SDMO R 340 U User And Maintenance Manual Download

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In automatic mode

Starting

If faults are present, the fault management screen can be accessed by pressing

Reset.

Refer to the section “Alarms and Faults” in the Operating menus” to
eliminate the faults.

If no faults are present, manual mode can be activated by pressing

Auto.

In AUTO mode, except for the test functions, the generating set starts as a result of an external command which may be triggered
by various sources:

power

loss

EJP command (France only)
client

command.

Check there are no faults:

grey: no fault.
red: fault present.

grey: no alarm.
orange: alarm present.

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Summary of Contents for R 340 U

Page 1: ...User and maintenance manual for generating sets R340U 33504081101NE_0_1 ...

Page 2: ...California to cause cancer birth defects and other reproductive harm If this product contains a gasoline engine WARNING The engine from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The state of California requires the above two warnings ...

Page 3: ...6 4 Trailer 27 4 1 Trailer linkage 27 4 2 Check before towing 27 4 3 Operation 28 4 4 Unhitching the trailer 28 4 5 Implementation for installation 29 4 6 Break transmission adjustment 29 4 7 Faults and repairs 31 4 8 Electrical connection diagram 32 4 9 Complete wheels technical information 32 5 Preparation before operating the set 33 5 1 Installation checks 33 5 2 Checks after starting the gener...

Page 4: ...79 6 3 5 4 Facility power outlet 83 6 3 5 5 Connecting cable between the generating sets power plant 84 6 3 5 6 Power 85 6 3 5 7 Client terminal block 85 6 3 6 Operation and setting menus 86 6 3 6 1 Layout of the menus 86 6 3 6 2 Setting of regional parameters 87 6 3 6 3 Information on the KERYS 89 6 3 6 4 Operating menus 91 6 3 7 Rental configurations 93 6 3 7 1 Choice of application configuratio...

Page 5: ...tached preventative maintenance tables If the electrical generating set is used under dusty or unfavourable conditions some of these periods will be shorter Ensure that all repairs and adjustments are carried out by personnel who have received appropriate training Dealers have this qualification and can answer all of your questions They can also supply you with spare parts and other services The l...

Page 6: ...othing must be worn Naked flames and unprotected lights prohibited No smoking Caution toxic materials Eyes and ears must be protected Entry prohibited to non authorised persons Caution pressurised fluids Periodic maintenance must be carried out Jet washing prohibited Caution high temperature risk of burns Battery level must be checked Earth Caution rotating or moving parts risk of getting caught i...

Page 7: ...ance operations DANGER Use diesel fuel only The fuel is highly flammable handle with care Do not smoke near the generating set or expose it to a naked flame or sparks Shut down the generating set engine before filling the fuel tank Fill with fuel outside To prevent fire risks clean the generating set regularly Wipe away any dirt and traces of grease or fuel WARNING DANGER The exhaust gases from th...

Page 8: ...osures Shut down the generating set before any maintenance or servicing operation DANGER Avoid any contact with the exhaust pipes turbochargers and silencers Keep flammable materials away from hot parts Wait for the machine to cool down completely before touching it WARNING DANGER The gas from the battery electrolyte is explosive Keep the batteries away from any flames The battery electrolyte sulp...

Page 9: ...ing set to an external earth terminal WARNING Voltage selector This function should be used by qualified persons only WARNING Adjust the output voltage correctly before connecting a load WARNING The voltage selector must not be used when the generating set is operating Figure 1 2 continued Pictograms and their meanings 7 285 ...

Page 10: ...rt the engine without fitting the air filter The compressor wheel rotating inside the turbocharger may cause serious bodily injury Foreign objects in the inlet pipe may cause mechanical damage Engine with air preheating starting components never use a starting spray or any other similar starter assistance product Upon contact with the starting component an explosion may occur in the inlet tube cau...

Page 11: ... serious damage Risk of blood contamination Drain and dispose of engine oil in a specially provided container fuel distributors can collect your used oil Except by special agreement once closed the gas supply main unit must only be re opened by the gas distributor However the user may access it under certain conditions Check these for each site 1 3 2 Risks related to exhaust gases and fuels The ca...

Page 12: ...rticular to the eyes Never cover the generating set pump unit or lighting tower with any material during operation or just after shutdown wait for the engine to cool Do not touch hot parts such as the exhaust pipe or put combustible materials on it Keep all flammable or explosive materials e g petrol oil cloth etc out of the way when the set is running Proper ventilation is required for your gener...

Page 13: ...ately and activate the emergency stop on the generating set or lighting column If the voltage has not yet been cut off move the victim out of contact with the live conductor as quickly as possible Avoid direct contact both with the live conductor and the victim s body Use a dry plank of wood dry clothes or other non conductive materials to move the victim away The live wire may be cut with an axe ...

Page 14: ...s of identification plates The precise rules for identifying each major component engine alternator etc are set out in each manufacturer s documents contained in this manual Examples of identification plates Generating set Engines Figure 1 2 Examples of identification plates 12 285 ...

Page 15: ...Alternator Cabinet Figure 1 3 Examples of identification plates 13 285 ...

Page 16: ...cription 2 1 Description Overview 1 Control unit 4 Protective grilles 2 External emergency stop 5 Chassis 3 Expansion bottle 6 Circuit breakers Figure 2 1 General description of the generating set 3 4 2 1 5 6 14 285 ...

Page 17: ...description of the generating set 9 Coolant filter 12 External fuel supply combined tap optional 10 Filling with fuel 13 Circuit breaker 11 Oil filters 14 Interchangeable fuel pre filters Figure 2 1 continued General description of the generating set 9 10 11 12 14 13 7 8 15 285 ...

Page 18: ...Sockets voltage 208 120V 16 285 ...

Page 19: ...7 274 2 342 7 380 220 V 60 3 0 8 573 301 6 377 274 2 342 7 220 127 V 60 3 0 8 989 301 6 377 274 2 342 7 208 120 V 60 3 0 8 1046 301 6 377 274 2 342 7 1 ESP Stand by output available for emergency use under variable charge up to 200hrs per year as per lSO 8528 1 no overload available under these service conditions 2 PRP Main output available continuously under variable load for an unlimited time pe...

Page 20: ...e AREP Voltage regulator R450 Short circuit current 3 IN Number of bearings 1 Coupling Direct Control unit s TELYS Standard specifications Voltmeter Ammeter Frequency meter Alarms and faults Oil pressure Water temperature Start failure Overspeed Alternator min max Battery voltage min max Emergency stop Engine parameters Timer Oil pressure Water temperature Fuel level Engine speed Battery voltage K...

Page 21: ... with the most demanding applications Depolluted engines complies with EURO 2 and EURO 3 technology and can be used with all types of diesel fuel especially ecological diesel with low sulphur content PERFORMANCE ACEA E3 API CH 4 Meets level E3 of the specifications defined by European manufacturers in the ACEA standards 98 edition ADVANTAGES Less frequent oil services this product has been put to ...

Page 22: ...against high temperature corrosion by oxidisation of ethylene cylinder head protection Protects against high temperature cavitation top of cylinder and coolant pump protection Non corrosive for seals and hoses Improves the efficiency and longevity of the cooling system GenCOOL PC 26 is especially recommended for engines fitted with aluminium or light alloy radiators HIGH TEMPERATURE SUITABILITY Pr...

Page 23: ...e observed Lifting machinery or equipment appropriate to the work required Slings positioned in the eyes provided for this operation or lifting arms resting fully underneath the chassis cross members Ground able to take the load of the set and the lifting machinery without stress otherwise lay down beams of sufficient strength and stability Set put down as close as possible to its point of use or ...

Page 24: ...tion Figure 3 1 Transporting a generating set using a forklift truck 3 2 Fluid retention Any outflow of the fluids contained in the generating sets fuel oil and coolant or rainwater or condensation will be collected in a retention container if the generating set is fitted with this option The containers have a capacity which allows 110 of the fluids contained in the generating set fitted with this...

Page 25: ... a high level indicator in the retention container In all cases the retention containers must be regularly checked to ensure they contain no fluid fuel oil and coolant or rainwater or condensation If necessary drain the containers either via the drain port or by using the drain pump for containers fitted with this pump Note Never allow these fluids to drain onto the ground ensure they are collecte...

Page 26: ...rnt gas evacuation and the direction of these gases and the noises emitted should be taken into account The choice of its position will be based on carefully considered compromise Examples of problems that may be encountered Incorrect exhaust and ventilation Ground too uneven or soft Set incorrectly positioned Reduced access Fuel filling impossible Opening cover doors impossible Figure 3 5 Example...

Page 27: ...7 16 5 63 16 5 16 5 25 3 80 25 3 25 3 35 2 100 35 2 35 2 4X 1X50 0 125 1 4X 1X50 0 4X 1X50 0 4X 1X70 2 0 160 1 4X 1X70 2 0 4X 1X70 2 0 4X 1X95 4 0 250 1 4X 1X95 4 0 4X 1X150 2350MCM 4X 1X150 2350MCM 400 1 4X 1X185 0400MCM 4X 1X185 0400MCM 4X 1X185 0400MCM 630 1 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM 4X 2X1X150 2x 2350MCM Single phase Calculation hypothesis Fitting method wiring in cable runs ...

