy of being a leader
and an innovator of the important
technologies of our times.
It has been a challenging and
rewarding journeyand it is just
getting started.
DAVID N. FARR
Chairman & CEO
Inspiring and Empowering the Next Generation

of Engineers and Scientists
To commemorate our 125th Anniversary, Emerson has launched initiatives
to raise young peoples awareness of the importance of Science, Technology,
Engineering and Math (STEM) in education, modern life and as career
opportunities for women and men. Visit Emerson.com/ILoveStem.
ILoveSTEM TV advertising and social media

campaign, in partnership with YouTube star and
self-proclaimed science nerd Hank Green, targets
young people through fun, engaging video content.
Emerson Charitable Trust has made a multimillion

dollar commitment through 2020 to support youthfocused STEM and robotics programs sponsored
by selected educational institutions and nonprofits.
Our Brand Promise

Emerson is where technology
and engineering come together
to create solutions for the benefit
of our customers, driven without
compromise for a world in action.
Emerson At-A-Glance
2014 Key Facts
Emerson Global Presence 2014

Eastern Europe & Russia
Western Europe
US & Canada
Sales $11.2 Billion
Employees 32,000
Locations 75
Sales $3.8 Billion

Employees 16,000
Locations 45
Sales $1.0 Billion

Employees 9,000
Locations 15
Asia
Middle East & Africa
Latin America
Sales $1.5 Billion

Employees 1,000
Locations 5
Sales $5.5 Billion

Employees 39,000
Locations 50
Sales $1.5 Billion

Employees 18,000
Locations 30
Our Business Objective

To design, engineer, manufacture, sell and support our
products and solutions in every region of the world
Note: Locations include manufacturing locations only.
6
Through Five Business Platforms,

Emerson Is Delivering on Our Brand Promise
Solving the process

industrys toughest
challenges with
predictable
success any time,
any place
Revolutionizing
manufacturing to
operate faster,
more efficiently and
cost effectively
Optimizing and
deploying critical
infrastructure for
todays mobile,
always-on world
Innovating to help
improve human
comfort, safeguard
food and protect
the environment
Making projects
easier, safer and
more efficient for
professionals,
contractors and
homeowners
Technical Training
Prepared for:
DP Consulting Co. Ltd.
8 May 2015
Leroy Somer Alternator Technical Training

Agenda
0. About Leroy Somer
1. Basic Generator Theory
2. Alternator Excitation Principle
3. Sizing
4. Automatic Voltage Regulator
5. Alternator Protection and Accessories
6. Pre Commissioning Checks
7. Parallel Operation
8. General Maintenance
9. Warranty Coverage
10. Troubleshooting and Repair
10
At a Glance
US $2.2 Billion Annual Turnover

Headquarters in
Angoulme, France
Electrical Power Generation ($1B)

Drives and Motors ($1.2B)
Electrical
Power
Generation
($1B)
40 Leroy-Somer production
sites around the world:
Electric Drive
Systems
($1.2B)
470 Leroy-Somer
service centers
10,000 employees across

50 nationalities around the
around the world
world
11
Electrical Power Generation At a Glance
1 in 4 Alternators is a Leroy-Somer Alternator
10 alternators production
sites around the world:
Europe, North America,
Central & Latin America,
India, China
2 renowned alternator brands
Founded in 1919
Founded in 1926
12
A Comprehensive Alternator Range

0
1000
2500
5000
10,000
20,000
Leroy Somer Range

Partner
Models: LSA40-51.2
Power
Models: LSA50-62
Kato Range
Models: 42.2 63.7
13
A Range for Every Mechanical Need

kVA 50Hz / kW 60 Hz
GASOLINE ENGINES
3000 / 3600 RPM
10
1000
2500
5000
12,000
20,000
LSA36
HIGH SPEED
DIESEL&GAS ENGINES
1200 / 1800 RPM
LSA37
up to
LSA55
MEDIUM SPEED
DIESEL&GAS ENGINES
720 / 1000 RPM
LSA49
LSA58
up to
LOW SPEED
DIESEL&GAS ENGINES
300 / 600 RPM
GAS TURBINES
1500 / 1800 RPM
LSA58
LSA50
up to
WATER TURBINES
300 / 1500 RPM
LSA50
up to
POWER SUPPLY
FOR ELECTRICAL
PROPULSION MARINE
450 / 1800 RPM
LSA53
up to
LSA62
up to
LSA58
LSA62
LSA 36
LSA62
14
World-Wide Manufacturing Capabilities

11 factories across the globe
Hungary
Czech Republic
France
Hungary
USA
Mexico
India
China
Certified:
15
Sales and Technical Support Across Asia

22 sales offices & technical workshops
CN
Both
Sales office
Technical workshop
KR
JP
CN
IN
MM
IN
TH
VN
TH
PH
M
SG
ID
AU
AU
16
Sales and Technical Support Across Asia-Pacific

22 sales offices & technical workshops
Beijing
Cheng Du
Da Lian
Fuzhou
Guangzhou
Shanghai
CN
Busan
Seoul
KR
JP
Bangalore
Hubli
Mumbai
IN
VN
TH
PH
MY
SG
Site consultation
Product training
Project management,
documentation
Osaka
Tokyo
Hanoi
Ho Chi Minh
MN
Bangkok
Sales offices
Both
Sales office
Technical support
Manila
Kuala Lumpur
ID
Jakarta
Technical workshops
Engineering & design support
Cooling
Prelim datasheet
Overall dimensions,
mounting, coupling,
reactances, efficiencies
Technical assistance at site
Training
Preventive / predictive
maintenance
Trouble-shooting, failure
analysis
Repair, spare parts
AU
AU
Brisbane
Darwin
Sydney
Melbourne
Perth
17
A Comprehensive Range of Applications

0
1000
2500
5000
10,000
20,000
Dedicated Range for Various Industries

Emergency / Back-Up
Data Center
Mining
Wind
Hydro
Oil and Gas
Marine
Cogen
Emergency /
Back-Up
Hydro
Data center
Mining
Wind
Oil and gas
Marine
Cogen
18
Value-Adding Alternator Features

