5 6 7 8 9 10 11 12 13 14 15 16

17
2

1
18

LSA 52.3 / LSA 53.2 / LSA 54.2

Industrial Range Alternators - 4 pole

Installation and maintenance
 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

TABLE OF CONTENTS

1. GENERAL INFORMATION 4 3.1 TRANSPORT AND STORAGE 10

3.1.1 Transportation 10
1.1 INTRODUCTION 4 3.1.2 Warehouse Storage 10
1.1.0 General information 4 3.1.3 Storage in maritime packaging 10
1.1.1 Safety Notes 4 3.1.4 Unpacking and Installation 10
1.1.2 Conditions of use 4 3.1.5 Roller bearing storage measures 10
1.1.2.1 Generalities 4 3.1.6 Uncovered machinery storage measures 10
1.1.2.2 Vibration analysis 4
3.2 INSTALLATION OF THE MACHINE 11
1.1.2.3 Short-circuit capacity 4
3.2.1 Coupling Assembly (double-bearing
1.1.2.4 Object projection risk 5
machine only) 11
1.2 GENERAL DESCRIPTION 5 3.2.2 Stator attaching 11
1.2.1 Generator (arep) 5
3.3 MACHINE ALIGNMENT 11
1.2.2 Excitation system 5
3.3.1 General information concerning the
alignment 11
2. DESCRIPTION OF SUB-ASSEMBLIES 5 3.3.1.1 General information 11
2.1 - STATOR 5 3.3.1.2 Shaft elevation caused by heat rise 11
2.1.1 Stator of the electric machine 5 3.3.1.3 Elevation of the shaft of a roller bearing
2.1.2 Excitation field winding 6 machine 11
2.1.3 Stator protection 6 3.3.1.4 Inspection of the generator before
2.1.3.1 Heating resistance 6 alignment 11
2.1.3.2 Stator winding temperature sensor 6 3.3.1.5 Alignment procedure with the “double
2.1.3.3 Stator air temperature probe 6 concentricity” method 11
2.1.3.4 Bearing vibration sensor 6 3.3.2 Alignment of a double-flanged bearing
machine 12
2.2 ROTOR 7 3.3.2.1 Machines without axial play (standard) 12
2.2.1 Pole wheel (laminated) 7
2.2.2 Excitation armature 7 3.4 ELECTRICAL CONNECTIONS 13
2.2.3 Fan (machines: IC 0 A1) 7 3.4.0. General information 13
2.2.4 Rotating diode bridge 7 3.4.1 Phase Order 13
2.2.5 Balancing (single fan machine) 7 3.4.1.1 Standard units; IEC 34-8 13
3.4.1.2 Upon request; NEMA 14
2.3 TERMINAL BOX 8 3.4.2 Insulation distances 14
2.3.0 Description (on damper buffers) 8 3.4.3 Added products in the terminal box 14
2.3.1 Automatic voltage regulator (AVR) 8
4. START-UP 15
2.4 NAMEPLATES 8
2.4.1. Main nameplate 8 4.1 ELECTRICAL START-UP INSPECTION 15
2.4.2. Lubrication nameplate 8 4.1.0 General information 15
2.4.3. Rotation direction nameplate 8 4.1.1 Insulation of the winding 15
4.1.2 Electrical connections 15
2.5 ROLLER-BEARING 8 4.1.3 Parallel operation 15
2.5.0 Description of roller-bearings 8 4.1.3.1 Definition of parallel operation 15
2.5.1 Bearing protection devices 8 4.1.3.2 Possibility of parallel operation 15
2.10 AIR FILTERS 9 4.1.3.3 Parallel coupling 15

2.12 TRANSPORT LOCKING SYSTEM 9 4.2 MECHANICAL START-UP INSPECTION 15

2.12.0 General information 9 4.2.0 General information 15
2.12.1 Machines with bearings 9 4.2.0.1 Alignment; attachment; drive motor 15
2.12.1.0 General information 9 4.2.0.2 Cooling 15
2.12.1.1 Double roller bearing machine 9 4.2.0.3 Lubrication 15
2.12.1.2 Single roller bearing machine 9 4.2.1 Starting roller-bearing machines 15
4.2.2 Terminal Box start-up 16
4.2.3 Vibrations 16
3. INSTALLATION 10
4.3 START-UP SEQUENCES 16
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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

4.3.1 Machine stopped checks 16 5.10 COIL CLEANING 27

4.3.2. Machine running checks 16 5.10.0 General information 27
4.3.2.0 Rotor speed ramp-up (Standard Machine) 5.10.1 Coil cleaning products 27
16 5.10.2 Cleaning Operation 27
4.3.2.1 Checks of machine running without
excitation 16
5.11 WINDING DRYING 28
4.3.2.2 Checks of excited machine running with no
5.11.0 General information 28
5.11.1 Drying Method 28
load 16
5.11.1.1 General information 28
4.3.2.3 Generator and site safety parameter 16
5.11.1.2 Drying generator in a stopped position 28
4.3.2.4 Checks of machine running under full load
5.11.1.3 Drying generator in rotation 28
checks 16
4.3.3 Generator start-up checklist 17 5.12 NEW VARNISH APPLICATION 29
5.13 TERMINAL BOX 29
5. MAINTENANCE AND SERVICING 19
5.14 SPARE PARTS 29
5.0 GENERAL INFORMATION 19
5.15 MECHANICAL DEFECTS 30
5.1 PREVENTIVE MAINTENANCE
PROGRAMME 20 5.16 ELECTRICAL FAULTS 31
5.1.0 General information 20
5.1.1 Stator 20 6. TYPICAL ASSEMBLIES AND DRAWINGS
5.1.2 Rotor 20 32
5.1.3 Terminal box 20
5.1.4 Roller bearing 21 6.1 MACHINE SECTION VIEWS 32
5.1.5 Rubber dampers 21 6.1.1 Machine type A52.3 32
5.1.6 Filters 21 6.1.2 Machine type A53; A54 34
5.1.7 Protection devices 21 6.2 ROLLER BEARING MOUNTING 35
5.2 AIR GAP CHECK 22 6.2.1 Machines A52, A53 and A54; standard 35
5.2.1 General information 22
5.2.2 Double-bearing machine 22 7. STANDARD SAFETY REGULATIONS 36
5.3 BEARINGS 22 7.1 EUROPEAN REGULATIONS AND
5.3.1 General information 22 DIRECTIVES 36
5.3.2 Cleaning of old bearing grease 22 7.1.1 Low Voltage Machines 36
5.3.3 Cleaning of the bearing assembly area 23 7.1.2 Medium and High Voltage Machines 37
5.3.4 Bearing disassembly 23 7.1.3 Short circuit capacity of the terminal box 38
5.3.5 Bearing reassembly 23
5.4 LUBRICANTS 24
5.4.1 Greases 24
5.5 AIR FILTER 24
5.5.1 Cleaning 24
5.5.1.1 Air Filter Cleaning Frequency 24
5.5.1.2 Air filter cleaning procedure 24
5.6 SCREW TIGHTENING 24
5.6.0 General information 24
5.6.1 Steel screws in steel tapping 25
5.6.2 Plugs 25
5.6.3 Electrical contact 25
5.6.4 Rotating diodes 25
5.6.5 Synthetic parts 25
5.7 ELECTRICAL MEASURING
INSTRUMENTS 25
5.7.1 Instruments used 25
5.8 INSULATION CHECK OF WINDINGS 25
5.8.0 General information 25
5.8.1 Insulation measurement 26
5.8.2 Polarisation Index 26
5.9 ROTARY DIODE BRIDGE TEST 27
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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

1. GENERAL INFORMATION Any modification of the machine structure must receive

approval from Leroy-Somer.

1.1 INTRODUCTION 1.1.2.2 Vibration analysis

It is the responsibility of the generator set manufacturer to
1.1.0 General information ensure that the different assembled system will be vibratory
compatible in terms of vibration. (ISO 8528-9 and
This manual provides installation, operation and BS5000-3).
maintenance instructions for synchronous machines. It also
describes the basic construction of these machines. This It is the responsibility of the generator set manufacturer to
manual is general; it applies to an entire group of ensure that the shaft line torsional analysis has been done
synchronous generators. Additionally, in order to make and accepted by the different parties (ISO 3046).
information-finding easier, Section 1, "Characteristics and
Performance", has been included, describing the machine
completely (type of construction, type of bearing, IP Code, CAUTION:
etc.); this will enable you to identify directly the chapters EXCEEDING THE LEVEL OF VIBRATIONS ALLOWED
which apply to your machine. BY THE STANDARD ISO 8528-9 & BS5000-3 MAY
This synchronous machine has been designed for a CREATE SERIOUS DAMAGE (BEARING DAMAGE,
maximum length of service. To achieve this, it is necessary STRUCTURAL CRACKS, ETC.).
to pay special attention to the chapter concerning the EXCEEDING THE LEVEL OF TORSIONAL VIBRATION
periodic maintenance schedule for the machines. OF THE SHAFT LINE (e.g.ABS, LLOYD, ETC.) MAY
CAUSE SERIOUS DAMAGE (CRANKSHAFT FAILURE,
1.1.1 Safety Notes GENERATOR SHAFT FAILURE, ETC.).
The warnings "DANGER, CAUTION, NOTE" are used to
Refer to chapter 2.1.3.4 for further information about the
draw the user’s attention to different points:
accepted vibration level of the standard ISO 8528-9 and
BS5000-3, consult chapter 2.1.3.4.
DANGER:
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE PERSONAL 1.1.2.3 Short-circuit capacity
INJURY OR LOSS OF LIFE. In the event of a fault, the terminal box is designed to
support the maximum current level generated by the
CAUTION: alternator.
THIS WARNING IS USED WHEN AN OPERATION, If the current is higher than these levels, as may be the
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR case with a fault coming from the electricity grid, the
DESTRUCTION OF EQUIPMENT. protection of the alternator must be ensured by the
protective device of the installation.
NOTE:
CAUTION:
This warning is used when a delicate operation,
procedure, or installation requires clarification. THE ALTERNATOR IS A SUB-ASSEMBLY SUPPLIED
WITHOUT A SHORT-CIRCUIT PROTECTION DEVICE.
1.1.2 Conditions of use
1.1.2.1 Generalities
A machine must only be installed and operated, by
qualified and trained persons.
Any technician using or maintaining this machine must be
authorised to do so by the local labour laws (e.g. holder of
a certification for working on high voltage systems).
Operation which require handling must be done by
qualified persons (Slinging techniques; use of lifting
devices, etc.). Local procedures must be strictly complied
with Any product (sealing paste, cleaning product, etc.)
used during maintenance or servicing must comply with
local regulations and environmental standards.
The disposal of waste coming from servicing the machine
must be managed in compliance with the local regulations
and environmental standards in force.
The main characteristics of this machine are summarized
in "Section 1" of this manual.