Page 28: ...ature of ground Length of rod in metres Thick arable land moist compact ballast 1 Lean arable land Gravel coarse ballast 1 Bare stony soils dry sand impermeable rock 3 6 To obtain an equivalent length you can use several earthing rods connected in parallel and set apart by at least their length Example 4 interconnected 1 metre rods separated by 1 metre Note For the United States National Electrica...

Page 29: ... the locks on each side of the wheels then lift up the front wheel fully using its handle Connect the electrical circuit of the trailer to that of the tow vehicle Hook the handbrake safety wire onto the hook on the tow vehicle Figure 4 1 Coupling a trailer 4 2 Check before towing Before towing check the following Tightness of the generating set enclosure bolts Wheel tightness Hitching hook locked ...

Page 30: ...les driving heating of the brake hubs and drums will actually reduce the wheel tightness It is therefore essential to check the tightness every 6 miles 10 kilometres until no further loosening is noted Nonetheless the tightness must be checked whenever you are about to tow the trailer Warning Lights signalling only for on road trailers Warning lights are obligatory for on road driving Signalling m...

Page 31: ...using the tensioner 6 until a gap J1 of 1 mm max is obtained between the linkage 9 and slide 2 Adjust the compensating spring 4 at one end pressing it against the anchorage plate and at the other end leaving a 2 mm gap J2 max between the spring and nuts 5 Tighten all the lock nuts Checking the setting trailer on axle stands Pull the parking lever 2 notches the wheels cannot turn in a FORWARD direc...

Page 32: ...Figure 4 3 Braking transmission Figure 4 4 Cross bar fitting Figure 4 5 Tandem bearing fitting 30 285 ...

Page 33: ...lide guide rings Replace the rings and possibly the slide and grease Faulty shock absorber Replace the shock absorber Trailer tending to swerve upon braking Cross bar s not balanced Adjust the cross bar s Different brake setting on the two sides Adjust the brake settings Cables damaged or incorrectly fitted Replace the damaged parts Refit the cables Poor load distribution Check the load distributi...

Page 34: ... 550 134 265 335 2 4 145 R 13 75 T 566 145 272 387 2 4 155 R 13 79 T 578 150 277 437 2 4 145 70 R 13 71 T 534 150 259 345 2 5 155 70 R 13 75 T 548 147 263 387 2 5 185 70 R 13 86 T 594 185 285 530 2 5 165 R 14 C 98 N 622 172 284 650 3 8 155 70 R12 100 N 525 155 244 650 1 800 2 6 25 185 R 14 C 102 P 650 188 316 675 1 850 2 4 5 195 R 14 C 106 P 666 198 32 950 4 5 195 50 x 10 98 N 450 190 750 6 0 1 Wh...

Page 35: ...mperature etc 6 Using the generator set 6 1 Pre Start Inspection Engine and engine compartment general check Visually check the engine and engine compartment before starting the engine and after stopping the engine Check there are no oil fuel or coolant leaks the screws are tightened the condition of the belts wear tension Fuel oil and grease deposits on the engine or in the engine compartment are...

Page 36: ... in the cooling system Only open the filler cap 1 Important The coolant level must be between the MIN and MAX marks Top up the oil if necessary Checking the air filter clogging indicator Special air filters must be used for extremely dusty conditions Important Replace the filter when the indicator remains in the red zone after the engine has been stopped Reset the indicator after the filter has be...

Page 37: ...eel for scrolling through the menus and screens and selecting items simply by pressing the wheel 5 STOP button press to switch off the generating set 6 START button press to switch on the generating set 7 Power ON LEDs and alarm fault warning LEDs 8 Location of USB ports 9 Mounting bolt 10 LCD for displaying alarms and faults operating statuses electrical and mechanical quantities 11 ESC button fo...

Page 38: ...shing red 3 Module on green on continuously Figure 6 6 Close up of USB ports 1 USB key connection HOST file transfer between USB key and TELYS and vice versa 2 Connection for microcomputer DEVICE file transfer between PC and TELYS and vice versa main module power supply 3 Protective cover 2 3 1 1 2 3 36 285 ...

Page 39: ...ams relating to dimensions measured are displayed as well as Alarm and Fault pictograms Zone 3 in this zone the measured values corresponding to the measured dimensions are displayed with the corresponding units of measurement Zone 4 in this zone messages relating to the control of the generating set and the menus are displayed Note the information displayed on measurements alarms and faults as we...

Page 40: ...NU mode AUTO Mode Fixed TELYS in automatic mode AUTO Flashing For 5 seconds when switching from MANU mode to AUTO mode Flashing Generating set in start up phase Fixed Generating set started Fixed Generating set stabilised voltage and frequency Flashing appearance of constant movement from left to right The generating set is powering the installation Fixed The installation is supplied Not used Not ...

Page 41: ...level fault alarm Alarm High temperature fault No preheating fault alarm Battery Min battery voltage flashing Max battery voltage flashing Battery charge indicator flashing bars Oil pressure temperature indicator Oil pressure Alarm Fault High or low oil level Alarm Fault High or low oil temperature Alarm Fault Emergency stop Emergency stop fault Overload or short circuit Tripping of circuit breake...

Page 42: ...ature coolant HT units according to settings menu Indication of Battery Voltage Indication of Oil Temperature units according to settings menu Generating set start up or generating set started or generating set switching off in progress Screen no Pictograms Data displayed P2 Engine Speed Indication Indication of Temperature of High Temperature coolant units according to settings menu Indication of...

Page 43: ...U31 Alternator composite Voltage Indicator Alternator Frequency Indicator P5 V1 Alternator single Voltage Indicator V2 Alternator single Voltage Indicator V3 Alternator single Voltage Indicator Alternator Frequency Indicator P6 U12 Alternator composite Voltage Indicator V2 Alternator single Voltage Indicator V1 Alternator single Voltage Indicator Alternator Frequency Indicator P7 V1 Alternator sin...

Page 44: ...el Level Indicator Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on Type of network Order of appearance 3P N 3P 2P N 1P N 1 P3 P3 P3 P3 2 P4 P4 P6 P7 3 P5 P8 P8 P9 4 P8 P9 P9 P2 5 P9 P2 P2 P10 6 P2 P10 P10 7 P10 Change screens by using the scrolling and selection wheel When the wheel is rotated clockwise the sc...

Page 45: ...displayed G 1 Initialisation of TELYS when the power is switched on and or when loading a configuration G 2 SERIAL No 08030010000 SOFTWARE 6 1 0 NOMINAL VOLTAGE 400V FREQUENCY 50Hz NOMINAL KW 320kW EARTH SYSTEM TNS Generating set serial no Software version of TELYS Alternator Nominal Voltage Alternator Nominal Frequency Nominal Active Output Neutral Point Bar graph indicating the display delay of ...

Page 46: ...UTOMATIC Start 19 min 30 sec 24 08 2005 13 12 Operating mode generating set in Auto Mode with programmed start Countdown to micro disconnection delay or EJP notice delay for France only Date and time depending on settings Generating set start up Screen no Screen Data displayed G 6 START UP IN PROGRESS 24 08 2005 13 12 Operating phase generating set in starting phase Date and time depending on sett...

Page 47: ... changeover switch controlled by TELYS Countdown for the mains return delay OR the load test delay Date and time depending on settings G 10 AUTOMATIC STOP IN PROGRESS COOLING DOWN 1 min 30 sec 24 08 2005 13 14 Operating mode operation in Auto Mode Generation set cooling in progress Countdown for Engine Stop delay cooling OR Gradual Stop delay Coolant temperature OR Overload Gradual Stop delay OR O...

Page 48: ...perating mode operation in Manual Mode AUTOMATIC start demand Generating set stop request due to fault or by pressing STOP in Auto Mode Screen no Screen Data displayed G 13 Manual Mode activated Do you wish to change to AUTO mode OK Esc Operating mode operation in Auto Mode generating set in operation Warning message for switching to Manual Mode after the STOP button has been pressed or a fault ha...

Page 49: ...3 12 Check the battery voltage Press START AIR PREHEATING 10 seconds 24 08 2005 13 12 If the engine is equipped with an air preheating system there is a delay adjustable before the engine starts preheating activation period If the motor is not fitted with an air preheating system or once the preheating delay has elapsed the engine starts up start of a cycle comprising 3 attempts to start up the en...

Page 50: ...6 2 4 1 Viewing alarms and faults Alarms and faults are displayed as follows Alarms All alarms will cause the yellow LED to flash General alarm In conjunction with this LED a flashing pictogram appears on the LCD screen representing the circuit affected by the alarm and the associated indicator if present example message on graphic display example FAULT ALARM Low Fuel Level 25 12 05 15 30 OK HELP ...