Built to International Standards
Quality Assurance for Your Project
Manufacturing Standards
Marine / Shipping Standards
19
Value-Adding Alternator Features

Customization for your project needs
For your various project needs
Single or double bearing arrangement
IP23, 44, 55, water or air heat exchanger
Ball, roller or sleeve bearings
Special mounting arrangement

Auxiliary terminal box, terminal box extension
Counter flange, bell housing adaptor
20
Leroy Somers Partners

Engines experts
21
Leroy Somers Partners

Engines experts
22
Basic Generator Theory

3. Sizing
23

Energy Transformation
Prime Mover (Engine):

CV / HP / kWm
1CV = 0,736 kW
1HP = 0,746 kW (USA)
The Active Power
(KW,speed) Is provided by the Prime
Mover (Engine)
Alternator:
KWe / kVA /
KWe = kWm x
kVA =
kWe kWm
=
PF
PF
The Reactive Power

(KVAR,volts,amps) Is provided by
the Alternator
24

With revolving armature alternators, the field is held stationary
and an AC voltage for external load is generated in the
revolving armature and transmitted by slip rings and brushes
25
STATOR
26
STATOR
ROTOR
27
STATOR
WINDING
ROTOR
WINDING
28
STATOR
WINDING
ROTOR
WINDING
29
STATOR
WINDING
ROTOR
WINDING
DIODES
30
EXCITER
STATOR
WINDING
ROTOR
WINDING
DIODES
31

EXCITER
STATOR
WINDING
ROTOR
WINDING
DIODES
BATTERY
Note : To obtain and maintain a specific AC output voltage,

a variable DC source is required to overcome the variation
of excitation requirement due to various load conditions.
32
EXCITER
STATOR
WINDING
ROTOR
WINDING
DIODES
AVR
33
Alternator Excitation Principle

3. Sizing
34
ALTERNATOR EXCITATION PRINCIPLE
For an alternator to obtain and maintain specific AC output

voltage, a variable DC source is required to overcome the
variation of excitation requirement due to various load
conditions.
Three basic types of excitation systems to provide DC supply
to the field
Shunt
Shunt + PMG
AREP
35
Shunt Excitation Principle
36
Alternator Excitation Principle: SHUNT Principle
STATOR
WINDING
RECTIFIERS
EXCITER FIELD &

EXCITER ARMATURE
ROTOR
WINDING
AVR
DIRECT
CURRENT
ALTERNATING
CURRENT
Energy to power the exciter is taken from the output of the alternator.
Advantages: Automatic start-up
Disadvantages: Low overload capability (Start-up or Short-circuit)
37

CONNECTION DIAGRAM
38

Basic installation with only one load circuit
Installation wherein shutdown is acceptable
For ratings up to 600kVA (LSA37 to LSA47.2)
39
Shunt + PMG Excitation Principle
40
Alternator Excitation Principle SHUNT + PMG
Energy is provided by a Permanent magnet.

Advantages:
The starting capability is enhanced but limited by the PMG.
Automatic start-up
41
CONNECTION DIAGRAM
42

Adaptation to be done with a PMG kit
Replace R250 by R438 or R448 + frame
Modify connections (wiring supplied)
Reconnect Exciter field (series to //)
Fit PMG
PMG adapted to ranges
PMG 1 for LSA 43.2 ,LSA 44.2
PMG 2 for LSA 46.2 AND 47.2,
PMG 3 for LSA 49.1,
PMG 4 for LSA 51.2,
PMG 5 for LSA 50.2

43

P M G - for Partner industrial range
PMG 1 for LSA 43.2 & 44.2
44

P M G - for Partner industrial range
Fitting the PMG kit
290
Housing
291
Adaptation shaft
292
Rotor magnets
293
Stator
297
296
295
294
294
293
Fixing screw
295
Tie rod
296
Washer & nut
297
End plate & screws
292
291
290
45
Used Mainly in Prime Power, Continuous or Marine Applications

PMG Excitation Provides Power Insulation to Voltage Regulator
Better Operation Under Harmonic Loads
Provides Short Circuit Sustaining Capability
(300% Rated Load for 10 Seconds)
Suggested when existing SHUNT machine needs upgrade
46
Auxiliary winding Regulation

Excitation Principle (A.R.E.P)
Excitation Principle
47
Alternator Excitation Principle A.R.E.P.
Two auxiliary windings provide the energy to the AVR:

H1 with a voltage proportional to the output voltage of the Alternator
H3 with a Current proportional to the output current of the Alternator
Advantages:
High starting capability
Automatic start-up
48
2 auxiliary windings:
Leroy-Somers patent since 25 years

Reliable fibre glass coated copper wire
1 coil proportional to stator voltage (shunt characteristic)
1 coil proportional to stator current (booster effect)
Permanent magnets inserts in exciter stator to secure voltage buildup
No additional rotating parts
49
Used Mainly in Prime Power, Continuous or Marine Applications

AREP Excitation Provides Power Insulation to Voltage Regulator
Better Operation Under Harmonic Loads
Provides Short Circuit Sustaining Capability
(300% Rated Load for 10 Seconds)
50
#1 Main Advantage: Short circuit capability

300% In for 10s for selective protection
SHUNT
AREP / PMG
Excitation drops,
short circuit current
shuts down, all
motors stop
Auxiliary winding or
PMG: alternator
sustains the short
circuit till fault
disappears or breaker
trips. Healthy motors
keep running
51

VOLTAGE U (%)
Un
SUSTAINED
VOLTAGE DIP
90%
LOAD In (%)
100%
180%
200% 250%
LOW OVERLOAD
300%
HIGH OVERLOAD - SHORT CIRCUIT
#2 Main Advantage: Short starting capability