Any operating condition other than those specified by the

original tender must receive a Leroy-Somer agreement.
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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

1.1.2.4 Object projection risk The pole wheel (rotating part; item 4) excites the alternator
armature (static part; item 5) which generates a three-
DANGER: phase current.
IN THE EVENT OF A MAJOR ACCIDENT, DEBRIS CAN
BE EJECTED FROM THE MACHINE THROUGH THE 6
AIR INLET OR OUTLET OPENINGS. THESE DEBRIS
CAN CAUSE A FATAL ACCIDENT. DO NOT ENTER
HAZARDOUS AREAS DURING MACHINE OPERATION.
H1 H3
5 1
NOTE: 3
This risk must be considered in the risk analysis of the 4 2
site concerned.

1- Excitation field winding

2- Excitation armature
3- Rotating diodes bridge
4- Revolving field
5- Alternator armature
6- Automatic Voltage Regulator
H1- AREP winding harmonic detection 1
H3- AREP winding harmonic detection 3

1.2.2 Excitation system

The excitation system is mounted at the rear of the
machine.

2. DESCRIPTION OF SUB-ASSEMBLIES

2.1 - STATOR

2.1.1 Stator of the electric machine

The alternator stator is a stack of low loss steel magnetic
laminations assembled under pressure. The stator coils are
inserted and blocked in the slots, then impregnated with
varnish and polymerised (VPI system).
(b) (a)
3

2 4

1.2 GENERAL DESCRIPTION (c)

5
1.2.1 Generator (arep)
1
The synchronous generator is an alternating-current
machine, without ring or brush. The machine is cooled by 1 - Stator
the flow of air through the machine. 2 - Rotor
Use the drawings of chapter 10 in order to better 3 - Exciter
understand the machine. 4 - Rotating diodes
The Automatic Voltage Regulator (item 6) supplies the 5 - Fan
inductor exciter field (static part; item 1) with DC current. a - Stator Air inlet (cold air)
The Exciter (item "1" & "2”) works as an inverse alternator.
The Exciter armature (rotating part; item 2) generates a
three-phase current which supplies the rotating diode
bridge (rotating part; item 3).
The Rotating diode bridge (rotating part; item 3) rectifies
the three-phase current into DC current which supplies the
Pole wheel (rotating part; item 4).
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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

b - Stator air exhaust (warmed air) NOTE:

c – Rotating diodes air cooling If quickly restarting after a shut-down, inhibit the stator air
sensor safety "alarm" for a few seconds (no more than 30
2.1.2 Excitation field winding s) during the machine start up.
The excitation field winding comprises a wound solid NOTE:
element. For a water cooled machine (CACW) the nominal air
The excitation is equipped with a flange at the rear bearing entering the stator may be approximated as following:
of the machine. Tair entering stator = Twater entering cooler + 15°K.
2.1.3.4 Bearing vibration sensor
2.1.3 Stator protection This chapter concerns the adjustment of seismic sensors.
2.1.3.1 Heating resistance For more information on adjusting proximity sensors, see
Chapter 2.2.6.1.
The heating element avoids internal condensation during
The level of vibration of the machines depends directly on
the shutdown periods. It is connected to the terminals of
the use made of them and on the characteristics of the site.
the main terminal box. The resistance heater is switched
on as soon as the machine is shut down. We propose the following adjustment:
The electrical characteristics are provided in Section 1 Vibration Alarm (*) = Site Highest Vibration level + 50%
"Technical Characteristics". Vibration Trip = Vibration Alarm + 50%
(*) do not exceed the values of the following chart.
2.1.3.2 Stator winding temperature sensor The machines are engineered to be able to withstand the
The temperature sensors are located in the zone assumed vibration level specified by the standard ISO8528-9 and
to be the hottest part of the machine. The sensors are BS5000-3.
connected to a terminal box. Maximum levels for: Internal combustion engines
Depending on the insulation class of the machine, the alternating current motors
temperature of the sensors must not exceed a maximum
of: Nominal speed kVA Generator vibration level
(rpm) (nominal conditions)
Overall Any harmonics
INSULATION CLASS ALARM TRIPPING (mm/s rms)
H (2–1000 Hz)
180 °C 185 °C
1300 to 2199 > 250 < 20
To improve the protection of the machine, we recommend 721 to 1299 ≥ 250 < 20 < 0.5 mm; pp
setting the alarm set-point according to the actual (5 – 8 Hz)
> < 18
conditions of the site obtained after a representative 1250
operating time: < 9 mm/s; rm
Alarm temperature (*) = Highest recorded temp + 10°K ≤ 720 > < 15 (8 – 200 Hz)
Trip temperature (*) = Alarm temperature + 5 °K 1250
(*) do not exceed the values of the previous table. < 10 (*)
(*) Max. recommended temp: Maximum temperature
measured at the stator after a representative operating (*) generator on concrete base
time under severe operating conditions.
E.g. a class H insulation machine of 3000 kVA reached a Maximum levels for: Turbines
maximum of 110°C at the stator after a representative time Turbines Max. recommended value:
of operation at the site. Set the alarm temperature to 120°C (hydraulics; gas; steam) 4.5
instead of 180°C indicated in the previous chart. Set the (global; mm/s (rms)
trip setting to 125°C instead of the 185°C shown in the
previous table.
2.1.3.3 Stator air temperature probe
As an option an RTD or thermostat can measure the stator
air inlet temperature (cold air).
Stator air inlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 5 K
• shutdown 80°C
Stator air outlet temperature; Alarm points and shutdown:
• alarm Nominal air inlet stator + 35K
• shutdown Nominal air inlet stator + 40K
NOTE:
For an open machine the nominal air temperature entering
the stator corresponds to the ambient temperature.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

2.2 ROTOR attached to the hub by screws. Ventilation is obtained by

means of inclined blades. The air is exhausted by
2.2.1 Pole wheel (laminated) centrifugation. The air inlet and outlet must remain free
during operation.
The pole wheel is produced by stacking cut laminations to
reproduce the profile of the pole (item 1).
2.2.4 Rotating diode bridge
Stacking of steel laminations is completed at each end by
high electrical conductivity laminations (item 2). The rectifier bridge, comprising six diodes, is placed at the
rear of the machine. The rotating bridge is made of
In order to allow the alternators to run in parallel, and so as
fibreglass with a printed circuit to connect the diodes
to ensure stability, bars with high electrical conductivity are
together. This bridge is supplied with alternating current by
inserted in holes passing through the poles from one end to
the excitation armature and supplies direct current to the
the other. These bars are welded together with the end
pole wheel. The diodes are protected against over voltage
plates so as to obtain a complete cage (or LEBLANC
by rotating resistors, or by varistors. These resistors (or
damper cage).
varistors) are mounted in parallel with the pole wheel.
The winding (item 4) is wound on the pole and then
impregnated. 2
The winding is made of insulated copper wire of
rectangular cross-section and high electrical conductivity. 1 + 3
Aluminium plates (item 5) are pressed against the winding
acting as dissipating radiators and ensuring excellent
wedging of the coils.
Retaining bars (item 6) on each pole protect the heads of
the coils from centrifugal forces.
-
The wound pole wheel is heated and shrink fitted onto the
shaft. 1 - Field
2 - Rotating resistors / varistors
2 1 2 6 3 - Exciter armature

5
The 2 radiators of the diode bridge are connected to the
pole wheel.

Radiator 1

3
2 Radiator 2

2.2.2 Excitation armature

1 - Radiator 1
The excitation armature is made by stacking magnetic steel 2 - Radiator 2
laminations. These steel laminations are held in place by
The diode fastening screws must be tightened to the
rivets.
correct torque.
The excitation armature is keyed and heat-shrunk onto the
shaft.
CAUTION:
The windings are enamelled copper wires, class "F" THE ROTATING DIODE FASTENING SCREWS MUST
insulation (or "H", depending on the customer's request or
BE TIGHTENED USING A TORQUE WRENCH
size of the machine).
CALIBRATED TO THE RECOMMENDED TORQUE.
2.2.3 Fan (machines: IC 0 A1)
2.2.5 Balancing (single fan machine)
The synchronous machine is characterized by a self-
ventilation system. A centrifugal fan is mounted between The complete rotor was balanced as per the ISO8221
the revolving field coil and the front bearing. standard to achieve a residual imbalance of less than:
Air intake is at the rear of the machine and the exhaust at
the front.
The fan consists of a hub, which is keyed and heat-shrunk
onto the shaft. The fan is made of welded steel sheet,
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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

Generator set: Class G2.5 2.4 NAMEPLATES

Turbine: Class G1
The shaft end is cold-stamped to indicate the type of 2.4.1. Main nameplate
balancing (as per ISO8221) The main nameplate is fitted to the stator. It gives the
H: balancing with Half-key carried out as manufacturer's electrical characteristics, the type of
standard machine and its serial number. The serial number is
F: balancing with Full key (upon request) necessary for any contact with the factory.
N: balancing without key (upon request)
For machines with anti-friction bearings lubrication
The balancing is carried out in two planes. parameters are indicated.
The first is on the fan. It is recommended, when the fan is
refitted (after servicing) to follow the initial indexing.
2.4.2. Lubrication nameplate
The second is at the rear of the machine.
The machines with anti-friction bearings have the
The coupling must be balanced to adapt to the generator
lubrication parameters indicated on the main nameplate
rotor balancing.
fixed on the stator, indicating:
• Type of bearing
2.3 TERMINAL BOX • Grease change frequency
• Amount of grease
• Grease type
2.3.0 Description (on damper buffers)
Use the attached Terminal box drawing.
2.4.3. Rotation direction nameplate
The openings provide access to the terminals.
Located on the stator an arrow indicates the direction of
The gland plates are made of non-magnetic materials in rotation.
order to avoid circulating currents.
If accessories not supplied by Leroy-Somer have to be
installed in the terminal box (CT’s, VT’s, Shunt, etc.) refer 2.5 ROLLER-BEARING
to chapter.3.4.3.
In order to limit the level of vibration of the accessories 2.5.0 Description of roller-bearings
contained in the terminal box, the terminal box is mounted The bearings ensure the guiding of rotor rotation and its
on rubber damper pads. axial positioning.
The bearings are protected from ambient dust by baffles.
They can be replaced.
The bearings must be lubricated regularly. The old grease
is forced out at the lower part of the bearings by the force
of the new grease being injected.