Page 51: ...f an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed examples below FAULT ALARM Low coolant Level 06 10 06 10 30 OK HELP FAULT FAULT Emergency Stop 06 10 06 15 30 Esc RESET OK HELP Press OK on the scrolling and selection wheel to access the help message if it is available example below HELP Check the level fuel Esc EXIT If the alarm is no longer...

Page 52: ...and selection wheel examples below FAULTS 1 2 FAULT 25 12 05 15 30 Emergency Stop ALARM 25 12 05 15 30 Low Fuel Level 12 OK HELP Esc Press Esc to return to the previous screen Press OK to go to the HELP screen help on the highlighted fault Use the scrolling and selection wheel to scroll through the list of faults HELP Check Emerg Stop Pos Connector s Esc If the alarm is no longer active it is rese...

Page 53: ...articularly to a specific component for example a sensor PPID Parameter Identifier This term used in the J1587 standard has an equivalent in the J1939 standard SPN PPID corresponds to PID but is only used by VOLVO FMI Failure Mode identifier This represents the type of fault that has occurred This may be an electrical mechanical or equipment fault VOLVO uses a SID FMI or PID FMI or PPID FMI combin...

Page 54: ...ult are included in the user and maintenance manuals of the engines supplied with the generating set documentation For JOHN DEERE JD PERKINS PE and VOLVO VO engines the codes displayed are SPN and FMI codes 6 2 4 5 Horn reset Depending on the settings made menu 363 HORN the activation of an alarm and or a fault leads to the horn sounding and the following screen appearing HORN STOP PRESS OK 25 12 ...

Page 55: ...ce module also called MMI module base module heart of the system regulation module protection module logic input output module analogue input output module temperature input module For the operation of a generating set in the smallest possible architecture at least the following elements will be found a man machine interface module a base module a regulation module 6 3 1 1 Operating conditions Ope...

Page 56: ...ency range 57Hz 150Hz Continuous 0 5 g constant acceleration Occasional 1 g constant acceleration Complies with standard IEC 68 2 6 test Fc Shock resistance Occasional shocks 15g 11ms semi sinus Complies with standard IEC 68 2 27 test Fa Emissions Complies with standard EN55022 class A Variation in supply voltage EN61131 2 6 3 7 3 Immunity Complies with standard IEC 61000 4 2 Electrostatic dischar...

Page 57: ...batch number 1800 the 1800th module manufactured since the start BATCH No 08 06 08 year of manufacture year 2008 06 week of manufacture week 6 Base module Base module P N 31613390901 Module item reference D338000 B8 D338000 manufacturer product reference B8 Module hardware upgrade index S N 3491 3491 serial number not related with a batch number 3491 the 3491 st module manufactured since the start...

Page 58: ... in week 04 of the year 2008 i e a maximum of 999 modules that can be related with a batch number Protection module Protection module 31613391601 Module item reference A44Z2 E A44Z2 manufacturer product reference E main module hardware upgrade index 4307A035 43 week of manufacture week 43 07 year of manufacture year 2007 A secondary module hardware upgrade index 035 serial number related with a ba...

Page 59: ...P N 31613391301 Module item reference D343000 B1 D343000 Manufacturer product reference B1 module hardware upgrade index S N 0200 0200 serial number not related with a batch number 0200 the 200th module manufactured since the start BATCH No 06 49 06 year of manufacture year 2006 49 week of manufacture week 49 Temperature inputs module Temperature inputs module ETEMP P N 31613391401 Module item ref...

Page 60: ...ific projects 2007_02_12 Date of software version in English year month day For a modification of a software version during the life of one of the products developments corrections etc the new software version implemented will be entered by hand in a space reserved for this The old software version will then be deleted factory soft version V1 05c 2007 02 12 Location of the version labels MMI Base ...

Page 61: ...cifications 7 inch colour TFT display 16 9 65536 colours dimensions 154 mm x 86 mm neon backlighting 480 x 234 resolution touch panel 8 columns x 8 rows Signalling control keys Operating buttons of the generating set Backlit display with touch sensitive keypad Alphanumeric keypad Navigation keys M M I operation LED flashing 59 285 ...

Page 62: ... breaker is open 8 Grid circuit breaker opening control 9 Led indicating that grid circuit breaker is open 10 Grid circuit breaker closing control 11 Led indicating that grid circuit breaker is closed 12 Led indicating the presence of grid voltage 13 Led indicating that grid circuit breaker is closed 14 Closing control for generating set circuit breaker 15 Led indicating the presence of generating...

Page 63: ...e numerical key corresponding to its name The alphanumeric keys They allow alphanumeric input by successive pressing of the keys The characters entered appear in the order they were typed on the keypad Move to the right Move up Move down Confirm function of selected key Return to upper level or escape for the dialogue boxes Move to the left 61 285 ...

Page 64: ...ance Navigation screens These screens enable the various sub menus to be accessed 15 07 09 19 10 00 GS 1 System Auto Faults Alarms 0 Welcome 1 Operation 2 Function keys 7 User adjustments 3 Synchro column 6 Alarms Faults 4 Central measurements summary 5 Measurements When a key is selected the lower level sub menu appears if available or the allocated operation screen A sub menu can also be accesse...

Page 65: ...ent archive Auto Faults Alarms 1 Electrical archive 2 Mechanical archive 3 Event metering Upper band Indications 15 07 09 19 10 00 GS 1 Welcome Auto Faults Alarms Upper band Central section Lower band Date of the system Time of the system Reference of the GS with which the M M I dialogues Indication of the presence of a fault on the GS concerned flashing red Indication of the presence of an alarm ...

Page 66: ... key Valid saves the modification the escape key Esc cancels the modification Access to the regional parameters screen Access to the regional parameters screen Access to the Drive or TOR variables screen Access to the Alarms and Faults screen Access to the Alarms and Faults screen When configured in power plant with switches displays a dialogue box enabling you to select the generating set to whic...

Page 67: ...concerned These indications are linked to the type of modified parameter Time in 1 10 second 6000 0 0000 9999 Valid Esc Saves the changes and closes the dialogue box Deletes the entire text Deletes the letter shown by the cursor Closes the menu without saving the changes Name of the modified function Text to be modified or created Inserts a space to the left of the cursor Saves the modifications a...

Page 68: ... flash operation Following a modification a red Sauvegarde à faire Save indicator light flashes at the top left of the screen Pressing this indicator light brings up one of the following dialogue boxes Save in flash Valid Esc Save in flash Customer 3 Factory Valid Esc Always select Client Pressing Valid confirms the operation pressing Esc cancels it List indicating possible selections Arrows for m...

Page 69: ...h A633 Automatic operation of a single genset Temporary coupling on grid return following interruption Without N E switch A632 Operation of a power plant without coupling to grid Normal emergency switch NES not controlled by Kerys Power plant gensets interconnected by parallel lines Operation of a power plant without coupling to grid Normal ermegency switch NES not controlled by Kerys Power plant ...

Page 70: ...ty for an installation from an external starting command dry contact The generation of electricity for an installation in forced operation Regulation module Base module CAN Bus Ethernet 3PH N 3PH M MMI module Application load Automatic operation Kerys in AUTO mode Loss of grid voltage Generating set start request dry contact switch clock etc The speed and voltage of the generating set increase Gen...

Page 71: ...y using the MMI keypad The generating set power unit is switched off by means of the MMI keys The safety devices of the generating set remain active in this mode of operation This mode of operation is the responsibility of the operator Temporary coupling to the grid A651 This configuration is designed to provide Emergency electricity supply to an installation following a grid loss Return to the gr...

Page 72: ...enerating set is stabilised in speed and voltage synchronisation of the generating set to the grid is requested After synchronisation the generating set power unit is switched off Transfer of the active and reactive power from the grid to the generating set according to a predetermined ramp The ramp does not exceed 10 seconds for transfer of the generating set s rated output The generating set pow...

Page 73: ...tion generating set voltage the generating sets are static Note 2 In an installation of the power station type several generating sets in parallel two modes of coupling between generating sets are possible Coupling when stopped Coupling in normal operation Principle of coupling when stopped all the generating set power units are switched off starting of all the generating sets when the speed reach...

Page 74: ...ircuit breaker 1 is closed the voltage is present on the busbar Kerys 2 analyses the differences between U2 and U of the busbar before coupling Kerys 3 analyses the differences between U3 and U of the busbar before coupling Each Kerys independently of its neighbour will close its discharge on the central busbar Wattmetric control The wattmetric control is used when two generating sets are coupled ...

Page 75: ...controlled by the mains detection module Generating set power units switched off Generating set start request The generating sets speed increases Speed stabilisation delay Order of excitation for each generating set at nominal speed the voltage is then quickly established on the busbar Start of distribution of active power Resumption of use at the rated power and frequency Wattmetric control This ...

Page 76: ...s remain active in this mode of operation This mode of operation is the responsibility of the operator Without common part and without Normal Emergency inverter A633 This configuration is designed to provide Emergency electricity supply to an installation following a grid loss The grid loss is not controlled by the Kerys Return to the grid can be achieved via Normal Emergency switchover with a sel...