Starting capability: 250% In at sustained voltage
1 auxiliary
winding
excitation drops,
motors cannot start
2 auxiliary
winding / PMG
Excitation delivers
enough current at
sustained voltage,
motor can start
52
EXCITATION SYSTEMS
ADVANTAGES
DISADVANTAGES
SHUNT + PMG
AREP
SHUNT
High starting
capacity
High starting
capacity
High starting
capacity ( LS version)
Short-circuit
capability
Short-circuit
capability
Self protected
against short circuit
Intrinsic build-up
No extra length
No extra length
Extra
length
Specific winding
No short- circuit
capability
High number
of components
Small added cost
Low starting
capacity
Added cost
Sensitive to
distorting loads if
thyristor controlled
53

4 winning advantages:
Performances equivalent to PMG

Shorter alternator
All cooling configurations possible
Maximum reliability
54

SHUNT or AREP or PMG ?
SITUATION
OVERLOAD OR SHORT CIRCUIT

ON THE INSTALLATION
AREP OR PMG
AREP PMG
THE ALTERNATOR CONTROLS THE SITUATION

DURING 10 SECONDS
THE DEFFECT IS RELEASED
THE BREAKER TRIPS
- THE POWER SUPPLY IS MAINTAINED
SHUNT
SHUNT
THE ALTERNATOR DOES NOT HOLD

THE SITUATION
DESENERGIZING OF THE ALTERNATOR
- THE POWER SUPPLY IS CUTTEN
55

SHUNT EXCITATION
AREP EXCITATION
PMG EXCITATION
Sensing Voltage
Excitation E+/EAVR Supply
SHUNT
PMG
AREP
56
Sizing
3. Sizing
57
Sizing - Insulation / Life time

According to IEC 60085
Thermal
Class
Temperature
90
C
Insulation qualification is based on

the design and manufacturing
process
105
C
120
C
Insulation gives the maximum

acceptable temperature regarding
the windings insulation system
130
C
155
C
180
C
Insulation class is defined with

specific temperature for a thermal
endurance of 20 000 hours.
58
58
Sizing - Temperature Rise / Insulation

According to IEC 60034-1
The temperature rise defines the
allowed increase of windings
temperature.
The temperature rise depends of :
the power rating
180
160
140
120
100
80
60
the type of windings

the method for measurement (by
resistance or by sensors)
40
20
0
Note: Temperature rise must be added to

the ambient temperature and not
exceeding the insulation class
59
cl. B
cl. F
Insulation
T rise
cl. H
Ambient
59
Sizing - Temperature Rise / Insulation (2)

Example :
Open machine with 40C ambient air
temperature
Open machine with 50C ambient air
temperature
Closed machine, with air-air cooler,
and 50C ambient air
Note: Temperature rise must be added to

the ambient temperature and not
exceeding the insulation class
60
180
160
140
120
100
80
60
40
20
0
cl. B
ODP
40C
Insulation
cl. B cl. B cl. F

ODP CACA CACA
50C 50C 50C
T rise
Ambient
60
Sizing - Ambient Temperature (example)

Site condition is important also to
estimate Life time
C
40
30
20
Possibly the alternator is not

running continuously
10
0
3m
Example emergency gen.set could be

running about 100h/y only
Or ambient temperature may

change also during the year
Example on beside graph
3m
3m
3m
40
30
20
12months continuous running, based on

average ambient graph, is equivalent to
5,5 months running with 40C ambient
Ambient temperature
Ambient
temperature
10
0
5,5 m
61
61
Sizing - Insulation
IEC60085 definition
Defined for 20,000h thermal endurance (L10)
Determines maximum acceptable temperature based on materials &
manufacturing process
During operation, the alternator heats within insulation limits
Temperature rises are calculated with resistance method and give an
average value. A safety factor is needed between calculated temperature
& maximum acceptable temperature
Ambient
Temperature
Insulation
Class B
Class F
Class H
0
40oC
130oC
155oC
180oC
62
Sizing - Temperature Rise vs. Insulation

End-user may want to limit the temperature rise to
Increase alternator life
Create a thermal reserve (for overloads, change in operating
conditions, lack of maintenance)
Ambient
Temperature
Permissible temperature rise
Class F
Insulation
40oC
Safety
Temp Rise F
F/F
Temp Rise B
F/B
Temp Rise H
Class H
Insulation
Thermal
reserve
H/H
Temp Rise F
H/F
Temp Rise B
H/B
120oC 145oC o
165oC o
155 C
180 C
130oC
63
Sizing - Impact on Alternator Life

IEC60085: Alternator life doubles when temperature rise
reduces by 10oC (L10)
Ambient
Temperature
Permissible
temperature rise
Thermal
reserve
Safety
Temp Rise F
F/F
Temp Rise H
H/H
20,000h
~ 2.5 years
same thermal reserve
40 C
Temp Rise B
F/B
Temp Rise F
H/F
Temp Rise B
H/B
o
80,000h
~ 10 years
320,000h
~ 40 years
120 C 145 C
165 C
o
o
o
130 C 155 C
180 C
64
Sizing - Impact on Alternator Life

To optimize the size / weight of the alternator, the right
insulation / temperature rise is key
Example: 1675kVA 690V 60Hz 1800rpm
Ambient
Temperature
Permissible
temperature rise
Thermal
reserve
Safety
H/B
Temp Rise B
F/B
5.6 tons
H/F
Temp Rise F
F/F
Temp Rise H
0
40 C
H/H
o
120 C 145 C
165 C
o
o
o
130 C 155 C
180 C
4.0 tons
3.3 tons
65
Sizing - Index of Protection

Choice of index of protection depends on
environment & air quality
Emersons offers
Open type IP23
Air filter IP44
Air-water heat exchanger IP44,
54, 55, 56
Air-air heat exchanger IP44,
54, 55, 56
Some of these configurations
are available for zone 2
environments
Base NEMA MG1-1 & IEC 60034-5, 200-12
66
Sizing - Cooling System

Choice of cooling system depends on environment,
air quality & cooling media available
IP23, IP44
IP44, 54, 55, 56
IP44, 54, 55, 56
Open configuration
Air - Water cooler
Air - Air cooler
Water
circulation
IC01
Air
outlet
IC8A1W7
Air inlet/outlet filters
Air
inlet
IC6A1A1
Air
outlet
Air
inlet
Warm Air
IC01
Cold Air
IC6A1A6
67
Sizing - Impact on Alternator Size