2.5.1 Bearing protection devices

Optionally, the bearing can be equipped with RTD sensors
to detect possible heating.
For special use in warm surroundings where the
temperature of the bearings exceeds the authorised limit
CAUTION: (for a bearing known to be in good condition), contact us.
RUBBER DAMPERS MUST BE CHECKED Bearing; Alarm points and shutdown:
PERIODICALLY AND REPLACED EVERY FIVE YEARS. • alarm 90°C (194°F)
• shutdown 95°C (203°F)
To improve the machine protection we recommend to set
the alarm point following effective site conditions:
2.3.1 Automatic voltage regulator (AVR)
Alarm temperature (*) = Highest recorded temp + 15°K
When the automatic voltage regulator is located in the (*) do not exceed the values of the previous table.
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampers. The operation of the E.g. On-site, the normal temperature of the bearing is
regulator is explained in Section 3. 60°C. Set the alarm temperature to 75°C instead of the
90°C shown in the previous table.
NOTE:
Specific dedicated devices based on the analysis of the
vibration signal are able to monitor bearings behaviour.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

2.10 AIR FILTERS Rear bearing; Locking system examples:

Only use approved filters. Any filter not correctly
engineered may conduce to air flow restriction and then to 1
abnormal generator cooling or to dust entering the
generator.

2
2.12 TRANSPORT LOCKING SYSTEM 3

2.12.0 General information

With certain types of machines, the alternator comes with a
rotor locking system for transport. 3
The locking systems must be removed just before the final
installation of the alternator and reinstalled if the alternator
is later re-transported. It is recommended to lock the rotor
1 3
during transport.

NOTE:
2 3
The locking systems are painted red or yellow.

CAUTION:
THE ROTOR LOCKING SYTEM MUST REMAIN IN
PLACE IF THE ALTERNATOR IS GOING TO BE
TRANSPORTED.
1 - Cable
NOTE: 2 – Red label out of the alternator indicating a Locking
Maritime and rail transport are particularly demanding system
for the alternator. 3 – Rotor locking system
2.12.1.1 Double roller bearing machine
2.12.1 Machines with bearings
A locking system is installed on the opposite side to the
2.12.1.0 General information shaft end in order to load the roller bearing sufficiently and
In case of re-use of the locking system for transport, the eliminate any possible movement of the rollers on their
system must be reinstalled taking care not to touch any tracks.
parts other than the shaft. If necessary, rotate the shaft so
2.12.1.2 Single roller bearing machine
that the locking system does not touch the rotor cables.
Machine transported alone:
CAUTION: On the front bearing, a threaded rod lifts the rotor and
THE ROTOR LOCKING FASTENING SCREW MUST BE brings it into contact with the stator. The rotor is locked
TIGHTENED TO THE NOMINAL RECOMMENDED axially and radially.
TORQUE (see chapter 5.6).
Transported machine coupled to its prime mover
NOTE: (single roller bearing machine only):
PMGs have very low air gaps, and may be damaged
A locking system is installed on the opposite side to the
during the installation of the transport locking system.
shaft end in order to load the roller bearing sufficiently and
eliminate any possible movement of the rollers on their
CAUTION:
tracks.
FOR SINGLE-BEARING PMG MACHINES, THE PMG
ROTOR MUST BE DISASSEMBLED BEFORE
INSTALLING ANY LOCKING SYSTEM FOR
TRANSPORT.

NOTE:
Leroy-Somer only provides the transport system
specific to the alternator transported alone. Upon
request Leroy-Somer can provide a locking system for
the transported alternator coupled to its “prime
mover”.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

3. INSTALLATION 3.1.4 Unpacking and Installation

DANGER:
3.1 TRANSPORT AND STORAGE THE DEDICATED LIFTING HOOKS MUST BE USED TO
LIFT THE MACHINE WITH SLINGS (ONE HOOK AT
3.1.1 Transportation EACH CORNER OF THE MACHINE).
During transport the level of intermittent shocks suffered by
Rotors of machines with Sleeve bearings and single-
the machines must remain below 30 m/s2. bearing machines, are blocked during transportation so as
Machines equipped with roller bearing(s) must have their to avoid any movement. Withdraw the retaining bars. The
rotor locked during the transport to avoid any "false retaining bar is screwed to the end of the shaft and to the
brineling" problem. front support.
The temperature of the machine must remain between
-20°C and +70°C. However, it is possible to go down to CAUTION:
-40°C if not for more than a few hours. TRANSPORT LOCKING DEVICES PAINTED RED OR
WITH RED STICKER MUST BE REMOVED.
The machine must be protected against the weather and
condensation. The end of the shaft is protected from corrosion. Clean it
before coupling.
3.1.2 Warehouse Storage The resistance heater must be switched on at all times.
This chapter applies to machinery not protected by a Before starting the machine up again, it will be necessary
sealed package (for machinery with a sealed package, see to carry out a start-up inspection.
Chapter 3.1.3).
3.1.5 Roller bearing storage measures
The machinery must be stored in a clean and dry place
This chapter must be followed if a machine remains
which is not subject to sudden temperature changes or
stationary for more than 6 months.
high humidity (75 % maximum).
After 6 months of stop; lubricate by injecting two times the
Storage at an ambient temperature of +5 to +45°C is grease volume used for a standard maintenance.
recommended. Then, every 3 months turn the machine shaft line by a few
The machine must not be subject to vibrations greater than turns while injecting a standard grease volume.
1mm/s rms.
3.1.6 Uncovered machinery storage measures
CAUTION: For an uncovered machine, it is recommended to close the
THE RESISTANCE HEATER MUST BE CONTINUOUSLY air inlet and outlet.
SWITCHED ON.

3.1.3 Storage in maritime packaging

The synchronous machine was hermetically sealed in the
factory and then packed in a wooden box (SEI class 4c
standard).
Storage in a hermetically sealed package and wooden box
made by Leroy-Somer is guaranteed 2 years. In this case,
there is no special weatherproof precaution to be taken.
In this case, the precautionary measures in Chapter 3.1.5;
3.1.6; 3.1.7; 3.1.8 do not apply.
The machine must not be subject to vibrations greater than
1mm/s rms.

CAUTION:
BREAKING THE HERMETIC PROTECTIVE FILM
DISCHARGES LEROY-SOMER OF ITS LONG STORAGE
GUARANTEE.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

3.2 INSTALLATION OF THE MACHINE

CAUTION:
THE ALIGNMENT STANDARDS OF MOTOR
3.2.1 Coupling Assembly (double-bearing MANUFACTURERS ARE FREQUENTLY MORE
machine only) ACCURATE THAN THOSE OF LEROY-SOMER.
The coupling must be balanced separately before being
assembled on the machine shaft. Refer to the balancing 3.3.1.2 Shaft elevation caused by heat rise
instructions in chapter 2.2.5. ∆ H (mm) =λ (°K-1) . H(m) . ∆T(°K)
The shrinking of the half coupling onto the electrical H(m) = Height of the machine axis
machine shaft end must be chosen, by the generator set ∆T= frame temperature rise = 30°C
manufacturer, in such way as it should be removable for
λ = Coefficient of steel elongation = 0.012 °K-1
maintenance (e.g. bearing change).
3.3.1.3 Elevation of the shaft of a roller bearing
3.2.2 Stator attaching machine
Four plates on the chassis allow the unit to be attached Caused by heat rise in the anti-friction bearing itself.
onto a pallet. "2"
The fixing bolts must support the forces created by the
static and dynamic loads. Y ° 0,01 mm
The machine may be positioned by means of 4 dowel pins.
The dowel pins make later realignment easier. (The use of
pins is optional). "1"
The machine may be aligned through the use of 4 jacking- 1 - cold, in rotation, or stopped
screws. These jacking-screws allow the machine to be 2 - hot, in rotation, or stopped
positioned along the various axes.
3.3.1.4 Inspection of the generator before alignment
Check the out-of-round of the generator shaft tip.
3.3 MACHINE ALIGNMENT The total reading must be within a tolerance of 0.04 mm.

3.3.1 General information concerning the alignment NOTE:

3.3.1.1 General information RUN OUT CHECK CAN BE INFEASABLE ON SLEEVE
BEARING MACHINE BECAUSE OF THE TOO HIGH
Alignment is intended to achieve coaxiality of the driving
and driven shafts under nominal operating conditions NECESSARY TURNING TORQUE NEEDED TO TURN
(machine running; at its operating temperature). THE ROTOR.
The machine must be aligned according to the Leroy-
Somer standard and adhere to the manufacturer's
alignment standard for the drive machine.
When heating the machine has its shaft line which grow up.
Between stop and rotation the shaft axis location inside its
bearing is different. The total axis height elevation is
composed of the thermal elevation and of the bearing
elevation.