Page 77: ...and frequency to a busbar supplied by a generating set designed as master at the output A number 1 to 15 is assigned to each Kerys This number serves solely to establish the IP address of each Kerys for communication by Ethernet and loading the programs A second number from 1 to 15 is also assigned to each Kerys and defines the priority Example let us assume a plant of 8 generating sets Gen set 1 ...

Page 78: ...ed with GS1 and GS2 Its flow is then closed The third GS thus coupled initiates its power on ramp adjustable delay and the distribution of power among the three generating sets takes place Each generating set will then take 33 33 of the required power i e 300 kW corresponding to 50 of its rated output 600 kW When the power required for the application reaches 75 of the power of the three GSs in op...

Page 79: ... Grid return acquisition delay controlled by the mains detection module Generating set power units switched on Cooling delay Generating sets stopped and set to standby The Kerys PLCs remain in AUTO mode FORCED OPERATION Start of FORCED OPERATION Generating set power units switched off Generating set start request The generating sets increase in speed Speed stabilisation delay Order of excitation f...

Page 80: ...33 Ground connection X X Ground connection box X X Facility power outlet O O O O Connecting cables between the generating sets CAN BUS X Connecting cables between the generating sets Parallel line X Power cables X X X X Customer terminal Remote operation z z z z External emergency stop z z z z EJP z z z z Switch grid detection 1 z z z Grid detection by regulation card 1 z X z z Emergency N E switc...

Page 81: ...pact hard core 1 Poor arable land 1 Poor arable land gravel coarse hard core 1 Stony bare soils dry sand impermeable rocks 3 6 To obtain an equivalent length several ground rods can be used connected in parallel and separated by at least their length Example Four 1 metre rods interconnected and separated by 1 metre respectively Check the earthing connection before switching on the generating set C...

Page 82: ...R N R S T Neutral Ground Ground rod DISJONCTEUR N R S T Neutral Ground Ground rod DISJONCTEUR N R S T Ground Ground rod Interconnection bar between genset grounds Interconnection bar between genset grounds Interconnection bar between genset grounds CIRCUIT BREAKER Neutral connected to grounds Current transformer Current transformer Current transformer CIRCUIT BREAKER CIRCUIT BREAKER 80 285 ...

Page 83: ...nd rod for one generating set power plant Important Genset 1 Genset 2 Ground rod Neutral Earth junction box GS1 current transformer link GS2 current transformer link GSX current transformer link 1 current transformer per GS Genset x Genset 2 Genset 1 Genset x 81 285 ...

Page 84: ...ral connected to grounds Ground Ground rod DISJONCTEUR N R S T Ground Ground rod DISJONCTEUR N R S T Neutral Ground Ground rod Junction box If equipped CIRCUIT BREAKER CIRCUIT BREAKER CIRCUIT BREAKER Current transformer Current transformer Isolated neutral Current transformer 82 285 ...

Page 85: ...ility power outlet if fitted provides the emergency supply to the generating set from an external electrical source It enables the different units preheating desk etc to be powered without using their batteries 7 44 45 42 43 40 41 38 39 36 37 34 35 32 33 30 31 28 29 46 47 48 Xcbc3 7 44 45 42 43 40 41 38 39 36 37 34 35 32 33 30 31 28 29 46 47 48 Xcbc3 Junction box Remove the shunts at terminals 45 ...

Page 86: ...t Important The generating set power cables the generating set connecting cable and the connections must be in perfect condition Replace them if necessary Important Generating set 1 019x04 019x12 Generating set 2 019x04 019x12 2 generating sets Generating set 1 019x04 019x12 Generating set 2 019x04 019x12 Generating set 3 019x04 019x12 Generating set x 019x04 019x12 3 or more generating sets Conne...

Page 87: ...k that the direction of rotation of the phases between the generating set and the application is the same Important Type of cables Use H074NF type cables according to the standards in force in the country of use of the generating set In France refer to the standard C15 100 6 3 5 7 Client terminal block Refer to the wiring diagrams according to the configuration selected and the requirements GENERA...

Page 88: ...es 3 1 Events archives 3 2 Electrical archives 3 3 Mechanical archives 3 4 Events metering 3 5 Mechanical metering 3 6 Electrical metering 1 1 Operation 4 1 Provider 4 2 Emails 4 3 Service intervals 4 4 Consumables 4 5 Progress reports 5 1 Equipment 5 2 Applications 5 3 Regulations 5 4 Safety features 6 1 Regional parameters 6 2 Application identification 6 3 Software versions 6 4 Printing 6 5 Acc...

Page 89: ...ers Stop Faults Alarms Français English Espanol Deutsch Portugues Language option Day Month Year hours Minutes Seconds 22 10 07 17 10 00 Inhibit the keys 1 Identification application 2 Software versions 3 Printing To clean the touch screen dust hydrocarbons etc the key inhibition function prevents keys on the screen from being pressed for some twenty seconds A special screen shows the time elapsin...

Page 90: ...inutes Seconds 22 10 07 17 10 00 Inhibit the keys SDMO welcome logo KOHLER welcome logo 1 Identification application 2 Software versions 3 Printing In this case the transmission of a signal to the bus enabling the different real time clocks to be reset is defined by the synchronisation time Pressing the KOHLER home logo key alters the appearance of the home screen by replacing the KOHLER logo with...

Page 91: ...eference 6 2 This screen enables SDMO to identify the project This information is required for queries sent to SDMO s customer service so that the associated file can be consulted 15 07 09 19 10 00 GS 1 Identification application Stop Faults Alarms Site name Dealership number 000000 OM number 000000 Connection number 000000 1 Software versions 2 Printing 3 Access management Project number referenc...

Page 92: ...menu Only the lines corresponding to the installed equipment appear 15 07 09 19 10 00 GS 1 Software versions Stop Faults Alarms Module Software versions Software version dates IHM 0 00 00 00 00 Base 0 00 00 00 00 Resident logic 0 00 00 00 00 Regulation 0 00 Protection 0 00 Engine 0 00 1 Identification application 2 Printing 3 Access management 90 285 ...

Page 93: ...and voltage adjustment keys are only displayed for coupled applications in manual mode Important Alarms and faults This menu can also be called directly by pressing the flashing Alarms and Faults keys on the upper band This screen allows the user to view the list of faults present on the installation The first two columns give details of the date and time that the fault appeared The Status column ...

Page 94: ...t the fault has disappeared status 0 and whether it is necessary to eliminate its causes select the line in question the text on the line is displayed in white press the Reset key on the keypad the line is deleted When a fault is displayed its effect on the operation remains active even if its cause has disappeared When in Manu or Auto mode if the user wants to clear a fault with a stopped clearan...

Page 95: ...THOUT GRID COUPLING APPLICATION A612 2 PRODUCTION POWER PLANT WITHOUT GRID COUPLING APPLICATION A632 A633 3 NOT APPLICABLE 4 SOLO GENERATING SET WITH GRID COUPLING APPLICATION A651 If the switch is already set to 1 turn the switch and return to position 1 After changeover the screen below appears 15 07 09 19 10 00 GS 1 Rental application Stop Faults Alarms A612 Single Genset without N E Validation...

Page 96: ...ng by means of an external switch you must select the configuration Mains supply detection using an external contact and connect the external switch to the terminals Xcbc3 32 33 For solo starting in the absence of a mains connection you must select the configuration Mains supply detection using an external contact No connection is necessary N B selecting detection depends on the connection made ac...

Page 97: ...isolator switch Wait 5 seconds Turn off the battery isolator switch Important Solo generating set CRF coupling A651 1 Turn off the battery isolator switch 2 Check that the emergency stop buttons are activated 3 Press the STOP button of the KERYS 4 Turn the changeover switch to position 4 1 SOLO GENERATING SET WITHOUT GRID COUPLING APPLICATION A612 2 PRODUCTION POWER PLANT WITHOUT GRID COUPLING APP...

Page 98: ...id CT ratio 20 0 5 To enter the value of the grid current transformer ratio press the GRID CT RATIO button on the touch screen Using the alphanumeric keys of the MICS KERYS enter the value of the CT ratio in tenths Example CT 100A 5A calculation 100 5 20 20x10 200 value to be entered 200 CT BUSBAR Grid setting 1 1 10 0 0200 32767 Valid Esc 6 Then press VALID 96 285 ...

Page 99: ...nset coupling Validation Grid CT ratio 20 0 7 Press the Validation button on the touch screen 15 07 09 19 10 00 GS 1 Rental application Stop Faults Alarms A651 Temporary power grid single Genset coupling Validation Grid CT ratio 20 0 8 The KERYS saves your new configuration Saving in flash 97 285 ...

Page 100: ...OLO GENERATING SET WITH GRID COUPLING APPLICATION A651 If the switch is already set to 2 turn the switch and return to position 2 After changeover the screen below appears Choix configuration centrale loueur A632 Power plant without shared switching unit without Normal Emergency parallel line A633 Power plant without shared switching unit without Normal Emergency Digital Bus 5 Select the configura...

Page 101: ...ental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 7 Enter the number of generating sets in the power plant using the numeric keypad Start with 0 if the number is less than 10 generating sets E g 2 generating sets enter 0 then 2 10 generating sets enter 1 then 0 8 Pr...