To optimize the size / weight / protection of the
alternator, the right IP / cooling system is key
IP23
IP44
IP55
Open Type
Water / Mist Separator
Air / Air Heat Exchanger
3.3 tons
4.5 tons
6.6 tons
68
Sizing - Marine Certifications Available
LRS (Lloyd Register of Shipping)
ABS (American Bureau of Shipping)
Class NK
DNV (Det Norske Veritas)
BV (Bureau Veritas)
GL (Germanisher Lloyds)
PRS (Polish register of Shipping
KRS (Korean register of Shipping)
RINA (Registro Italiano Navale)
RS
CCS (China Classification Society)
CGSS (Coast Guard Steam Ship TP 127)
69
Minimum features for typical certification:

Space heater
PMG
Stator RTDs
Specific shaft material
70

Minimum additional tests for certification:
Air-gap test
Overspeed test
Overload test
Steady state short-circuit test
Heat run test on 1st of design
71
Automatic Voltage Regulator

3. Sizing
72
AUTOMATIC VOLTAGE REGULATOR
LEROY SOMER
Excitation
Range
KVA
Shunt
Shunt for //
PMG
AREP
LSA40
10 23
R220
R450
R438
R438
LSA42.3
25 60
R220
R450
R438
R438
LSA43.2/44.2
35 165
R250
R450
R438
R438
LSA44.3
70 - 150
R250
R450
R438
R438
LSA46.2/47.2
180 600
R250
R450
R450
R448
LSA49.1
660 910
R450
R450
LSA50.2
1040 - 1640
R450
R450
LSA51.2
1800 - 2250
R449
R449
73

R220
74
75

R250
76
R250 REPLACED R230

For alternator Model
LSA42.2
LSA43.2
LSA44.2
LSA46.2
LSA47.2
77

R250 REPLACED R230
78

R449, R450 and R438
79

Same electronic structure as the R449
Regulation accuracy : 0.5%
Same dimesion as the R449
Three rotating switch selector for
better ergonomic
80

R450 REPLACED R448
Series of Male and Female Fast-on connector
in order to avoid misconnections and
irreversible damage to the AVR.
R450
Male and Female Fast-on
Use straight connector or replace terminal lugs
R448
All Male Fast-on connector
81

R450 New functionalities & options
R450 replaces R448 and R448 V50
Suitable from LSA46.2 to 50.2
R450
Male and Female Fast-on
Both R450 and R449

Suitable for SHUNT, AREP and PMG
excited alternators
Two Fuses
R449
All Male Fast-on connector
82

Connections are the same
Potentiometer
R449
R450
Voltage
P2
P1
Stability
P3
P2
Ex. Limit
P5
P3
Droop
P1
P4
Droop CT
/1A
/1A or /A5
83

LAM /
Frequency selector
84

1ph / 3ph (R731 module)
sensing selector
85
AREP / PMG
response selector
86
LAM
Load Acceptance Module (LAM)

Genset performance requirements
Purpose of LAM
Electronic feature designed to help the engine in load change situations
(load impact & load rejection) to comply with the rules on voltage and
frequency drop, as well as allow larger load impact on engine
Genset performance is ruled by ISO8528
ISO8528-1 Applications, ratings & performance

ISO8528-2 Engine (similar to ISO3046)
ISO8528-3 AC alternators for generator sets
ISO8528-5 Generating sets
88

Alternator performance requirements
The alternator should comply with ISO8528-3 - table 3
alternator operating limits
Operating limit values
Term
Symbol
Unit
Performance class
G1
G2
G3
G4
Related range of voltage setting
Us
Steady-state voltage deviation
Ust
2.5
AMC*
Transient voltage deviation on load increase
Udy n-
- 30
- 24
- 18
AMC*
Transient voltage deviation on load decrease
Udy n+
35
25
20
AMC*
tu
< 2.5
< 1.5
< 1.5
AMC*
U2,0
Voltage recovery time

Voltage unbalance
AMC*
* AMC = by agreement between manufacturer and customer
The engine should also comply operating limits defined in ISO8528, ISO3046.
89

Genset performance requirements
ISO8528-5 (table 4) limits value for operation of generating
set, depending on engine, alternator & complete
generating set performance
Operating limit values
Term
Transient frequency
deviation from rated
frequency
Transient voltage
deviation
Symbol
Unit
100% sudden power decrease

sudden power increase
100% sudden power decrease
sudden power increase
fdy n
Udy n+
Udy n-
Performance class
G1
G2
G3
+ 18
+ 12
+ 10
- 15
- 10
-7
- 25
- 20
- 15
+ 35
+ 25
+ 20
- 25
- 20
- 15
G4
AMC*
AMC*
* AMC = by agreement between manufacturer and customer
90

In case the engine fails to take the load impact in G2
or G3 time criteria, LAM can help engine recovery
During large load impacts the engine speed drops; recovery takes seconds
When the LAM detects a change in frequency of more than 4%, it reduces
rapidly the voltage by 13%, which reduces load on engine by 25%
This helps engine speed & alternator voltage recover faster
VOLTAGE
SETTING
PERCENT OF SET VOLTAGE
100%
Without LAM
(V/Hz)
0,3 sec. delay
85%
2%
LAM
1%
50%
50%
FREQUENCY
THRESHOLD
SETTING
PERCENT OF
SPEED / FREQUENCY
91

Benefits of LAM
Scenario without LAM
When load impacts, the voltage
drops & recovers very rapidly (AVR
fast response)
Meanwhile, the engine speed will
continue to drop until torque is
sufficient to pick-up the load
The generator may not recover
speed & voltage according to
ISO8528 class G3 criteria
92

Benefits of LAM
Scenario with LAM
When load impacts, the LAM maintains
voltage 13% below nominal value
At lower voltage, the engine load reduces
up to 25%*
This helps engine speed recover
Alternator voltage recovers proportionally
after short time lag
The LAM helps comply with ISO8528 class
G3 voltage dip criteria
* The % of load reduction depends on type of load & base load if
any
93