CAUTION: 3.3.1.5 Alignment procedure with the “double

THE ALIGNMENT MUST BE DONE TAKING INTO concentricity” method
ACCOUNT, THE CORRECTION FOR THE THERMAL
EXPANSION OF THE SHAFT. NOTE:
The correct locating of the parts must be obtained by LASER DEVICES CAN MAKE THE JOB EASIER THAN
inserting shims under the machine feet. WITH THE PROCEDURE INDICATED.
The double-bearing machines are mounted with bearings This method is not sensitive to axial movements.
(ball or roller) or Sleeve bearings. The axial clearance of (Alignment methods using axial measurement are often
the bearings (if the machine has Sleeve bearings) must be disrupted by a small axial movement of the rotor).
distributed as uniformly as possible, taking into account the It is possible to check the alignment with the coupling
axial thermal expansion. The roller bearing machines with installed.
a positioning bearing (standard machine) do not have axial
Equipment required:
play.
Two rigid supports. The rigidity of the two supports is very
The machines are delivered with the rotor mechanically important.
centred (axially and radially) in relation to the stator. Two micrometers

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

Implementation: C1
During the measurements, both shafts must turn B
simultaneously in the same direction. (For example: the
coupling installed with its screws loosened). By turning A
both shafts simultaneously, the measurement is not 0.16
affected by the error resulting from run out of the two shaft
ends. C2
0.05

Regarding the vertical plane, the angular alignment error is:

C1 (0.16 + 0.05) *100 / 400 = 0.0525 mm/100mm (not
acceptable).
12h B Measurements referring to the horizontal axis:
In the plane "C1" the axis "B" is further to the right than "A”
9h
(1.04 – 0.86) / 2 = 0.09 mm
A In the plane "C2" the axis "B" is further to the left than "A”
3h (0.70 – 1.64) / 2 = - 0.47 mm
The representation of the shafts is as follows:

6h C2 C1
B
L A
0.47
The "C1" and "C2" micrometers are located at an angular
difference of 180°. C2
0.09
The longer the distance "L" the higher the sensitivity for
detecting angular errors. Regarding the horizontal plane the angular error is:
(0.47 + 0.09) *100/ 400 = 0.14 mm/100mm
The reading should be performed 4 times for the "C1" and
(not acceptable)
"C2" micrometers: at 12h, 3h, 6h, 9h.
In the both planes the parallelism error is:
It is recommended to record the results and draw the axes
for better evaluation, as explained below. Interpretation of 52 + 92 = 0.103mm or 162 + 47 2 = 0.496mm (not
measurements by means of an example. acceptable)
Values given in millimetres. The reading is considered
positive (+) when the micrometer stylus is pushed inwards. 3.3.2 Alignment of a double-flanged bearing machine
MEASUREMENTS
+ 1.34 3.3.2.1 Machines without axial play (standard)
C1 C2 Alignment must take into account, coupling tolerances.

+ 0.90
+ 0.70
CAUTION:
12h B A MISALIGNMENT EVEN IF ACCEPTABLE BY THE
+ 1.64 COUPLING MUST NOT CREATE UNACCEPTABLE
STRESS LEVELS FOR THE BEARING.
9h 3h Shafts alignment limits to comply with:
+ 0.86 A
+ 1,04
+ 1.02
Angular error
6h L=400

+ 1.00 0.05 mm
Measurements referring to the vertical plane: 0.08 mm 100 mm
Considering the vertical plane "C1": The vertical action Parallel Error
towards the top of shaft "A" on the micrometer is dominant. To check the alignment, there are different methods: the
In the plane "C1" the axis "A" is higher than axis "B” "double concentricity" method is described in the
(0.9 – 1) / 2 = - 0.05 mm "alignment procedure" chapter 3.3.1.6.
In the vertical plane "C2", the vertical action towards the
top of shaft "B" on the micrometer is greater.
In the plane "C2" the axis "B" is higher than axis "A"
(1.34 – 1.02) / 2 = 0.16 mm
The respective position of the axes is as follows:

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

3.4 ELECTRICAL CONNECTIONS 3.4.1 Phase Order

3.4.1.1 Standard units; IEC 34-8
3.4.0. General information
Except by special request of the customer, the phase-
The installation must comply with the electrical schematics sequence is chosen as per the IEC 34-8 standard.
attached in Section 5.
An arrow located on the front bearing indicates the
Check that all the protection devices are correctly direction of rotation.
connected and in good working order.
In the terminal box a specific marking plate indicates the
The assembler has the responsibility to mechanically and specific generator phase sequence.
electrically protect the generator within the best practice
rules and to secure any operation over the defined tender
(respect of capability curve; overspeed, etc.). Clockwise rotation viewed Counter clockwise rotation
For low-voltage machines, power supply cables must be from the shaft drive end viewed from the shaft
connected directly to the machine terminals (without adding drive end
washers, etc). The phases are identified: The phases are identified:
For high-voltage machines, power supply cables should be U1, V1, W1. U1, V1, W1.
connected to separate terminals or to current transformer
terminals. The installer connects the The installer connects the
following: following:
NOTE: L1 --> U1 L3 --> U1
The gland plate is made of non-magnetic material. L2 --> V1 L2 --> V1
L3 --> W1 L1 --> W1
CAUTION:
DO NOT ADD WASHERS TO THE POWER SUPPLY
CABLE TERMINALS OTHER THAN THOSE USED BY
THE MANUFACTURER OF THE ELECTRIC MACHINE.
U2 V2 W2 U2 V2 W2
Make sure the lugs are tight. Refer to chapter 5.8.

CAUTION:
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED OR SHUNTED.

CAUTION:
THE VOLTAGE TRANSFORMER MUST NEVER BE U1 V1 W1 U1 V1 W1
SHUNTED.

CAUTION:
THE INSTALLED POWER CABLES MUST BE
FASTENED AND SUPPORTED IN SUCH A WAY AS TO L1 L2 L3 L3 L2 L1
BE ABLE TO WITHSTAND THE VIBRATION LEVEL
REACHED BY THE GENERATOR IN OPERATION (refer
to chapter 2.1.3.4).
The power cables must not stress (push, pull, flex, etc.) the
generator terminals.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

3.4.1.2 Upon request; NEMA 3.4.2 Insulation distances

An arrow located on the front bearing indicates the Products not delivered by Leroy-Somer and then installed
direction of rotation. in the terminal box must meet the electrical insulating
In the terminal box a specific marking plate indicates the distances.
specific generator phase sequence. This applies to power cables and lugs, and to added
transformers, etc.
Counter clockwise rotation Clockwise rotation viewed Nominal Voltage 500 V 1 KV 2 KV 3 KV
viewed from the stator from the stator connection Phase-Phase in 25 30 40 60
connection (NEMA) (NEMA) the air (mm)
(Clockwise rotation viewed (Counter clockwise
from the shaft drive end rotation viewed from the Phase-Earth in the 25 30 40 60
following IEC) shaft drive end following air (mm)
IEC) Phase-Phase 25 30 40 70
The cables are marked: The cables are marked: Creeping (mm)
U1, V1, W1. U1, V1, W1. Phase-Earth 25 30 40 70
The terminals are marked: The terminals are marked: Creeping (mm)
T3, T2, T1 T3, T2, T1
The installer connects the The installer connects the
Nominal Voltage 5 KV 7.5KV 12.5KV 15 KV
following: following:
L1 --> (U1) T3 L3 --> (U1) T3 Phase-Phase in 120 180 190 190
L2 --> (V1) T2 L2 --> (V1) T2 the air (mm)
L3 --> (W1) T1 L1 --> (W1) T1 Phase-Earth in the 90 120 125 125
air (mm)
Phase-Phase 120 180 190 190
Creeping (mm)
T6 T5 T4 T6 T5 T4 Phase-Earth 120 180 190 190
Creeping (mm)

3.4.3 Added products in the terminal box

This may apply to site added customer CTs; VTs etc.
U1 V1 W1 U1 V1 W1
Leroy-Somer must be informed if some appliances have to
be installed in the generator terminal box.
T3 T2 T1 T3 T2 T1
The products not delivered by Leroy-Somer and then
installed in the terminal box must meet the electrical
insulating distances. Refer to chapter 3.4.2.
The installed appliances must be able to withstand
L1 L2 L3 L3 L2 L1 vibration.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

4. START-UP 4.1.3.3 Parallel coupling

CAUTION:
4.1 ELECTRICAL START-UP INSPECTION A WRONG SYNCHRONIZATION CAN LEAD TO
SERIOUS DAMAGE(HIGH MECHANICAL
4.1.0 General information OVERTORQUE AND OVER CURRENT).
Electrical connections (auxiliaries, safety and power lines)
must comply with the drawings provided. During synchronization the following values must not be
Refer to Section 5 to get the concerned schematics. exceeded:
Max frequency shift: 0.1 Hz
DANGER: Max phase offset: 10° (electrical angle)
Check that all safety equipment operates correctly. Max voltage (phase - neutral) between machines:
(at phase offset =0) 5 % of the nominal
4.1.1 Insulation of the winding voltage
Isolation and polarisation index must be measured at start- Leroy-Somer will not be considered as liable for any
up and then as recommended in Chapter 5.1.0. damage in case of incorrect synchronisation, or mains
To measure the insulation (refer to chapter 5.10). micro-interruption inducing a fault over the indicated limits.