Page 102: ...n Back up to perform GS 1 Rental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 10 Select the number of the generating set with the arrows The number of the generating set determines its type of connection see the section Electrical connections Important 11 Press Valid...

Page 103: ...er of gen sets in power plant 2 Genset number 1 12 Press Validation on the touch screen Back up to perform GS 1 Rental application Stop Faults Alarms A633 Power plant without shared switching unit without Normal Emergency Digital Bus Validation Number of gen sets in power plant 2 Genset number 1 13 The Kerys saves your new configuration Saving in flash 101 285 ...

Page 104: ...Important Operations to be carried out on each generating set of the power plant Important 6 3 8 Use 6 3 8 1 Choice of priority generating set in power plant if equipped Mnemonic aid info for menus 1 7 4 3 GS selection Priority selection Valid 15 07 09 19 10 00 GS 1 Welcome Stop Faults Alarms 1 Operation 6 System 2 Fault finding 5 Configuration 3 Archiving Metering 4 Maintenance 1 Press Operation ...

Page 105: ...hro column 6 Alarms Faults 4 Central unit measure summary 5 Measurements 2 Press User settings on the touch screen 15 07 09 19 10 00 GS 1 User adjustments Stop Faults Alarms 0 Operation 1 Set point 2 Output threshold 3 Wattmetric Control 4 User parameters 1 2 3 Press User parameters 1 2 on the touch screen 103 285 ...

Page 106: ... coupl In normal mode 1 Set point 2 Wattmetric COntrol 3 Generating set priority 4 Press Generating set priority on the touch screen 15 07 09 19 10 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 5 Press the selection arrows on the touch screen to selec...

Page 107: ...eral parameters 2 Thresholds 6 Press the selection arrows on the touch screen to select the priority of the generating set selected 15 07 09 19 10 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 7 Press Valid on the touch screen 105 285 ...

Page 108: ... GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 8 Press Save on the touch screen Back up to perform GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 9 Press Valid on the touch screen Save in flash Valid Esc 106 285 ...

Page 109: ...0 00 GS 1 Generating set priority Stop Faults Alarms Modification GS select 01 Priority select 02 Valid Return to the previous priorities Display GS 1 2 PRI 02 01 1 General parameters 2 Thresholds 11 Press Generating set priority on the touch screen to return to the home screen The configuration will only be considered valid if the following operations are carried out Open the battery cutout Wait ...

Page 110: ... screen can be accessed by pressing Reset Refer to the section Alarms and Faults in the Operating menus to eliminate the faults If no faults are present manual mode can be activated by pressing Manu Check there are no faults grey no fault red fault present grey no alarm orange alarm present 108 285 ...

Page 111: ...tances be used to turn the engine over manually During the start up phase and until the alternator voltage and speed of the generating set stabilise the green LED under the generating set symbol flashes and then lights up permanently once the phase is complete Tests If no faults are present automatic mode can be activated by pressing Auto The test starting phase is then initiated after pressing 1 ...

Page 112: ...e orange LED on the test keypad lights up steady During the start up phase and until the alternator voltage and generating set speed stabilise the green LED underneath the symbol for the generating set flashes and becomes steady at the end of this phase The installation is then controlled via the programmable controller in accordance with the configuration of the application normal emergency sourc...

Page 113: ...t Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped Switching off The generating set may be stopped at any time by pressing Stop or 0 on the test keypad The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped Pressing Stop stops the generating set immediately Pressing 0 does not ...

Page 114: ...nate the faults If no faults are present manual mode can be activated by pressing Auto In AUTO mode except for the test functions the generating set starts as a result of an external command which may be triggered by various sources power loss EJP command France only client command Check there are no faults grey no fault red fault present grey no alarm orange alarm present 112 285 ...

Page 115: ...up the following window for selecting the test type 15 07 09 19 10 00 GS 1 Operation Manu Faults Alarms I1 A 2701 F P 0 9 L Q kVAr Speed rpm 1505 765 Operating time 10 05 Speed Speed U U 1 Function keys 2 Synchronisation column 3 Power plant measurements summary Using the KERYS Tactil Man Machine Interface the under load test is started by pressing the corresponding key Using the KERYS Tactil Man ...

Page 116: ...g etc The Normal Emergency switchover with grid coupling is only possible by carrying out a load test The purpose of the off load test is to start a single GS or to couple a power plant x generating sets to the emergency busbar Important At any time the generating set may be stopped by pressing Stop or by pressing 0 on the test keypad Pressing Stop may interrupt the power supply depending on its s...

Page 117: ...nerating set will stop after the cooling delay 180 seconds by default Important The green LED underneath the generating set symbol goes out to indicate that the generating set has stopped 6 3 8 3 Rental options Damper valve Optional X If the generating set stops when the valve damper is closed repair the fault Y Display the fault according Z Press Reset to clear the fault after it has been repaire...

Page 118: ...r plant Important Bi frequency Optional Turn the switch to the desired frequency and voltage FREQUENCY Earthing system Turn the switch to the desired earthing system EARTHING SYSTEM 1 IT 2 TN TNS 3 TT TT or EDF APPLICATION The EDF earthing system is only used in the so called rental configurations The switch must necessarily correspond to the wiring described in the section on Connection of the ge...

Page 119: ...akage I Inspection with VODIA diagnostic tool I Engine and transmission abnormal noises I Stop engine Engine oil and oil filters by pass filter R Restart engine Oil pressuer oil leakage I Every 50 600 hours At least every month 12 24 48 Engine oil and oil filters by pass filter R After the first 1 000 hours Valve clearance I Every 500 hours At least every month 12 24 48 Fuel tank sludge trap drain...

Page 120: ...Alternator After 20 hours in operation check the tightness of all the mounting bolts the general condition of the machine and the various electrical connections of the installation The bearings fitted on the machine are greased for life to around the service life of the grease depending on use 20 000 hours or 3 years Regularly clean the inlet and outlet grid 118 285 ...

Page 121: ...itch to the OFF position or disconnect the battery negative cable to cut off the electrical current Electrolyte contains dilute sulphuric acid Careless handling of the battery causing contact with sulphuric acid could damage your eyesight or cause burns Wear safety goggles and rubber gloves when working with the battery topping up fluid charging etc If electrolyte comes into contact with your skin...

Page 122: ...ttery rest for 20 minutes Before fitting the battery stop the engine and any power consumer clean the terminals and give them a light coating of grease When connecting connect the positive terminal first and then the negative terminal 8 3 Check Acid density Charge status Voltage when idle 1 27 100 Above 12 60 V 1 25 80 12 54 V 1 20 60 12 36 V From 50 recharge 1 19 40 12 18 V Risk of sulphation 1 1...

Page 123: ...the charge current to the lowest battery The power difference between the batteries must be as low as possible Example of charge 12V 60 Ah battery charging current 6 A Charge status 50 acid density 1 21 voltage when idle 12 30V The battery is short 30 Ah and this must be recharged Charge factor 1 2 Ah x 1 2 36 Ah to be charged Charging current 6A approximately 6 hours charging required Recharging ...

Page 124: ...city too low Battery sulphated Recharge the battery Fit a new battery Battery terminals melted Incorrect electrical connection Incorrect battery wiring Tighten the ends of the battery cables or replace them if necessary One or two cells release a lot of gas at high charge Cell s faulty Fit a new battery The battery discharges very quickly Charge status too low Short circuit in the current circuit ...

Page 125: ...9 Appendix 9 1 Appendix A Engine user and maintenance manual 123 285 ...

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Page 127: ...ual V VO OL LV VO O E En ng gi in ne e T TA AD D9 94 40 0V VE E T TA AD D9 94 41 1V VE E T TA AD D9 94 42 2V VE E T TA AD D9 94 43 3V VE E T TA AD D9 94 40 0G GE E T TA AD D9 94 41 1G GE E 47702660 01 01 2012 33522062701_2_1 125 285 ...

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Page 211: ...9 2 Appendix B Alternator user and maintenance manual 209 285 ...

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Page 213: ...manual L LE ER RO OY Y S SO OM ME ER R A Al lt te er rn na at to or r L LS SA A4 46 6 2 2 L L6 6 L L9 9 L LS SA A4 46 6 2 2 M M3 3 M M5 5 4 46 6 2 2 S SH HU UN NT T A AR RE EP P P PM MG G 3856 h 01 03 2012 33522061001_8_1 211 285 ...

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Page 215: ...5 122 1 36 323 322 325 320 15 321 34 4 48 28 41 371 198 364 51 30 124 31 33 466 177 91 120 367 49 21 72 343 100 347 This manual is to be given to the end user 3856 en LSA 46 2 4 POLES ALTERNATORS Installation and maintenance 213 285 ...

Page 216: ...w anyone to stand in front of the air outlet guards in case anything is ejected from them b Do not allow children younger than 14 to go near the air outlet guards Aset of self adhesive stickers depicting the various warning symbols is included with this maintenance manual They should be positioned as shown in the drawing below once the machine has been fully installed WARNING The alternators must ...