Benefits of LAM
Comparison without and with LAM
Example: 0 to 70% load impact PF1
Without LAM
Without LAM, alternator response
complies with G3, but not engine
Voltage drop < -18%
With LAM
With LAM, both engine &
alternator comply
Voltage drop < -18%
G3
Frequency drop > -13%
G3
Frequency drop < -9%
G3
G3
Depending on engine inertia reserve, improvement on load impact can be 10% to 15%
94
Alternator Protection and Accessories

3. Sizing
95
Protective Devices and Accessories
96

Anti-Condensation Heater
250W for
ALTERNATOR MODEL
LSA46.2
LSA47.2
LSA49.1
500W for
ALTERNATOR MODEL
LSA50.2
500W for
ALTERNATOR MODEL
LSA50.1
LSA51.2
97

Paralleling / Droop CT
Half Current
Full Current
Quarter Current
98

Paralleling / Droop CT
Half Current
Full Current
Quarter Current
99

PTC Thermistor Positive Temperature Coefficient
A PTC thermistor is a thermally sensitive resistor whose resistance increase
significantly with temperature.
100

Resistance temperature detector
WINDING TEMPERATURE PT100 SENSORS
(Resistance Temperature Detector)
101

Resistance temperature detector
WINDING TEMPERATURE PT100 SENSORS
(Resistance Temperature Detector)
102

Winding Temperature PT110 Sensors
103

Alarm and Trip setting
ALARM
TRIP
Stator Winding B Temp rise
130C
135C
Stator Winding F Temp rise
150C
155C
Stator Winding H Temp rise
175C
180C
Anti Friction Bearing sensor
90C
95C
Sleeve Bearing Sensor
90C
95C
Oil Bearing Sensor
85C
90C
104
Parts, Protective Devices and Accessories

ROTOR EXCITER AND ROTATING DIODE ASSEMBLY
EMI CAPACITOR
105
ROTOR EXCITER AND ROTATING DIODE ASSEMBLY
VOLTAGE BIASING
106

IP
Protection
1st digit - #2 = protected against 12 mm objects

#4 = protected against 1 mm objects
#5 = dust protected
#6 = dust tight
2nd digit
#1 = protected against dripping water

#2 = protected against 15 deg water spray
#3 = protected against 60 deg water spray
#4 = protected against splashing water
#5 = protected against water jets
#6 = protected against powerful water jets
107

Most Common IP
Codes
IP21 (ODP)
IP23
IP43
IP44
IP54
IP55
IP56
Selecting the correct enclosure

Clean and well ventilated machine room
IP 21-23 is perfectly suited
90% of all generators installed are IP21-23
108
109
Air Filter
IP 23 - Optional
INLET
OUTLET
110

Water Separator IP 44
111

Totally Enclosed / With additional cooler - IP54/IP55
Air to Air cooler
Air
outlet
Air
inlet
112

Air ducted IP44S
Air chaud
Warm Air
Air froid
Cold Air
113

114

Air to Water Cooler
Water
circulation
115

116

Ex. based on 1675kVA 690V 1800rpm 60Hz 4P
In class B - Tamb 45C Marine requirement
Config
IP23
Open
IP55
With Air to Air
Cooler
IP44
With Air Filter
+ water mist separator
Model
LSA 52,2 L70
LSA 53,1 M70
LSA 53,1 M60
Dim (mm)
1900*1080*1400
2950*2050*2000
(x4,2)
2600*1500*1400
(x1,9)
Weight
4,0 T
7,6 T (x1,9)
5,5 T (x1,375)
Much Larger & longer
Larger & longer
117
Pre- Commissioning Checks

3. Sizing
118
Pre Commissioning Checks

Electrical Checking before start-up of the Alternator
Measurement of Insulation Resistance:
For Main stator winding disconnect all out going cables,
PT connection, check with only bare terminals
For Main rotor winding, disconnect leads from rotating
diode bridge then conduct measurements.
For Exciter Armature winding, disconnect leads from
rotating diode bridge then conduct measurements.
For Exciter Field, disconnect the two leads from AVR,
then conduct measurements.
119

Measurement of Insulation Resistance
Static Parts
@ C
U / Ground
V / Ground
Voltage
Rotating Parts
1 minute
(M)
@ C
Voltage
Main Rotor / Ground
500V
Exciter Armature /
Ground
500V
500V
500V
W / Ground
500V
U/V
500V
U/W
500V
V/W
500V
Exciter field / Ground
500V
1 minute
(M)
120
Pre Commissioning Checks:

Measurement of winding resistances
@ C
R ()
U1 - U2
V1 - V2
W1 - W2
Main Rotor
Exciter armature
Exciter field 1 2
Exciter field 1 3
Exciter field 2 3
Diodes, Anode-to-Cathode
A good diode
will allow the
current flow
in only one
direction
121
PRE COMMISSIONING CHECKS
Connect AVR as per schematic diagram provided in the

installation & maintenance manual.
Check the correct position of the frequency selection
strap and the voltage reference wires as per
requirement.
122
Pre Commissioning Checks:

Check connection comply with schematic diagram
6 WIRE CONNECTION
12 WIRE CONNECTION
123

A.R.E.P. Connection Diagram
124

Run generator at rated speed.
Do not use the Alternator at a higher power than
indicated on the nameplate.
Ensure safety trips. Over current, Earth fault,
Reverse Power, Differential Protection.
After successful checks Alternator may be run at
full rated RPM at No-Load and record Terminal
Voltage between phase, and between phase & N,
Excitation Voltage and Excitation Current.
Now Alternator is ready to put Run Generator on
load.
125
126
127
Parallel Operation
3. Sizing
128
ISLAND MODE
A generating set (engine+alternator) can be operated alone.
The alternator supply power to the load on which it is connected.
It operates only in voltage regulation mode.
All the power delivered by the gen.set is consummed by the load.
The voltage is controlled and regulated by the alternator regulator.
The alternator operating point is related to the load.
P
129
ISLAND MODE
Load
Gen. 1
kW
The alternator is producing