4.1.2 Electrical connections 4.2 MECHANICAL START-UP INSPECTION

The phases must be connected directly to the bars of the
machine (without spacers or washers, etc.). 4.2.0 General information
Make sure that the lugs are sufficiently tightened.
4.2.0.1 Alignment; attachment; drive motor
CAUTION: The installation must comply with the drive motor
ALL CURRENT TRANSFORMERS MUST BE manufacturer’s installation requirements (alignment,
CONNECTED BEFORE STARTING. IF A CURRENT mounting).
TRANSFORMER IS NOT USED, ITS OUTPUT MUST BE An arrow at the drive end, end shield, indicates the
SHORTED. direction of rotation.
4.2.0.2 Cooling
4.1.3 Parallel operation The air inlet and outlet must not be obstructed.
4.1.3.1 Definition of parallel operation The cooling auxiliaries (water circulation in the cooler, etc)
• Between machines must be operating.
Operation mode named by Leroy-Somer "1F". 4.2.0.3 Lubrication
At least two alternators are connected in parallel to supply Lubrication must be carried out in accordance with Chapter
a load. 5. Lubricant quantity and periodicity as per Section 1.
The automatic voltage regulator is in voltage regulation
mode. 4.2.1 Starting roller-bearing machines
A droop current transformer is necessary to share the
reactive load. The bearings are pre-lubricated in the factory, but it is
necessary to re-lubricate them before they are put into
• With the mains
service in order to fill any gaps in the lubrication circuit and
Operation mode named by Leroy-Somer "3F". to remove the storage grease.
At least one alternator is connected in parallel with the
mains (Public electricity network).
CAUTION:
The Automatic Voltage Regulator is in Power Factor
WHEN STARTING UP, LUBRICATE THE MACHINE
regulation mode.
WITH THE AMOUNT OF GREASE INDICATED ON THE
4.1.3.2 Possibility of parallel operation NAMEPLATE WHILE IT IS IN OPERATION.
Record the temperature of the bearings during the initial
CAUTION: operating hours. Poor lubrication can cause abnormal
PARALLEL OPERATION CAN ONLY BE USED FOR heating.
ALTERNATOR ENGINEERED FOR SUCH OPERATION.
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not operate
at normal temperature. This may occur if the weather is
very cold or when the machine is operating under abnormal
temperature conditions (start-up phase, for example). The
bearings will become quieter after having reached their
normal operating temperature.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

4.2.2 Terminal Box start-up 4.3.2. Machine running checks

The terminal box is mounted on damper pads. 4.3.2.0 Rotor speed ramp-up (Standard Machine)
There are no restrictions on the rate of rotor speed
CAUTION:
increase between stop and rated speed.
BEFORE THE ALTERNATOR STARTS, ALL FOUR
There is no restriction regarding the rate of load
BLOCKING SYSTEMS FOR TRANSPORT MUST BE
application.
DISASSEMBLED.
4.3.2.1 Checks of machine running without excitation
CAUTION: Run the generator without excitation by steps to verify the
THE BLOCKING SYSTEMS FOR THE TRANSPORT OF bearings temperature as per chapter 2.5.1 or 2.6.2.
THE TERMINAL BOX MUST BE INSTALLED EACH At the nominal speed (not excited) measure the vibrations.
TIME THE ALTERNATOR IS TRANSPORTED (ALONE Check that the vibration level is in accordance with the use
OR WITH ITS MOTOR). of the generator (as per chapter 2.1.3.4).
4.3.2.2 Checks of excited machine running with no load
In manual AVR voltage regulation mode, check the
excitation current value (refer to Section 4 for more
information on manual AVR mode and to Section 2 for the
generator test report).
In AVR automatic mode; Voltage adjustments; Voltage
range; check the excitation current value (refer to Section 4
for the AVR manual and to Section 2 for the generator test
report).
The four locking brackets (each fastened by 4 M10 screws; At the nominal speed (excited) measure the vibrations.
red parts in the diagram above) must be removed and kept. Check that the vibration level is in accordance with the use
of the generator (as per chapter 2.1.3.4).
4.2.3 Vibrations 4.3.2.3 Generator and site safety parameter
The vibration measurement must be taken on each bearing Adjust the site safety systems (surge voltage relay, surge
in all three directions. The measured levels must be lower current relay, residual current protection, negative
than the specified values indicated in the chapter 2.1.3.4. sequence relay, etc.) The setting points are not in the
Adjust the sensor as per chapter 2.1.3.4. Leroy-Somer scope of supply.
The settings must comply with the generator data sheet
(e.g. capacity curve; thermal damage curve, etc.).
4.3 START-UP SEQUENCES Check the synchronizer setting as per chapter 4.1.3.3.
Start-up (commissioning) of the generator must follow the For any operation at a speed exceeding the nominal range
following sequences: (generally the main frequency +3%) the generator
excitation must be shut off (refer to the electrical
4.3.1 Machine stopped checks schematics).
Mounting of the machine as per chapter 4.2.
4.3.2.4 Checks of machine running under full load
Alignment as per chapter 3.3.
Cooling as per Chapter 4.2.0.2 & 4.2.3. checks
Lubrication of bearings as per Chapter 4.2.2. Grid-coupled operation.
Electrical connections as per chapter 4.1.2. Adjust the Power Factor.
Winding insulation as per chapter 5.10. Progressively apply load to the generator:
Check the excitation current at 25% of the rated load.
Check the excitation current at 100% of the rated load.
At the nominal speed (full load) measure the vibrations.
Check that the vibration level is in accordance with the use
of the generator (as per chapter 2.1.3.4).

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

4.3.3 Generator start-up checklist

TYPE SERIAL No.

Voltage V Frequency Hz Speed rpm

Output Power kVA Power Factor

STATIC CHECKS

Mechanical checks
• Direction of Rotation (refer to Section1) Clockwise or Anti-clockwise
• Mechanical fastening of the generator (see Chapter 4.2) ____________________________________________
• Coupling - Alignment with the motor (refer to chapter 3.3) _______________________________________
• Cooling: Coolant flow rate (see section 1; Chapters 4.2.0.2 & 4.2.3) _____________________________________
• Open air inlet and outlet _____________________________________________________________
• Bearing lubrication: Lubrication of plain bearings (flow rate; level; oil) (Section 1 & Chapter 4.2.2) ___________
Or Roller bearings lubrication (refer to Section1 & chapter 4.2.1)
Temperature sensors (correct readings) (Section 1& Chapters 2.5.1 & 2.6.2) ____________
• Heating by additional resistance heaters (see section 1) ____________________________________________

Type of AVR : 1F 3F

Electrical connections between alternator, AVR and main panel: (refer to Section 4 & drawing Section 5)
• Output power cable connections in phase order (see Chapter 3.4.1) _
• Terminal box connections ________________________________________
• AVR detection voltage ________________________________________
• Supply power and excitation terminals ________________________________________
• Network detection (3F only) ________________________________________
• Command signals (equalisation and synchronisation for 3F) ________________________________
• Excitation polarity and booster ________________________________________
• Protective devices: (Bearing oil level fault detectors; Temperature sensors, etc) ______________________
• External accessories (e.g. remote potentiometer) ________________________________________

ALL CURRENT TRANSFORMERS MUST BE CONNECTED.

Windings insulation
Winding temp.:…….°C Voltage 1 minute 10 minutes Polarisation
(MΩ) (MΩ) index
3 Phases / Ground
"U" /Ground
"V" /Ground
Static parts

"W" /Ground
"U" / "V"
"U" / "W"
"V"/"W"
Exciter field / Ground
If the 3 phases/earth IR measurement is compliant then the rest of the measurements are not required for a Commissioning

Rotor / Ground ≤ 500 V

Rotating

Exciter armature / Ground ≤ 500 V

parts

Rotating resistances ≤ 500 V

Rotating diodes ≤ 500 V

All works must be carried out by a qualified and authorised person.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

RUNNING CHECKS
WITH EXCITATION - AT NO LOAD CONDITIONS
• Verification of the temperature of the bearings (refer to chapter 2.5.1 or 2.6.2) °C_____________

• In manual mode: Voltage setting ___________________________________

Excitation current check ___________________________________

• In automatic mode: Voltage Setting (referring to nominal voltage) ________________________

Excitation current check ________________________

• Parallel coupling: Adjustment for parallel operation (3F) ___________________________________

FAULTY SYNCHRONISATION CAN LEAD TO DAMAGE (HIGH MECHANICAL OVER-TORQUE)

• Maximum acceptable values for synchronisation with the mains:
Maximum frequency shift 0.1 Hz _________________________
Maximum Phase offset 10 ° _________________________
Maximum voltage (P.N.) difference 5% of Un _________________________

Control / Adjustment of the site safety parameters

• Over-voltage _____________________________________________________________
• Over-current (by short-circuit on stator in separate excitation mode) _________________________
• Negative sequence relay _____________________________________________________________
• Over-speed _____________________________________________________________
• Differential protection (in static conditions) _____________________________________
• Other protective device _____________________________________________________________

CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY.

WITH EXCITATION - LOADED

Take the load gradually from 0 to 100% in steps of 25%.
Record for each step (refer to Section 1):
• Electrical output (KW)
• POWER FACTOR
• Voltage (V)
• Current (A)
• Excitation Current / voltage
• Winding temperature
Time KW pf Volts I (A) I (ex) U1 (°C) V1 (°C) W1 (°C)

• Temperature of the bearings (if thrust sensor available, please record its value)
Time DE Thrust (°C) DE Radial (°C) NDE Radial (°C)

• Oil inlet temperature (if applicable; refer to Section 1)

• Oil flows (if applicable; refer to Section 1)
• Vibrations of the bearings (mm/s) (refer to chapter 2.1.3.4)
DE-V DE-H DE-A DE-V DE-H DE-A

All maintenance must be carried out by a qualified and authorised person.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5. MAINTENANCE AND SERVICING

5.0 GENERAL INFORMATION

DANGER:
BEFORE ANY WORK ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED
BY ANY MANUAL OR AUTOMATIC SIGNAL.
CHECK THAT ALL LOCKS ARE ENGAGED AND
FOLLOW THE SITE SAFETY PROCEDURES.

DANGER:
Before working on the machine, make sure that you
have understood the operating principles of the
system. If necessary, refer to the appropriate chapters
in this manual.
To obtain additional information on the maintenance of
sub-assemblies, refer to the chapters dealing with the sub-
assemblies concerned.
When a defective part is replaced with a spare part, make
sure that it is in good condition.
For any electrical work use electrical schematics for
assistance.
The whole machine must be kept clean.

CAUTION:
ANY OF THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) DEPENDING ON SITE CONDITIONS.
The air inlet and air outlet surfaces must be kept clean
(louvers can be cleaned like for the filters). Refer to
chapter 5.5.1.

CAUTION:
DIRT ENTERING THE MACHINE MAY POLLUTE AND
THUS REDUCE THE ELECTRICAL INSULATION.

CAUTION:
ANY PRODUCT (SEALANT, CLEANING PRODUCT,
ETC.) USED DURING MAINTENANCE OR CLEANING
MUST COMPLY WITH LOCAL REGULATIONS AND
ENVIRONMENTAL STANDARDS.