Page 217: ...embly 6 3 2 Checks prior to first use 7 3 3 Terminal connection diagrams 7 3 4 Commissioning 10 3 5 Setting up 10 4 SERVICING MAINTENANCE 11 4 1 Safety measures 11 4 2 Routine maintenance 11 4 3 Fault detection 11 4 4 Mechanical defects 12 4 5 Electrical faults 12 4 6 Dismantling reassembly 14 4 7 Installation and maintenance of the PMG 16 4 8 Table of characteristics 17 5 SPARE PARTS 18 5 1 First...

Page 218: ...achine quickly and accurately we suggest you write its specifications on the nameplate below 1 4 Storage Prior to commissioning machines should be stored Away from humidity 90 after a long period of storage check the machine insulation section 3 2 1 To prevent the bearings from becoming marked do not store in an environment with significant vibration 1 5 Application These alternators are mainly de...

Page 219: ... bearings greased for life Mounting arrangements IM 1201 MD 35 foot and flange mounted single bearing with SAE coupling disc IM 1001 B 34 double bearing with SAE flange and standard cylindrical shaft extension Drip proof machine self cooled Degree of protection IP 23 2 1 1 Mechanical options Air inlet filter Regreasable ball bearings IP 44 protection T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11...

Page 220: ...e compatible by undertaking a torsional analysis of the transmission checking the dimensions of the flywheel and its housing the flange coupling discs and offset When coupling the alternator to the prime mover do not use the fan to turn the alternator or rotor The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine Make sure the alternator is securely bedde...

Page 221: ... 240 220 190 208 6 7 8 6 7 8 9 N T1 T7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L1 U L3 W L2 V D R 250 voltage detection 0 T8 110 V T11 R 450 voltage detection 0 T3 220 V T2 L1 U L2 V L3 W NDE Winding 60 Hz 50 Hz 380 415 380 480 440 600 500 380 416 R 250 voltage detection 0 T8 110 V T11 R 450 voltage detection 0 T3 380 V T2 NDE L1 U L2 V L3 W N T3 T2 T1 T11 T4 T12 T6 T10 T5 T7 T8 T9 N T3 T2 T1 T11 T4 T12 ...

Page 222: ...T2 NDE M T3 T2 T1 T11 T4 T12 T6 T10 T5 T7 T8 T9 6 7 8 6 7 8 F L1 U M L3 W T1 T7 T12 T10 T4 T9 T3 T6 T11 T5 T2 T8 L2 V L1 U L2 V L1 U L2 V L3 W 1 phase 1 phase or 3 phase FF G Winding 60 Hz 50 Hz 220 240 220 240 220 240 240 254 R 250 voltage detection 0 T4 110 V T1 R 450 voltage detection 0 T10 220 V T1 R 250 voltage detection 0 T8 110 V T11 R 450 voltage detection 0 T3 220 V T2 NDE Winding 6 7 8 W...

Page 223: ...9 R 450 voltage detection transformer See specific diagram In case of reconnection ensure that the AVR voltage detection is correct The factory can supply a set of flexible shunts and special connection links as an option for making these connections 3 3 3 Option connection diagram R 791 T interference suppression kit standard for CE marking Remote voltage potentiometer Black Black Black Blue Whit...

Page 224: ...chine should be connected with the busbar separating the terminals as shown in the terminal connection diagram 3 4 Commissioning The machine can only be started up and used if the installation is in accordance with the regulations and instructions defined in this manual The machine is tested and set up at the factory When first used with no load make sure that the drive speed is correct and stable...

Page 225: ...3 In the factory the grease used for lubrication is ESSO Unirex N3 Before using another grease check for compatibility with the original one Monitor the temperature rise in the bearings see section 4 4 4 2 3 Electrical servicing Commercially available volatile degreasing agents can be used Do not use trichlorethylene perchlo rethylene trichloroethaneoranyalkaline products These operations must be ...

Page 226: ...still correct when the battery is removed Lack of residual magnetism The alternator builds up but its voltage does not reach the rated value when the battery is removed Check the connection of the voltage reference to theAVR Faulty diodes Armature short circuit The alternator builds up but its voltage disappears when the battery is removed FaultyAVR Field windings open circuit check winding Revolv...

Page 227: ...Assembly A Connect a 12 V battery in series with a rheostat of approximately 50 ohms 300 W and a diode on both exciter field wires 5 and 6 6 5 Diode 1A 12V battery Rh 50Ω 300W ASSEMBLY A Exciter field Assembly B Connect a Variac variable power supply and a diode bridge on both exciter field wires 5 and 6 Both these systems should have characteristics which are compatible with the field excitation ...

Page 228: ...d the regulation system Access directly by removing the top of the cover 48 or the AVR access door 466 4 6 5 Replacing the NDE bearing Remove the box lid 48 and the NDE panel 365 and remove the 2 screws from the part 122 Disconnect the stator outputs T1 to T12 Disconnect the auxiliary winding wires AREP X1 X2 Z1 Z2 Disconnect the exciter wires 5 6 Remove the air inlet louvre 51 If using a single b...

Page 229: ...ntral screw see section 4 6 5 Fit the new bearing after heating it by induction to approximately 80 C Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Tighten the bottom thrust bearing screws 78 remove the threaded rod and fit the other screws Tighten the 6 shield screws 31...

Page 230: ... new O ring seal 349 in the shield 36 Refit the shield 36 on the machine using a dowel and nut in the shaft extension see diagram Tighten the 4 shield screws 37 Reconnect exciter wires E E Finish reassembling the cover Screw a threaded rod into the thrust bearing 68 Refit the shield 30 on the machine Slide the threaded rod into the shield hole to make it easier to assemble see basic diagram Fit th...

Page 231: ...264 8 8 0 035 L9 0 012 0 295 8 8 0 035 VL12 0 0085 0 343 10 0 037 Resistance of AREP auxiliary windings at 20 C Ω LSA 46 2 Auxil wdg X1 X2 Auxil wdg Z1 Z2 M3 0 24 0 4 M5 0 215 0 36 L6 0 185 0 36 L9 0 19 0 32 VL12 0 17 0 32 Field excitation current i exc A Symbols i exc excitation current of the exciter field LSA 46 2 No load At rated load M3 1 1 4 M5 1 1 3 8 L6 1 1 4 1 L9 1 2 4 VL12 1 1 3 5 For 60...

Page 232: ...etwork of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this advice the manufacturer cannot be held responsible for any damage 5 3 Accessories 5 3 1 Space heater for use when stopped The space heater must run as soon as the alt...

Page 233: ... 2 4 POLES ALTERNATORS 3856 en 5 4 Exploded view parts list and tightening torque 5 4 1 LSA 46 2 single bearing 78 37 79 349 70 90 365 122 1 36 323 322 325 320 15 321 34 4 48 28 41 371 198 364 51 30 124 31 33 466 177 91 120 367 49 21 53 71 72 343 100 347 231 285 ...

Page 234: ...llation and maintenance LSA 46 2 4 POLES ALTERNATORS 3856 en 5 4 2 LSA 46 2 double bearing 37 79 349 70 90 365 122 1 36 15 4 28 51 31 91 21 53 71 30 33 60 284 68 62 22 34 48 41 371 198 364 124 466 177 120 367 49 343 100 347 232 285 ...

Page 235: ...otective grille 284 1 Circlips 34 2 Fixing screws M6 5 320 1 Coupling sleeve 36 1 Exciter end shield 321 1 Sleeve key 37 4 Fixing screws M12 50 322 3 Coupling disc 41 1 Cover front panel 323 6 Fixing screw M16 230 48 1 Cover top panel 325 Spacer shim 49 Cover screws M6 5 343 1 Diode bridge assembly M6 4 51 1 Air intake grille 347 1 Protection varistor PCB 53 1 Plug 349 1 O ring 60 1 Drive end bear...

Page 236: ...34 1 and 60034 5 ISO 8528 3 Reciprocating internal combustion engine driven alternating current generating sets Part 3 Alternating current generators for generating sets Low Voltage Directive Nr 2006 95 CE dated 12 December 2006 Furthermore these generators designed in compliance with the Machine Directive Nr 2006 42 are therefore able to be incorporated into Electrical Gen Sets complying with the...

Page 237: ...23 LEROY SOMER 2011 01 h Installation and maintenance LSA 46 2 4 POLES ALTERNATORS 3856 en 235 285 ...

Page 238: ...LEROY SOMER16015ANGOULÊMECEDEX FRANCE 338 567 258 RCS ANGOULÊME www leroy somer com 236 285 ...

Page 239: ...11 T12 STATOR 12 wires marking T1 to T12 MAIN FIELD R 250 VOLT FREQ L A M CONFIG STAB F1 Slow fuse 250V 8 A P1 Voltage P2 Stability 110 E E 0V 0 9 8 7 6 5 4 3 2 1 o 1 2 3 5 6 7 9 8 4 60Hz 65Hz 57Hz 47 5Hz 50Hz KNEE SPECIAL LAM OFF OFF 13 13 25 25 LAM KNEE KNEE LAM OFF LAM OFF LAM OFF External potentiometrer for voltage adjusting ST4 Option Frequency selector 50 Hz 60 Hz for U F fonction and LAM ad...