all the needs for the load.
The load imposes the
active power needed (kW) &
the Power Factor ( (kVAR)
alternator
operating area
kVAR
130
PARALLEL OPERATIONS
What is synchronisation?
In terms of power generation, synchronisation is the
matching of the output voltage waveform of one of the AC
generator with the voltage waveform of another AC
electrical system.
Why???
P
Q
Tension
U0
G1
G2
Charge
Q2 Q1
131
PARALLEL OPERATIONS
Load
Gen. 1
There is no supply from the mains.
Gen. 2
kW
The alternators running in parallel

are producing all the needs for the
load.
The load imposes the :
the active and reactive power
needed
alternator
operating area
kVAR
The reactive power is shared

between the different generating
sets.
132
PARALLEL OPERATIONS
What is synchronisation?
In terms of power generation, synchronisation is the
matching of the output voltage waveform of one of the
AC generator with the voltage waveform of another AC
electrical system.
When two or more systems are required to be paralleled
to feed the same distribution system, the power sources
must be synchronised properly.
Without proper synchronisation of the oncoming system,
power surges and mechanical or electrical stresses will
result when the breaker is closed.
133
PARALLEL OPERATIONS
To synchronised, five conditions must followed

The number of phases in each system
The direction of rotation of these phases
The voltage amplitudes of the two systems
The frequencies of the two systems
The phase angle of the voltage of the two systems
134
PARALLEL OPERATIONS
Number of Phases
The generating set of the oncoming system must have the same
number of phases as those of the system it is to be paralleled.
Confirm sync mode across the breaker during the commissioning
L1
L1
L2
L2
L3
L3
Mains or
Generator
135
PARALLEL OPERATIONS
Same Phase Sequence
3
2
1
2
136
PARALLEL OPERATIONS
Phase Order
Clockwise Rotation
Counter Clockwise Rotation
generator power terminals

U1 - V1 - W1
generator power terminals

U1 - V1 - W1
Network connections
L1 - L2 - L3
Network connections
L3- L2 - L1
U2
V2
W2
U2
V2
W2
U1
V1
W1
U1
V1
W1
L1
L2
L3
L3
L2
L1
137
PARALLEL OPERATIONS
maximum frequency shift : 0,1 Hz.
Frequency
maximum voltage difference : 5%

Voltage
maximum phase offset :10

Phase
138
PARALLEL OPERATIONS
V
Volt Meter
KW
Ampere Meter
Watt Meter
50
Hz
Cos
Frequency Meter
Power Factor Meter
to slow
to fast
Synchronoscope
139
PARALLEL OPERATIONS
Voltage droop compensation
For two alternators (or several) to work in parallel, their voltage
droop must be similar. Droop value is between 0 and 5%: the
value generally applied is 3 %.
It is necessary to provide a droop CT to run the alternator in
parallel.
The droop CT is generally fitted on one phase of the Alternator
bus bar inside the terminal box.
The AVR is considering the CT current and the Alternator voltage
in order to increase or decrease the excitation current according
to the pre-set droop value or power factor.
140
PARALLEL OPERATIONS
Alternator 1
G1
Alternator 2
G2
Advantage =
Independant of alternator ratings
Easy to connect :
No extra wiring
No extra device
Inconvenient =
Voltage Drop :
less than 5% max !
Dynamic response:
depends on each unit time constants
141
PARALLEL OPERATIONS
Voltage
Droop Principle 2
U0
Um
Gen 1
Gen 2
P2
0
P1
100% Load
Situation : 2 generators are running in parallel, with different droop adjustment. When
the 2 units are connected together, the output voltage is equal on both units (= Um).
Graph show operating point is between generator is different.
P1 for Gen1 & P2 for Gen 2
The load is not equal on both units. Gen1 is more loaded than Gen2
It is important to adjust the droop at the same setting in order to get the same load
on both units (green dot lines)
142
PARALLEL OPERATIONS
Therefore for proper operation between alternators it is
absolutely necessary to respect following:
Equalise perfectly the no load voltage of each alternators.
Ensure that each alternator has the same droop adjustment
After closing the breaker, equalise the active power (kW ~ Engine)
of each set according to their rated power.
The reactive power of each set must be roughly the same without
any adjustment of the voltage. Setting of Droop Voltage.
The cos Fi of each set is identical & imposed by the load.
143
PARALLEL OPERATIONS
WARNING
Incorrect synchronisation under the worst conditions can
lead to: Voltage's being twice the rated voltage
One system can place a dead short on the other
High currents placing both systems under stress
Bent shafts and broken coupling discs
Power surges which build on each other until both
systems are disabled
144
PARALLEL OPERATIONS
145
General Maintenance
3. Sizing
146
ALTERNATOR MAINTENANCE
Year
Alt 1-2
Alt 3
Y0
Y1
X
Y2
X
Y3
X
Y4
X
Y5
X
X
Y6
Y7
X
Y8
X
Y9
X
Y10
X
X
Alt 1 - Static electrical checks