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.1 PREVENTIVE MAINTENANCE PROGRAMME

5.1.0 General information

The purpose of the general preventive maintenance programme below is to assist in establishing the installation-specific
maintenance programme. Suggestions and recommendations should be followed as closely as possible to keep the machine
efficient so as not reduce its service-life.
The maintenance operations are detailed in the chapters dedicated to the topics concerned.
The time required for the operations is indicated for information purposes only.
Hours Comments Task duration
Major overhaul 40000 Or 5-7 years depending on on-site conditions 4 weeks

5.1.1 Stator
Hours Comments Task duration
Winding temperature 24 Daily operation, (without generator set). Refer to chapter
2.1.3.2
Insulation 8000 (*1) Refer to 5.8
4 hrs
Polarisation index 8000 (*1) Refer to chapter 5.8.2
Bolt tightening 8000 (*1) Refer to chapter 5.6 2 hrs
Winding visual inspection 8000 (*1) Refer to 5.8 1 hr
Stator RTD function 8000 (*1) Refer to 2.1.3.2
Cleaning air inlet and outlet 1000 (*1) Refer to chapter 5.5

(*1): or once a year, whichever comes first

5.1.2 Rotor
Insulation 8000 (*1) Refer to 5.8
0.5 hr
Polarisation index 8000 (*1) Refer to chapter 5.8.2
Winding visual inspection 8000 (*1) Refer to 5.8
Cleaning diodes 8000 (*1) Refer to chapter 5.9
Diodes and varistor check 8000 (*1) Refer to chapter 5.9 0.5 hr
Diode tightening 8000 (*1) Refer to chapter 5.6.4

(*1): or once a year, whichever comes first

5.1.3 Terminal box

Cleaning 8000 (*1) 0.5 hr
Regulator assembly & supports 8000 (*1) Applicable if mounted in the terminal box
Bolt tightening 8000 (*1) Refer to chapter 5.6.3 1.5 hrs

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.1.4 Roller bearing

According to the technical characteristics indicated in Section 1.

The bearings can be re-lubricated as With regard to the type of grease, the lubricating Minimum
standard intervals and the quantity to be supplied to each every 6
bearing: refer to nameplate directions months
Standard grease MOBIL POLYREX™ EM: NLGI grade 2
Factory lubrication MOBIL POLYREX™ EM: NLGI grade 2
Special grease Refer to nameplate directions

Following the requirements of the nameplate is essential. Other priority information may be mentioned.

Lubricating the alternator in operation and during the first commissioning is essential.
Before using any other grease, check its compatibility with the original grease.
On some 52.3, 3 lubricators are available on the bearings so that the maintenance operator can choose the
most accessible. Lubrication is effectively ensured regardless of the lubricator used.

Bearing temperature 24 Daily operation, (without generator set). Refer to chapter

2.5.1

5.1.5 Rubber dampers

Rubber dampers 8000 Refer to chapter 2.3.1
Refer to chapter 5.13

5.1.6 Filters
According to the technical characteristics indicated in Section 1
Cleaning 1000 Cleaning following site conditions; Refer to chapter 5.5.1 4 hrs

5.1.7 Protection devices

Protection devices 8000 (*1)

(*1): or once a year, whichever comes first

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.2 AIR GAP CHECK 5.3 BEARINGS

5.2.1 General information 5.3.1 General information

Measuring air gap is not always possible due to lack of
access. When the air gap can be reached the measure can NOTE:
be distorted because of paint and resin coating on the Some international studies indicate that over 80% of
checked surfaces. roller bearings installed worldwide, regardless of the
Measure the air gap at different points (minimum four context, are damaged prematurely due to a lubrication
different points spaced by 90°). problem.
Calculate an averaged value (sum of the measures divided To preserve your machine we recommend closely
by the number of measurements). fulfilling the recommendations of this manual.
Compare the averaged value to the measured values.
Main field air gap accuracy: They must be lubricated regularly with the same type of
Acceptable offset (mm)
grease as used in the factory. For information concerning
the lubrication quantity and interval, refer to Section 1:
10% off-centring for an air gap "Characteristics and Performance".
greater than 18mm

CAUTION:
15% off-centring for an air gap LUBRICATION MUST BE CARRIED OUT AS PER
4 to 12mm
SECTION 1 OR AT LEAST EVERY 6 MONTHS
WHICHEVER COME FIRST.
20% off-centring for an air gap
less than 3mm Air gap (mm)
NOTE:
After a relubricating, the bearing temperature may
E.g.: for a nominal air gap of 3 mm a measured air gap increase by 10 to 20°C.
value of 2.4 mm is acceptable. This temporary temperature increase may persist for a
E.g.: for a nominal air gap of 10 mm an air gap measured few tens of hours.
value of 8.5 mm is acceptable.
Exciter air gap accuracy: NOTE:
50% of the nominal value (e.g.: for a nominal air gap of In case of a "stand by" duty or generator with short
3 mm a reading of 1.5 mm is acceptable). operation cycles, it is recommended to run the
Permanent Magnet Generator (optional) air gap tolerance: machine for at least 3 hours after each regreasing.
50% of the nominal value (e.g.: for a nominal air gap of
1 mm a reading of 0.5 mm is acceptable). NOTE:
For regreasing period less than 2,000 hours we
5.2.2 Double-bearing machine recommend installing a continuous lubrication system
It is not necessary to check the air gap. The rotor is to limit the maintenance operator interventions.
mechanically centred by its construction. Even after This type of system must be deactivated during
dismantling and reassembling the machine, the rotor will machine shut-down.
return to its position without verification of the air gap. The grease contained in these systems must not
The exciter air gap of generators type A60 and A62 can be remain there over a period of more than 1 year.
adjusted on site by 2 jacking screws.
5.3.2 Cleaning of old bearing grease
This chapter applies in the event of a change in the type of
grease.
Dismantle the machine in order to have access to the
bearing.
Remove the old grease with a palette knife.
Clean the lubricator and the grease removal tube.
For greater cleaning efficiency, use a brush with solvent.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

NOTE:
The solvent used must be in accordance with local
regulations and environmental standards.

DANGER:
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH
BECOMES ACID.
FUEL-OIL (EVAPORATES TOO SLOWLY).
GASOLINE CONTAINING LEAD
BENZENE (TOXIC). 5.3.5 Bearing reassembly
After cleaning ensure that the bearing becomes perfectly A bearing can be reused if it is found to be in perfect
dry. condition. As far as possible, we recommend to use a
brand new bearing.
Fill the bearing with the new grease.
Before refitting a bearing, carefully clean the surface of the
Re-assemble the cage and the parts, which have been
bearing and the other parts of the bearing.
dismantled, filling them with grease (2/3 of the empty
spaces must be filled with new grease). Measure the shaft diameter to check it is within the
recommended tolerances.
Use a grease pump to complete the bearing lubrication
(while machine running). To install the bearing on the shaft, it is necessary to heat
the bearing. The heat source may be an oven or a space
heater (the use of oil baths is not recommended). The use
5.3.3 Cleaning of the bearing assembly area
of an induction bearing heater is recommended.
The bearing service-life depends directly on the cleanliness
of the lubricant. Dirt must not enter or pollute the bearings.
CAUTION:
Excess grease must be removed before operation in order NEVER HEAT A BEARING TO MORE THAN 125°C
to avoid pollution of the environment as well as the (257°F).
alternator.
Periodically: Push the bearing up to the shaft shoulder, and check after
clean the labyrinth seals outside face. Remove any excess cooling that the inner ring is still in contact with the
grease which may appear on the shaft. shoulder. Lubricate using the recommended grease. Fill
Remove the excess of dry old grease from the bearing the bearing covers with new grease.
exhaust channel (use a clean blade).
After removing the old grease, check that a small fresh
volume of grease will plug the exhaust channel (to avoid
pollution coming back to the bearing).

5.3.4 Bearing disassembly

The bearing inner ring is shrink fitted onto the shaft.
The outer bearing race is free, or slightly tightened, on the
hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a dedicated
hub-puller to avoid damaging the surface of the shaft.
Typical bearing drawing assembly is given in chapter 10.

CAUTION:
CLEANLINESS IS IMPERATIVE.

NOTE:
Heating the bearing during the pulling operation is
recommended to prevent the shaft from being scored.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.4 LUBRICANTS 5.5 AIR FILTER

5.4.1 Greases 5.5.1 Cleaning

Recommended lubricant: 5.5.1.1 Air Filter Cleaning Frequency
MOBIL POLYREX EM (polyurea base).
The frequency of cleaning depends on the on-site
conditions and may vary.
Recommendation for a substitution grease choice:
Cleaning of the filter becomes necessary if the temperature
Mineral oil or PAO (SHC)
of the stator winding (measured by probes) indicates an
Base (soap) grade NLGI 2
abnormal increase.
Lithium complex base (Lithium base accepted)
Basic viscosity of oil at 40°C: from 100 to 200 mm2/s 5.5.1.2 Air filter cleaning procedure
Dye penetration test (DIN 51817): 2% minimum The filter element (flat or cylindrical) is immersed in a tank
of cold or warm water (temperature less than 50°C). Use
Greases recognised as possible substitution grease: water with detergent added.
SKF LGWA2 (lithium complex base). Recommended Shake the filter gently to ensure that the water flows
lubricant): through the filter in both directions.
CASTROL LMX NLGI2 When the filter is clean, rinse it with clear water.
TOTAL Multis complex EP2
Drain the filter properly (there must be no more formation
of droplets).
CAUTION:
Refit the filter on the machine.
THE USE OF A SUBSTITUTION GREASE REDUCES
THE RE-LUBRICATING PERIOD BY 40%.
CAUTION:
DO NOT USE WATER WITH A TEMPERATURE HIGHER
NOTE:
THAN 50°C, DO NOT USE SOLVENTS.
Lithium soap and lithium complex can be mixed.
Lithium complex and calcium lithium soap can be
NOTE:
mixed.
Do not clean the filter using compressed air. This
If the brand of grease is changed, it is recommended to
procedure would reduce filter efficiency.
do intense lubrication to eliminate the old grease.