Page 240: ...e following warning symbols Warningsymbolforanoperationcapable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments The information conta...

Page 241: ...reakdown operations on the A V R are to be done by personnel trained on commisioning servicing and maintenance for the electrical and mechanical elements The R250 is an IP00 product It must be installed inside a unit so that this unit s cover can provide IP20 minimum total protection it must only be installed on LS alternators in the appropriate location so that when viewed externally it has a hig...

Page 242: ...a short circuit capacity 4 x holes Ø 5 8 x 50 x 115 mm 140 mm 75 mm SHUNT SYSTEM Field Induced T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11 T12 STATOR 12 wires marking T1 to T12 MAIN FIELD R 250 VOLT FREQ L A M CONFIG STAB F1 Slow fuse 250V 8 A P1 Voltage P2 Stability 110 E E 0V 0 9 8 7 6 5 4 3 2 1 o 1 2 3 5 6 7 9 8 4 60Hz 65Hz 57Hz 47 5Hz 50Hz KNEE SPECIAL LAM OFF OFF 13 13 25 25 LAM KNEE KNEE...

Page 243: ...houtLAMforimpacts between 30 and 40 of the rated load 1 threshold at 48 Hz with LAM 13 for impacts between 40 and 70 of the rated load 2 threshold at 48 Hz with LAM 25 for impacts 70 of the rated load Operating at 60 Hz U F gradient 3 thresholdat58HzwithoutLAMforimpacts between 30 and 40 of the rated load 4 threshold at 58Hz with LAM 13 for impacts 40 and 70 of the rated load 5 threshold at 58Hz w...

Page 244: ... speed reaches its rated value again Hence the LAM can be used either to reduce the speed variation frequency and its duration for a given applied load or to increase the applied load possible for one speed variation turbo charged engines To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the lowest frequency in steady state It is advised t...

Page 245: ...a diesel engine or without a LAM U F only 2 5 1 Voltage 2 5 2 Frequency 2 5 3 Power UN 0 0 9 0 8 U f with LAM Time without LAM 1 s 2 s 3 s Transient voltage drop 0 9 0 8 fN Max speed drop 0 with LAM Time without LAM 1 s 2 s 3 s 0 1 s 2 s 3 s Time LAM Load variation Load on shaft kW Shedding due to LAM 243 285 ...

Page 246: ...er positions voltage setting potentiometer P1 for the A V R full left remote voltage setting potentiometer in the middle Operate the alternator at its rated speed if the voltage does not rise it is necessary to re magnatise the magnetic circuit slowly adjust the voltage potentiometer of theA V R P1untiltheoutputvoltagereaches its rated value Stability setting with P2 3 2 2 Special type of use Exci...

Page 247: ...urnt out Main field winding short circuited Check the resistance Speed too low Increase the drive speed Do not touch the A V R pot P1 before returning to the correct speed Voltage too high Adjust A V R potentiometer Adjustment ineffective Faulty A V R 1 faulty diode Voltage oscillations Adjust A V R stability potentiometer Check the speed possibility of cyclic irregularity Loose terminals Faulty A...

Page 248: ... For replacement part orders it is necessary to indicate the type and the code number of the A V R Please contact your usual correspondant An extensive network of service centres is available to rapidly supply any necessary parts In order to ensure the correct operation and safety of our machines we strongly recommend that original manufacturer s spare parts are used Failure to do so will discharg...

Page 249: ...Installation and maintenance R250 A V R 4067 en 2009 05 b LEROY SOMER 11 247 285 ...

Page 250: ...MOTEURS LEROY SOMER 16015 ANGOULÊME CEDEX FRANCE 338 567 258 RCS ANGOULÊME S A au capital de 62 779 000 www leroy somer com 248 285 ...

Page 251: ...S LSA 49 1 50 2 7000 8000 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 46 2 47 2 5000 6000 SERIES LSA 46 2 47 2 5000 6000 1 PHASE SENSING 3 PAHASES SENSING 2 3 0 1 RAPIDE FAST RAPIDE FAST NORMAL NORMAL NORMAL NORMAL SHUNT AREP PMG 2 3 0 1 0 9 8 7 6 5 4 3 2 1 0 3 2 1 0 3 2 1 LEDS US C Installation maintenance manual www leroy somer com 380V 220 110 0V E E Z2 X1 Z1 X2 2012 03 e This manual is to be giv...

Page 252: ... take notice of the various warning symbols used Warningsymbolforanoperationcapable of damaging or destroying the machine or surrounding equipment Warning symbol for general danger to personnel Warning symbol for electrical danger to personnel Note LEROY SOMER reserves the right to modify the characteristics of its products at any time in order to incorporate the latest technological developments ...

Page 253: ...or without a LAM U F only 12 3 5 AVR options 13 4 INSTALLATION COMMISSIONING 14 4 1 Electrical checks on the AVR 14 4 2 Setting up 14 4 3 Electrical faults 17 5 SPARE PARTS 18 5 1 Designation 18 5 2 Technical support service 18 All servicing or repair operations performed on the AVR should be undertaken by personnel trained in the commissioning servicing and maintenance of electrical and mechanica...

Page 254: ...OIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 0 5 6 9 8 1 2 3 4 RAPIDE FAST RAPIDE FAST NORMAL NORMAL NORMAL NORMAL SHUNT AREP PMG 2 3 0 1 0 9 8 7 6 5 4 3 2 1 0 3 2 1 140 mm LEDS P1 Voltage P2 Stability P3 Exc...

Page 255: ...ould be in the AREP position see 3 2 3 AREP SYSTEM Field Armature T1 T2 T3 T4 T5 T6 Varistor 5 6 T7 T8 T9 T10 T11 T12 according to voltage Aux windings 10 Yellow 11 Red 9 Green 12 Black 10 Yellow 11 Red 9 Green 12 Black STATOR 6 wires T1 to T6 STATOR 12 wires T1 to T12 MAIN FIELD R 450 VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LA...

Page 256: ... T9 T10 T11 T12 according to voltage Field Armature STATOR 6 wires T1 to T6 STATOR 12 wires T1 to T12 MAIN FIELD R 450 VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 60Hz 0 5 6 9 8 1 2 3 4 SERIES LSA 49 1 50 2...

Page 257: ... VOIR NOTICE SEE NOTICE VOLT STAB I EXC STAT FUSIBLES FUSES 1k 3PH S1 S2 50 Hz 60 Hz EXT FREQ SETTING 7 LAM OFF LAM ON ONLY FOR SPECIAL CONFIG KNEE LAM OFF 65Hz LAM OFF LAM MODE 2 LAM MODE 1 LAM OFF LAM MODE 2 LAM MODE 1 50Hz EXT FREQ SET 60Hz 0 5 6 9 8 1 2 3 4 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 49 1 50 2 7000 8000 SERIES LSA 46 2 47 2 5000 6000 SERIES LSA 46 2 47 2 5000 6000 2 3 0 1 RAPIDE...

Page 258: ...tentiometer P4 within a range from 0 to 8 with a PF 0 8 for 400V applications From 0 to 14 with a PF 0 8 for 240V applications From 0 to 8 for 110V applications with a step up transformer ratio of 4 placed on the voltage reference The potentiometer P4 has a non linear response Then when a 1Asecondary CT is connected the effective range starts from the the second 1 3 of P4 range and in the case of ...

Page 259: ...ation current must be limited to 9 A 0 5 A Overrun indications One green LED Lights up when the excitation current is below the continuous operation threshold It signals the AVR normal operation Turnsoffwhentheexcitationcurrentceiling used to obtain short circuit operation is reached and when the excitation current is reduced to the shutdown value Flashes when the over excitation counter is decrem...

Page 260: ...ys on flashes when the excitation current has reached the ceiling in 10s with PMG excitation ftays on if Iexc I Shutdown WARNING If the overload protection is activated a voltage drop possibly exceeding 10 of the reference voltage will be observed The AVR does not provide undervoltage protection The customer will need to make sure that their installation is correctly protected against under voltag...

Page 261: ...ecial not used Pos 8 Change in the voltage according to the U F ratio knee point position at 48 Hz or 58Hzaccordingtoselectionofthefrequency by an external contact Pos 9 Change in the voltage according to LAM 1 knee point position at 48 Hz or 58 Hz according to selection of the frequency by an external contact WARNING For Pavers and hydraulic applications select positions 0 50 Hz or 3 60 Hz 3 2 3 ...

Page 262: ...oad or to increase the applied load possible for one speed variation turbo charged engine To avoid voltage oscillations the trip threshold for the LAM function should be set approximately 2 Hz below the rated frequency LAM UN 0 48 or 58 Hz 0 85 UN Voltage Voltage U f 50 or 60 Hz fC fN ST3 3 3 2 2 Soft voltage recovery function During load impacts the function helps the genset to return to its rate...