Remove the terminal box cover and lateral sides
Remove rotating diodes cover
Controls of rotating diodes and resistances / varistors
Resistance insulation measurement and polarization index of the stator (phase to phase and phase with earth)
Resistance insulation measurement of the rotor and exciter field (stator-rotor)
Inspection of the electrical connections tightening of the rotating rectifier and the terminal box
Visual check of the windings ,look for presence of humidity , heat, or weak insulation (pollution )
Tightening check on auxiliary terminal block of the AVR
Alt 2- Dynamic mechanical maintenance
Start with no load, non excited and measure the bearing vibrations (RMS value)
Switch ON the excitation: record the vibrations and no load excitation current vs output voltage
Temperature recording on the bearing DE, NDE and excitation current measurement, stator voltage (phases
balancing check)
Alt 3- Replacement of bearing
147
Alternator Maintenance:
Current measurement
148
Winding resistance measurement
149
Insulation resistance measurement
150
Temperature Measurement
151
Vibration measurement
152
Performing insulation test
1. Minimum acceptable value of insulation to earth is one Megohm.
2.The AVR MUST be disconnected before meggering the windings.
3. Insulation Resistance to be measured :
Main stator winding to body & between phase
Main rotor winding to body
Exciter stator winding to body
Exciter rotor winding to body
4. Meggering is only necessary if the generator has become wet or has
not been used for a long time.
5. Use a 500V insulation tester.
153
Low insulation resistance
Alternator has not been in use for a long period (few months)
Alternator become wet and dirty (water projection, condensation, fog, dust...
Equipment to use for measuring insulation.
Megohm meter 500Vdc for machine with nominal voltage less than 750volts
Disconnect all electronic devices, such as voltage control units, AVR, diodes etc during test.
Because it could result in permanent damage to electronic components.
Results
Insulation resistance between phases and earth must be minimum one megohm for
Alternators of 415 Volts.
Dont
Do not run the alternator if the minimum insulation level is not reached, dry the windings.
154
Cleaning the windings
The cleaning of the windings become necessary when the
Insulation Resistance is not satisfactory
Coil-cleaning products : Use pure de-greasing and volatile
agents which are well-defined such as : Gasoline (without
additives) Toluene (slightly toxic ) ; inflammable Benzene
or benzine (toxic ; inflammable) Ciclohexaire (non-toxic;
inflammable) Soft water
155
Cleaning the windows
Clean the stator, rotor, excitation windings and diodes
It is essential to avoid entry of cleaning agents into the
slots.
Apply the product with a brush, sponging frequently in
order to avoid accumulation in the housing.
Dry the winding with a dry cloth. Allow the traces to
evaporate before reassembling the machine.
CAUTION: AFTER CLEANING THE ALTERNATOR,
DRYING IS IMPERATIVE TO RECOVER THE BETTER
WINDING INSULATION
156
Procedure to recover good insulation
When to do it
1. Found the winding insulation resistance are low
2. After cleaning the winding of grease and dirt remover
3. Found individual winding resistance values are not within original specification
How to proceed
1. Put alternator into oven (100/110C for 24 hrs) .
2. Blowing hot air into alternator (Run machine and disconnect exciter field)
3. Short circuit stator winding. (See Instruction below)
* AVR disconnected
* Short circuit three phase output (used appropriate cable link)
* Put a clamp ampere meter onto the connection.
* Connect 12Vbattery + rheostat (10ohm, 50W) to exciter field
* Open all ventilating holes
REFER
SCHEMATIC
ON NEXT
SLIDE
* Run alternator to rated speed

* Adjust rheostat to obtain alternator rated current.
157
Drying by short circuit method
SWITCHBOARD
Amp Amp Amp
SHORT CIRCUITED
A.C.
GENERATOR
E
Exciter Field+
E-
RESISTOR
24Vdc BATTERY
WITH POTENTIOMETER
158
Warranty Coverage
3. Sizing
159
WARRANTY COVERAGE
160
SPARE PARTS
161
WARRANTY COVERAGE
Leroy Somer warrants the product to support user
against all operating defects caused by material quality
or manufacturing fault for a period of twelve months.
Warranty is only applicable insofar Products have been
stored, installed, used and maintained in accordance
with Leroy Somer instructions and manuals
The user must adhere to all recommendations as listed
in Leroy Somer Installation and Maintenance manual.
162
WARRANTY COVERAGE
Warranty does not apply when the defect results
from:
In adequate storage and monitoring.
Faulty installation and operation of the Alternator.
Repair or modification of Alternator without prior
authorization from Leroy Somer.
Failure to use genuine spare parts.
Normal wear and tear
163
WARRANTY COVERAGE
164
WARRANTY COVERAGE
STATOR WINDING FAILURE
HIGHLY CORROSIVE ATMOSPHERE-CORE METAL RUSTED
165
WARRANTY COVERAGE
STATOR WINDING FAILURE -WARRANTY NOT COVERED
INSULATION FAILURE CAUSED BY DUST AND MOISTURE
166
WARRANTY COVERAGE
STATOR WINDING FAILURE - WARRANTY NOT COVERED
INSULATION FAILURE CAUSED BY DUST AND MOISTURE
167
WARRANTY COVERAGE
FAILURE DUE TO DUST DEPOSITE WARRANTY NOT COVERED
DUST ACCUMULATION INSIDE TERMINAL BOX
168
WARRANTY COVERAGE
INSULATION FAILURE CAUSED BY MOISTURE
WARRANTY NOT COVERED
EXCITER FAILURE CAUSED BY MOISTURE
169
WARRANTY COVERAGE
INSULATION FAILURE CAUSED BY MOISTURE
EXCITER FAILURE CAUSED BY MOISTURE
170
WARRANTY COVERAGE
CONNECTING LUG BROKEN
BREAKAGE OF CONNECTING LUG DUE TO WRONG TIGHTENING
171
WARRANTY COVERAGE
ALTERNATOR LEADS FAILURE
WRONGLY FITTED CT AT SITE CAUSED DAMAGE TO ALTERNATOR LEADS
172
WARRANTY COVERAGE
ALTERNATOR LEADS FAILURE
WRONGLY FITTED CT AT SITE CAUSED DAMAGE TO ALTERNATOR LEADS
173
WARRANTY COVERAGE
ROTOR CAGE (DAMPER) OVERHEAT
174
WARRANTY COVERAGE
LOOSE CONNECTION
ORIGINALLY LOOSE CONNECTION
175
Troubleshooting and Repair