NOTE: 5.6 SCREW TIGHTENING

Mixing different types of grease never improves the
positive properties of greases! Mixing of different 5.6.0 General information
types of grease must be done only after obtaining It is recommended to use a thread-locking compound on all
agreement from the grease supplier or after cleaning fastening screws, or plugs (except for electrical contacts)
off the old grease from the bearing. that have been loosened or disassembled during any
operation.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

A medium strength thread locking compound such as or 5.6.4 Rotating diodes

similar to "Loctite 242"; or "Omnifit 100M" (from Henkel).
CAUTION:
5.6.1 Steel screws in steel tapping THE ROTATING DIODE FASTENING SCREWS MUST
If no torque value is specified in the relevant chapter, apply BE TIGHTENED USING A TORQUE WRENCH
the following values to secure the metal parts together. CALIBRATED TO THE RECOMMENDED TORQUE.
Fasteners: Steel / Steel
Diode Tightening torque
(with medium strength thread locking compound)
SKR 100/.. 10 N.m
Ø nominal Torque Ø nominal Torque
(mm) (N.m) (mm) (N.m) SKR 130/.. 10 N.m
3 1.0 18 222 SKN 240/.. 30 N.m
4 2.3 20 313
5 4.6 22 430
6 7.9 24 540
5.6.5 Synthetic parts
8 19.2 27 798
10 37.7 30 1083 This applies to lightweight parts made of synthetic
12 64.9 33 1467 materials (plastic covers, fiberglass covers; fiberglass fan
air deflector, etc.).
14 103 36 1890
16 160
CAUTION:
THE USE OF A THREAD LOCKING COMPOUND IS
IMPERATIVE.
5.6.2 Plugs
If no torque value is specified in the relevant chapter, apply Thread M8 M10 M12 M14 M16
the following values to tighten the plugs.
Torque 15 15 15 15 15
Steel and copper alloy Plugs
[N.m]
(with medium strength thread locking compound)
Ø nominal Torque Ø nominal Torque
(inches) (N.m) (inches) (N.m)
5.7 ELECTRICAL MEASURING
G3/8 30 G1 ¼ 160 INSTRUMENTS
G1/2 40 G1 ½ 230
G3/4 60 G2 320 5.7.1 Instruments used
G1 110 G2 ½ 500 - AC voltmeter 0-600 Volts
- DC voltmeter 0-150 Volts
- Ohmmeter 10E-3 to 10 ohms
5.6.3 Electrical contact - Megohmmeter 1 to 100 MOhms / 500 Volts
If no torque value is specified in the relevant chapter, apply - AC Ammeter 0- 4500 A
the following values for clean and dry brass (or copper - DC Ammeter 0-150 A
alloy) threads. - Frequency meter 0-80 Hz
Low resistance can be measured by means of an
CAUTION: appropriate ohmmeter or by using a Kelvin or Wheatstone
THE USE OF THREAD LOCKING COMPOUND ON bridge.
ELECTRICAL FASTENERS IS PROHIBITED. NOTE:
The identification of the equipment polarity may differ from
Thread M5 M6 M8 M10 M12 M14 M16 one ammeter to another.
Torque 3.3 5.7 14 28 48 76 118
[N.m] 5.8 INSULATION CHECK OF WINDINGS

5.8.0 General information

The insulation resistance is used to check the insulation
status of the machine.
The following measurements can be taken at any time
without any damage to the machine insulating material.
The insulation check must be done:
- Before the start up
- After a long shut-down

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

- As soon as an abnormal operation occurs 100

- At maintenance intervals (refer to chapter 5.1)
LV

Kt40°C
If the measurement indicates a poor result, we advise
contacting our Service department. 10
The generator must be stopped to perform the
measurement. HV
If the insulation resistance is less than that required, it is
1
necessary, to clean and dry the machine (refer to chapter
5.11).

DANGER: 0,1
BEFORE ANY WORK, THE RULES CONCERNING THE
SAFETY OF MATERIALS AND PERSONS MUST BE (°C)
APPLIED (TOTAL LOCKING OF THE GENERATOR 0,01
FUNCTIONS, GROUNDING OF THE PHASES , ETC.). -10 0 10 20 30 40 50 60 70 80 90 100
If the minimum insulation level is not reached, dry the
5.8.1 Insulation measurement windings (see Chapter 5.11) and measure after drying.
Disconnect the three phases at the generator terminals. Start-up can only be allowed if the insulation value has
increased and is above the recommended minimum value.
CAUTION:
5.8.2 Polarisation Index
ALL ACCESSORIES MUST BE DISCONNECTED (AVR,
EMC FILTER, ETC.). The polarisation index is used to check the insulation
REFER TO THE ELECTRICAL SCHEMATICS TO status of the machine and gives an indication of the
pollution of the winding.
IDENTIFY THE ACCESSORIES TO DISCONNECT.
A poor polarisation index may be corrected by a cleaning
The measurement has to be taken between one phase and and drying of the winding.
the earth. The reading is taken after 1 minute of test. The following measurements can be taken at any time
Test voltage Criteria without any damage to the machine insulating material.
(VDC) (MΩ; 40°C)
CAUTION:
Stator: U ≤ 1 kV 500 5 ALL ACCESSORIES MUST BE DISCONNECTED (AVR,
Stator: 1 kV< U ≤ 6.6 kV 2500 100 EMC FILTER, ETC.).
REFER TO THE ELECTRICAL SCHEMATICS TO
Stator: U > 6.6 kV 5000 100 IDENTIFY THE ACCESSORIES TO DISCONNECT.
Rotor 500 5
NOTE:
Exciter (Stator & Rotor) 500 5 It must be done using a stable DC source.
Use a specific polarisation index appliance (refer to
Excitation auxiliary 250 5 chapter 5.8.1 for the correct applied voltage).
windings (AREP)
Proceed for each phase.
PMG (stator) 100 5 Open the winding star point.
Heating element 500 5
Temperature sensors 500 5
IEEE 43 recommendations

If the insulation resistance is not measured with a tested

element à 40°C, a corrective factor has to be used.
Rm 40°C= Rt x Kt40
Rt Measured insulation resistance
Kt40 Corrective factor
LV curve for generator voltage ≤ 1 kV Apply the requested voltage.
HV curve or generator voltage > 1 kV
After 1 minute record the Insulating resistance "R 1 min".
After 10 minutes record the Insulating resistance "R 10 min".

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

𝑅𝑅 (t=10minutes) A site cleaning, because less efficient, can be considered

𝑖𝑖𝑝𝑝 = only for a transient period.
𝑅𝑅 (t=1minute)
Polarisation index Diagnostic Action CAUTION:
ip USED CLEANING AGENT MUST BE IN ACCORDANCE
<1 Poor Intervene
WITH LOCAL REGULATION AND ENVIRONMENTAL
ip STANDARDS.
1< <2 Fair Monitor
ip
2< <4 Good Nothing to CAUTION:
report SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
ip SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
>4 Very good Nothing to
report ARE PROHIBITED. They quickly become acidified,
producing corrosive and conducting hydrochloric acid.

CAUTION:
5.9 ROTARY DIODE BRIDGE TEST DO NOT USE TRICHLORETHYLENE,
PERCHLORETHYLENE, OR TRICHLORETHANE.
Carry out the test using a D.C. source as indicated below.
A diode in good condition should allow the current to flow Avoid mixtures sold under various trademarks which often
only in the anode-to-cathode direction. contain white spirit (which evaporates too slowly) or
Disconnect the diodes before the test. chlorinated products (which are likely to become acidified).
3 ... 48 volts
CAUTION:
- + DO NOT USE TOO STRONG ALKALINE PRODUCTS.
2 THEY ARE DIFFICULT TO RINSE AND CAUSE
1 REDUCTION OF INSULATION RESISTANCE BY
ATTRACTING MOISTURE.

5.10.2 Cleaning Operation

1 - Anode Use a mild alkaline product or a dedicated cleaning
2 - Cathode product.
We recommend the use of the cleaning agent "ASOREL
CN" from "Rhône Chimie Industrie"; 07300 Tournon;
Diode type Positive Negative France. This cleaning agent Does not require any rinsing
operation.
SKR diode housing diode wire It is essential to avoid entry of cleaning agents and dirt into
SKN diode wire diode housing the notches. Apply the product with a brush, sponging
frequently in order to avoid accumulation in the housing.
After cleaning, a rinsing operation must be performed. Hot
When reassembling, ensure that the diodes are tightened soft water (less than 80°C) used under pressure (less than
to the correct torque. 20 bars) can be used.

CAUTION:
5.10 COIL CLEANING AFTER CLEANING THE GENERATOR, DRYING IS
ESSENTIAL FOR RECOVERING THE CORRECT
5.10.0 General information WINDING INSULATION.
The cleaning of the winding is a very demanding operation
which must be carried out only if necessary.
The cleaning of the windings become necessary as soon
as the insulation resistance and/or the polarisation index
are not satisfactory (refer to chapter 5.8.2).