Page 263: ...phase current and voltage sensing for parallel operation on unbalanced installations unbalance 15 R 726 module regulation system changed to 4 function see the maintenance manual and connection diagram PF regulation 2F Equalization of voltages before paralleling 3 F Possibility of coupling to the mains of alternators already running in parallel 4F R729 module same as R726 with additional functions ...

Page 264: ...3 P4 10 A maximum 400 V 50 Hz Not set centre position Not set fully anti clockwise Excitation ceiling Factory sealed Voltage quadrature droop operation with C T 0 quadrature droop fully anti clockwise Voltage minimum fully anti clockwise Stability Stability adjustments in standalone operation b Install a D C analogue voltmeter needle dial cal 100 V on terminals F F and an A C voltmeter cal 300 500...

Page 265: ...e speed match the kW or divide the rated power of the units proportionally By altering the quadrature droop potentiometer P4 match or divide the currents 4 2 2 Max excitation adjustment excitation ceiling In standard setting the potentiometer P3 is in maximum position However for applications requiring an overload protection see 3 2 1 4 the excitation ceiling must be adjusted by using the followin...

Page 266: ...ly 1 wire X1 or X2 Contact rating 16 A 250 V A C 4 2 3 2 R450 AREP PMG field weakening X2 Z1 X1 Z2 E E The exciter is switched off by disconnecting the AVR power supply 1 wire on each auxiliary winding contact rating 16 A 250 V A C Connection is identical for resetting theAVR internal protection If field weakening is used provide field forcing 4 2 3 3 R450 field forcing Applications B Volt Time t ...

Page 267: ...h Adjust AVR voltage potentiometer Adjustment ineffective Faulty AVR 1 faulty diode Voltage oscillations Adjust AVR stability potentiometer If no effect try normal fast recovery modes Check the speed possibility of cyclic irregularity Loose connections Faulty AVR Speed too low when on load or U F knee point set too high Voltage correct at no load and too low when on load Run at no load and check t...

Page 268: ...l information you may require When ordering spare parts you should indicate the AVR type and code number Address your enquiry to your usual contact Our extensive network of service centres can dispatch the necessary parts without delay To ensure correct operation and the safety of our machines we recommend the use of original manufacturer spare parts In the event of failure to comply with this adv...

Page 269: ...2012 03 e LEROY SOMER 19 Installation and maintenance R 450 AVRs 4531 en 267 285 ...

Page 270: ...www leroy somer com 268 285 ...

Page 271: ...078 X 1 Thermostat 330051467 X 1 Thermostat seal 330051539 X 1 Fan belt 330051419 X 1 Rocker cover seal 330051468 X 1 Water temperature sensor 330051466 X 1 Oil pressure sensor 330051465 X 1 Alternator belt 330051418 X 1 GENLUB x 25 L 330910094 X 1 x 208 L 330910095 GENCOOL x 20 L 330910098 X 1 x 60 L 330910099 x 210 L 330910100 269 285 ...

Page 272: ...X 1 330510015 330560617 X 1 330560551 X 2 330560634 X 1 LEROY SOMER LSA462VL12 ALTERNATOR Diode bridge 330410126 X 1 Varistor 330410109 X 1 Note For all technical assistance or spare part requests contact your nearest SDMO agent 270 285 ...

Page 273: ... throttle abnormal pulse width 9 Throttle invalid CAN value 10 Throttle voltage out of range low 13 Throttle calibration aborted 14 Throttle voltage out of range 94 94 Fuel rail pressure sensor 1 Fuel supply pressure extremely low 3 Fuel rail pressure input voltage high Short to V 4 Fuel rail pressure input voltage low Short to V 5 Fuel rail pressure sensor open circuit 10 Fuel rail pressure lost ...

Page 274: ...urbo speed sensor 0 Turbo speed too high 5 Turbo speed sensor circuit open 6 Sensor shorted to earth Short to V 8 Speed signal invalid 31 Intermittent problem with speed information 105 105 Manifold air temperature sensor 0 Manifold air temperature extremely high 3 Manifold air temperature sensor input voltage high 4 Manifold air temperature sensor input voltage low 5 Manifold air temperature sens...

Page 275: ...re high 111 111 Coolant level sensor 0 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 153 153 Crankcase pressure sensor 0 Value above normal 3 Crankcase pressure sensor input voltage high 5 Crankcase pressure sensor open circuit 157 Fuel pressure sensor in the common rail 1 Fuel pressure too low 3 Input voltage...

Page 276: ...lty 175 175 Oil temperature sensor 0 Oil temperature extremely high 3 Oil temperature sensor input voltage high 4 Oil temperature sensor input voltage low 5 Oil temperature sensor open circuit 177 Transmission oil temperature sensor 9 Transmission oil temperature invalid Not possible with Genset application 189 Rated engine speed 0 Engine speed de rated 31 Engine speed de rated 190 190 190 Engine ...

Page 277: ...utput open circuit 412 Temperature sensor in the EGR valve 0 Temperature in the EGR extremely high 3 Input voltage of the temperature sensor high Short to V 4 Input voltage of the temperature sensor low Short to V 15 Temperature in the EGR high 16 Temperature in the EGR moderately high 443 443 ENGINE RUN output status 3 Engine run output open short to B 4 Engine run output short to B 523 Gear sele...

Page 278: ... injection pump communication error Possible only with 6068HF475 VP44 630 253 Data set memory EEPROM 632 Injection status 2 Fuel shutoff error 5 Fuel shutoff non functional 636 21 Pump position sensor Cam position sensor Speed sensor CAM Pump position or CAM position in function of the type of injection 2 Pump position sensor cam position sensor input noise 3 Permanent loss of signal 5 High impeda...

Page 279: ...ications Recalibration of the injectors required 1 Injector outside specifications Recalibration of the injectors required 2 Short circuit high side to B 3 Short circuit high side to low side or low side to B 4 Short circuit high or low side to ground 5 Cylinder 1 circuit open 6 Cylinder 1 circuit shorted 7 Cylinder 1 balancing error mechanical failure 11 Cylinder 1 unknown error mechanical failur...

Page 280: ...rs required 1 Injector outside the specifications Recalibration of the injectors required 2 Short circuit high side to B 3 Short circuit high side to low side or low side to B 4 Short circuit high or low side to ground 5 Cylinder 4 circuit open 6 Cylinder 4 circuit shorted 7 Cylinder 4 balancing error mechanical failure 11 Cylinder 4 unknown error mechanical failure 655 5 5 655 Cylinder 5 injector...

Page 281: ...trol open circuit 678 41 8 Volt power supply 3 ACM 8 Volt DC supply open short to B 4 ACM 8 Volt DC supply open short to ground 679 42 Regulation sensor of the injection pressure control 723 342 Secondary speed sensor 2 Secondary engine speed sensor data intermittent 11 Secondary engine speed sensor loss of signal 12 Loss of signal sensor failure 729 70 Inlet air heater signal Preheat detection 3 ...

Page 282: ...ent decay time invalid Injection DE10 1077 Fuel injection pump controller status 7 Attempting to fuel without command 11 Pump supply voltage out of range 12 Pump self test error 19 Pump detected communication error 31 Pump initiated engine protection 1078 ECU Pump timing status 7 ECU Pump timing moderately out of synchronisation 11 ECU Pump timing speed out of synchronisation 31 ECU Pump timing ex...

Page 283: ...ontrol error 10 Pump control valve fuel flow not detected 1348 Pump control valve 2 status Only for 6081HF070 5 Pump control valve 2 error mismatch 10 Pump control valve 2 fuel flow not detected 1485 1485 5 Pump power relay status ECU main relay of VOLVO EMS EDC 2 Pump power relay fault 3 ECU main relay short circuit high 1568 Torque curve selection 2 Torque curve selection invalid 4 Torque curve ...

Page 284: ...n of the EGR valve 2795 Position of TGV actuator 7 The actuator does not respond or is not in the expected position 3509 Common supply voltage of the sensors output 1 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of the sensor shorted to ground 3510 Common supply voltage of the sensors output 2 3 Supply voltage of the sensor too high Exceeding 5 volts Supply voltage of t...

Page 285: ...dcast of data value is substituted with the error indicator value FMI 5 CURRENT BELOW NORMAL OR OPEN CIRCUIT a A current signal data or otherwise is below the predefined limits that bound the range Region e of the signal range definition Broadcast of data value is substituted with the error indicator value b Any signal external to an electronic control module whose current remains off when the ECM...

Page 286: ...icated as a specific component and failure mode Possible reasons for using a System Diagnostic Code include 1 Cost of specific component fault isolation is not justified or 2 New concepts in Total Vehicle Diagnostics are being developed or 3 New diagnostic strategies that are not component specific are being developed Due to the fact that SPNs 611 615 are manufacturer defined and are not component...

Page 287: ... cases when the reported SPN name spells out the component and a non standard failure mode This type of fault may or may be directly associated with the value of general broadcast information This FMI will mean not available when the associated SPN is also not available as when the remainder of the packet is filled with binary ones after all data has been transmitted 285 285 ...

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