3. Sizing
176
TROUBLE SHOOTING
AND
REPAIR
177
TROUBLE SHOOTING
TROUBLE : ALTERNATOR DOES NOT BUILD UP VOLTAGE ON
START UP
CHECK AVR CONNECTIONS.REFER TO CONNECTION DIAGRAM.
CHECK FUSE
RUN GENERATOR TO RATED SPEED AND CHECK VOLTAGE
LINE TO LINE FOR RESIDUAL VOLTAGE. (10% Vrated)
IF NO VOLTAGE OUTPUT. FLASH EXCITER FIELD WITH 12VDC
BATTERY. RESPECT POLARITY.
178
TROUBLE SHOOTING
TROUBLE : ALTERNATOR DOES NOT BUILD UP VOLTAGE ON
START UP
MONITOR OUTPUT OF ALTERNATOR UNTIL IT REACH RATED
VOLTAGE BEFORE DISCONNECTING THE BATTERY.
IFVOLTAGE REMAINS AFTER REMOVING THE BATTERY. THE
PROBLEM IS DUE TO LACK OF RESIDUAL MAGNETISM.
(Check excitation voltage and current)
IF VOLTAGE COLLAPSE AFTER REMOVING BATTERY.
DISCONNECT EXCITER FIELD FROM THE AVR AND CONNECT
TO A 12VDC BATTERY.
IF VOLTAGE CORRECT OR REACHED RATED VOLTAGE.
CHECK AUXILIARY WINDING X1X2 AND FUSE OF AVR. IF
BOTH GOOD, REPLACE THE AVR.
179
TROUBLE SHOOTING
TROUBLE : TERMINAL VOLTAGE TOO LOW AT NO-LOAD
CHECK DRIVE SPEED. DO NOT ADJUST VOLTAGE IF DRIVE IS

NOT AT THE CORRECT SPEED.
IF DRIVE SPEED IS OK, ADJUST AVR POTENTIOMETER TO
BRING VOLTAGE TO REQUIRED VALUE. CHECK EXCITATION
VOLTAGE.
IF AVR NOT RESPONDING, REPLACE THE AVR.
180
TROUBLE SHOOTING
TROUBLE : VOLTAGE IS CORRECT AT NO LOAD BUT TOO LOW
WHEN ON LOAD
CHECK ENGINE SPEED

RUN ALTERNATOR AT NO-LOAD AND CHECK EXCITATION
VOLTAGE BETWEEN E+ AND E- ON AVR TERMINALS.
CHECK ROTATING DIODE, EXCITER WINDING AND MAIN
FIELD WINDING IS FAULTY.
REPLACE AVR.
181
TROUBLE SHOOTING
TROUBLE : VOLTAGE COLLAPSE DURING NORMAL OPERATION
VISUALLY CHECK ALTERNATOR FOR ANY SIGN OF
FLASH POINT OR SHORT CIRCUIT.
DISCONNECT AVR AND CONNECT 12VDC TO EXCITER FIELD.
IF REACHED RATED VOLTAGE, CHANGE THE AVR.
IF VOLTAGE LOW, CHECK SURGE SUPPRESSOR AND
ROTATING DIODE. REPLACE WHICH EVER IS FOUND FAULTY.
IF BOTH ARE FOUND GOOD, CHECK EXCITER FIELD AND
MAIN ROTOR WINDING.
182
TROUBLE SHOOTING
TROUBLE : VOLTAGE OSCILLATIONS
CHECK SPEED. POSSIBILITY OF CYCLIC IRREGULARITY OR
TOO LOW WHEN ON LOAD
ADJUST AVR STABILITY POTENTIOMETER.
IF NO EFFECT TRY BY CHANGING NORMAL TO FAST
RECOVERY MODE.
AVR IS FAULTY
183
TROUBLE SHOOTING
TROUBLE : EXCESSIVE HEATING OF ALTERNATOR BODY
BODY TEMPERATURE MORE THAN 40C ABOVE AMBIENT IS
SIGN OF PROBLEM
CHECK ALTERNATOR AIR FLOW INLET-OUTLET ARE NOT
CLOGGED. NEEDS TO BE CLEARED
HOT AIR BEING RECYCLED WITHIN THE CONTAINER.
CHECK EXHAUST
ALTERNATOR IS OVER LOADED. CHECK KVA, KVAR AND
CURRENT ARE WITHIN THE ALTERNATOR RATING.
184
Actions to Prevent Recurrence

Are there other areas or processes where this action can be
implemented?
Implement Permanent Corrective Actions
Quantitatively confirm that the selected corrective actions will resolve
the problem without undesirable side effects
Choose on-going controls to ensure the root cause is eliminated
Once in production, monitor the long-term effects and implement
contingency actions, if necessary
Think prevention instead of detection
Modify the management systems, operating systems, policies,
practices, and procedures to prevent recurrence of this and all similar
problems.
185
186
Case Study
187
Case Study
188
Case Study
189
Case Study
190
Case Study
191
Case Study
192

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1

2015 - Celebrating Our 125th Anniversary

Inspiring and Empowering the Next Generation

ILoveSTEM TV advertising and social media

Emerson Charitable Trust has made a multimillion

Our Brand Promise

Emerson Global Presence 2014

Sales $3.8 Billion

Sales $1.0 Billion

Sales $1.5 Billion

Sales $5.5 Billion

Sales $1.5 Billion

Our Business Objective

Through Five Business Platforms,

Solving the process

Leroy Somer Alternator Technical Training

US $2.2 Billion Annual Turnover

Electrical Power Generation ($1B)

10,000 employees across

around the world

Electrical Power Generation At a Glance

1 in 4 Alternators is a Leroy-Somer Alternator

2 renowned alternator brands

A Comprehensive Alternator Range

Leroy Somer Range

A Range for Every Mechanical Need

World-Wide Manufacturing Capabilities

Sales and Technical Support Across Asia

Sales and Technical Support Across Asia-Pacific

A Comprehensive Range of Applications

Dedicated Range for Various Industries

Oil and gas

Value-Adding Alternator Features

Marine / Shipping Standards

Value-Adding Alternator Features

Special mounting arrangement

Leroy Somers Partners

Leroy Somers Partners

Basic Generator Theory

Basic Generator Theory

Prime Mover (Engine):

The Reactive Power

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Basic Generator Theory

Note : To obtain and maintain a specific AC output voltage,

Basic Generator Theory

Alternator Excitation Principle

ALTERNATOR EXCITATION PRINCIPLE

For an alternator to obtain and maintain specific AC output

ALTERNATOR EXCITATION PRINCIPLE

Shunt Excitation Principle

Alternator Excitation Principle: SHUNT Principle

EXCITER FIELD &

Alternator Excitation Principle: SHUNT Principle

Alternator Excitation Principle: SHUNT Principle

ALTERNATOR EXCITATION PRINCIPLE

Shunt + PMG Excitation Principle