5.10.1 Coil cleaning products

Effective long-term cleaning can only be performed in a
workshop with specialised equipment.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.11 WINDING DRYING 5.11.1.3 Drying generator in rotation

5.11.0 General information CAUTION:

All electrical machines must be stored dry. If a machine is THIS OPERATION MUST BE DONE BY A QUALIFIED
placed in a damp environment, it should be dried prior to OPERATOR.
start-up. Units operating intermittently or placed in areas
Disconnect the machine from the mains.
with high temperature variations, are exposed to dampness
and must be dried very thoroughly if necessary. Short circuit the machine stator at the machine terminals.
Disconnect the voltage regulator. If a booster current
5.11.1 Drying Method transformer used, short-circuit the booster.
Run the machine at its nominal speed (to air cool the
5.11.1.1 General information machine) with the cooling system in operation.
During the drying operation, measure the coil insulation Energise the machine (exciter field) using an separate
and polarisation index every 12 hours. excitation source. Use a DC source (batteries, etc.).
To survey the insulation progress, record the measured Install an ammeter on excitation supply line.
values and plot the obtained progress function of the time. Adjust the excitation current to get 2/3 of the nominal
When the insulation value becomes constant, the machine excitation current (refer to name plate data or alternator
can be considered as dry. test report).
When the resistance is constant, it may be assumed that Warm up during 4 hours, stop and leave it to cool down
the machine is dry. This operation may take up to 72 hours, (winding temperature < 50°C).
depending on the size of the machine and on the degree of Check the winding insulation and the polarisation index.
dampness.
If necessary, repeat the drying.
CAUTION: U1 E
TAKE FIRE-PREVENTION MEASURES DURING THE U2
DRYING OF THE MACHINE. V1 S R
V2
ALL THE CONNECTIONS MUST BE TIGHTENED.
W1
W2
5.11.1.2 Drying generator in a stopped position
The procedure " Drying generator in rotation" should be
preferred to the following one if it is possible to run the
+ -
A
generator at its nominal speed.
DC
Several thermometers must be positioned on the winding
and the temperature must not exceed 75°C (167°F). If one
of the thermometers exceeds this value, immediately S - Stator
reduce the heating. R - Rotor
Dry by using an external source of heat, for example, E - Exciter
heaters, lamps, or hot air blowers.
Leave openings to exhaust the damp air.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.12 NEW VARNISH APPLICATION 5.14 SPARE PARTS

CAUTION: LSA 52.3 LSA 53.2 LSA 54.2

A NEW VARNISH APPLICATION SHOULD ONLY BE
Emergency kit
CONSIDERED IF IT IS ABSOLUTELY NECESSARY. A 5178320 5084565 5084580
AREP/PMG
NEW APPLICATION OF VARNISH MADE ON A COIL
WHICH IS STILL DIRTY OR NOT PERFECTLY DRY CAN Single bearing kit 5084681
RESULT IN A DEFINITIVE LOSS OF INSULATION.

Two-bearing kit 5084674

5.13 TERMINAL BOX

CAUTION:
DAMPER PADS SHOULD BE CHECKED
PERIODICALLY AND REPLACED EVERY FIVE YEARS.

CAUTION:
BEFORE ANY INTERVENTION ON THE ALTERNATOR,
MAKE SURE THAT STARTING CAN NOT BE
ACTIVATED BY ANY MANUAL OR AUTOMATIC
SYSTEM.
CHECK THAT ALL LOCKS ARE ACTIVE AND FOLLOW
SITE SAFETY PROCEDURES.

2 4

Damper pads must not show any cracks. If a crack is

detected, or if the replacement period has come to term,
change the pads for new ones.
Change of pads:
Lift the terminal box using the jack screw (item “2”).
Loosen the 8 M10 screws (item “1”).
Remove the block from the pad assembly (item “3”).
Remove the M10 nut from the damper pad (item “4”) to
remove the lower plate.
Unscrew the damper pad from the top plate.
Mount a new damper pad (part ref: 13 160 700 015) on the
upper plate and rest the lower plate with its nut M10 (item “4”).
Place the damper block between the terminal box and the
stator bracket (item “5”) and fit the screws (item “1”). Do not
tighten to torque at this stage.
Loosen the jack screw (item “2”) so as to obtain a clearance
at the end of the screw on the order of 5 mm.
Tighten all fastening screws (8 screws on each damper block;
item ‘1’) to their nominal torque (according to Chapter 5.6.1).
The four damper pads (one at each corner of the terminal
box) must be changed at the same time.

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.15 MECHANICAL DEFECTS

Fault Action
Excessive overheating of one or - If the bearing has turned blue or if the grease has turned
both bearings black, change the bearing.
Bearing (bearing temperature 80°C above - Bearing not fully locked (abnormal play in the bearing cage)
the ambient temperature) - End shields incorrectly aligned
- Air flow (inlet-outlet) partially clogged or hot air is being
Excessive overheating of recycled from the alternator or engine
Abnormal alternator frame (more than - Alternator operating at too high a voltage (>105% of Un on
temperature 40° C above the ambient
temperature) load)
- Alternator overloaded
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibrations - Rotor balancing fault (Engine - Alternator)
Excessive vibration and humming - Phase imbalance
noise coming from the machine - Stator short-circuit

- System short-circuit
- Misparalleling
Alternator damaged by a Possible consequences
Abnormal - Broken or damaged coupling
noise significant impact, followed by
humming and vibration - Broken or bent shaft end
- Shifting and short-circuit of main field
- Fan fractured or coming loose on shaft
- Irreparable damage to rotating diodes/AVR, surge suppressor

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

5.16 ELECTRICAL FAULTS

Fault Action Effect Check/Cause
The alternator builds up and
its voltage is still correct - Lack of residual magnetism
Connect a new when the battery is removed
battery of 4 to 12 The alternator builds up but - Check the connection of the voltage reference
No voltage volts to terminals its voltage does not reach to the AVR
at no load on E- and E+, the rated value when the - Faulty diodes
start-up respecting the battery is removed - Armature short-circuit
polarity, for 2 to 3 - Faulty AVR
seconds The alternator builds up but - Field windings open circuit (check winding)
its voltage disappears when - Revolving field coil open circuit (check the
the battery is removed
resistance)
Check the AVR connections (AVR may be
faulty)
- Field windings short-circuited
Correct speed - Rotating diodes burn out
Voltage too Check the drive - Revolving field coil short-circuited (check the
low speed resistance)
Increase the drive speed (do not touch the AVR
Speed too low voltage pot. (P2) before running at the correct
speed)
Adjust AVR - Faulty AVR
Voltage too voltage Adjustment ineffective
high - 1 faulty diode
potentiometer
- Check the speed: possibility of cyclic
irregularity
Voltage Adjust the If no effect: try normal or fast - Loose connections
AVR stability - Faulty AVR
oscillations potentiometer stability modes (ST2)
- Speed too low when on load (or AVR LAM set
too high)
Voltage between E+ and E-
Voltage - Check the speed (or AVR LAM set too high)
Run at no load and AREP / PMG < 10V
correct at no check the voltage
load and too - Faulty rotating diodes
low when on between E+ and Voltage between E+ and E- - Short-circuit in the revolving field coil (check
load E- on the AVR AREP / PMG > 15V the resistance)
- Faulty exciter armature (check the resistance)
Check the AVR,
the - Exciter winding open circuit
Voltage surge suppressor, - Faulty exciter armature
disappears the rotating The voltage does not return
to the rated value - Faulty AVR
during diodes, and - Revolving field coil open circuit or short-
operation replace any
defective circuited
components

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

6. TYPICAL ASSEMBLIES AND DRAWINGS

6.1 MACHINE SECTION VIEWS

6.1.1 Machine type A52.3

• Single-bearing

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

• Two-bearing

Ref. Qty Description Screw Torque Ref. Qty Description Screw Torque
Ø N.m Ø N.m
1 1 Stator assembly - - 90 1 Exciter field (stator) M8 20
4 1 Rotor assembly - - 96 2 Air inlet cover IP21 - -
15 1 Fan - - 98 2 Air inlet cover IP23 - -

21 1 Lifting eye - - 100 1 Exciter armature (rotor)

- -
Drive end (DE) flange
30 1 (single bearing) or M12 69 110 6 Diode - -
drive end (DE)
bracket (two-bearing)
33 2 Air outlet grille M6 8.3 120 1 Terminal support - -
36 1 Non drive end (NDE) M12 69 124 5 Terminals - -
bracket
41 1 Terminal box front M6 8.3 128 3 Phase busbar M12 35
panel
47 1 Terminal box rear M6 8.3 130 1 Neutral busbar M12 35
panel
48 1 Terminal box top M6 8.3 190 1 Terminal block - -
panel
49-50 1 Terminal box access M6 8.3 198 1 Voltage regulator (AVR) - -
door
51 1 Air intake grille M6 8.3 199 1 Protective cover IP23 - -
53 1 Sealing cap - - 320 1 Coupling sleeve - -
59 1 AVR inspection door M6 8.3 322 6 Coupling disc M20 340
60 1 Drive end (DE) - - 343 1 Diode bridge assembly M6 4
bearing
68 1 Inner bearing - - 347 1 Surge suppressor - -
retainer (+ PCB)
70 1 Non drive end - - 366 1 Terminal box side M6 8.3
(NDE) bearing panel
Terminal box side
78 1 Inner bearing retainer M8 20 367 1 panel for inspection M6 8.3
door
Preloading (wavy)
79 1 - -
washer
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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

6.1.2 Machine type A53; A54

1 Rotor 10 Polar wheel
2 Bearing (front) 11 Balancing disc
3 Fan hub 12 Exciter field
4 Front spacer 13 Exciter armature
5 Fan 14 Rear spacer
6 Fan screen 15 Bearing (rear)
7 Stator winding 16 Rotating resistances
8 Stator ribs 17 Rotating diodes
9 Stator lamination 18 Diode bridge cover

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LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

6.2 ROLLER BEARING MOUNTING

6.2.1 Machines A52, A53 and A54; standard

3 2

2 1
4 3
5
2
3 4
Ø 290 H6

Ø 160 n5

Ø 300 H6

Ø 140 n5
Bearing assembly "Standard "
Drive end Non drive end
1 End shield 1 End shield
2 End cover 2 End cover
3 End cover stud 3 End cover stud
4 Ball bearing 4 Ball bearing
5 Bearing preload spring

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

7. STANDARD SAFETY REGULATIONS

7.1 EUROPEAN REGULATIONS AND DIRECTIVES

7.1.1 Low Voltage Machines

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

7.1.2 Medium and High Voltage Machines

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 Electric Power Generation Installation and maintenance 5382 en - 2023.02 / i
LSA 52.3 / LSA 53.2 / LSA 54.2
Industrial Range Alternators

7.1.3 Short circuit capacity of the terminal box

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38
 Service & Support

Our worldwide service network of over 80 facilities is at your service.

This local presence is our guarantee for fast and efficient repair, support and
maintenance services.
Trust your alternator maintenance and support to electric power generation experts.
Our field personnel are 100% qualified and fully trained to operate in all environments
and on all machine types.
We have a deep understanding of alternator operation, providing the best value
service to optimise your cost of ownership.
Where we can help:
Design
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Optimisation
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5382 en - 2023.02 / i