ALTERNATORS

Rf. 3361 - 4.33/a - 05.00

P5
P4

P3

P2 P1

PART NUMBER : 278 - 997

8100 - 9100
ALTERNATORS
Installation and maintenance
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS

This manual applies to the alternator mounted on We would like to draw your attention to the
the genset. contents of this maintenance manual. By following
certain important instructions during installation,
The latest addition to a whole new generation of use and servicing of your alternator, you can look
products, this range benefits from the experience forward to many years of trouble-free operation.
of one of the largest manufacturers in the world,
using advanced technology and incorporating
strict quality control.

RECEIPT ................................................ 3 SERVICING - MAINTENANCE ...................12

Standards and Safety measures Safety measures
Checks Regular maintenance
Identification Checks after start-up
Storage Cooling circuit
Bearings
TECHNICAL CHARACTERISTICS ............... 4 Electrical servicing
Electrical characteristics Mechanical maintenance
Options Fault detection
Mechanical characteristics Mechanical defects
Options Electrical faults
Excitation system Checking the windings
R 449 regulator Checking the diode bridge
R 449 supply connection Checking the windings and rotating diodes
Frequency compared with voltage using separate excitation
LAM characteristics Dismantling, reassembly
Typical effects of the LAM Tools required
R 449 A.V.R. options Screw tightening torque
Access to diodes
INSTALLATION ........................................ 7 Access to connections and regulation system
Assembly N.D.E. ball bearing replacing on single
Handling bearing alternator
Coupling D.E. ball bearing replacing on two bearing
Location alternator
Inspection prior to first use Complete dismantling
Electrical checks End shield reassembling
Physical and visual checks Rotor reassembling
Terminal connection diagrams Installation and maintenance of PMG
Terminal connection 8000 / 9000 Mechanical fitting
Connection checks Electrical connection
Electrical checks on the A.V.R. Electrical characteristics table
Commissioning
Setting up SPARE PARTS ....................................... 18
R 449 main adjustments First maintenance parts
Max. excitation adjustment Technical support service
Special type of use Exploded view
Part list
Single bearing
Two bearing
D.E. bearing mounting
N.D.E. bearing mounting
PMG mounting

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 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

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ALTERNATORS
RECEIPT

1 - RECEIPT on the frame .

Make sure that the nameplate on the machine conforms to
your order.
1.1 - Standards and Safety measures The machine name is defined according to various criteria
(see below).
Our alternators comply with most international standards and
are compatible with:
- the recommendations of the
A.C. SYNCHRONOUS GENERATOR
International Electro technical Commission
IEC 34-1, (EN 60034).
SERIAL N FRAME WDG
- the recommendations of the
International Standards Organisation ISO 8528.
- the European Community directive on Electromagnetic
Compatibility (EMC) 89/336/EEC.
- the European Community directives 73/23/EEC and 93/ ISO 8528-3 IEC 34-1 BS 5000-PT3 NEMA MG1-22 VDE 0530
68/EEC (Low Voltage Directive).

They are CE marked with regard to the LVD (Low Voltage

Directive) in their role as a machine component. A declaration 1.4 - Storage
of incorporation can be supplied on request.
Before using your generator for the first time, read with care Whilst awaiting installation, the machines should be stored
the contents of this installation and maintenance manual, away from humidity: in conditions of relative humidity of more
supplied with the machine. All operations performed on the than 90%, the machine insulation can drop very rapidly to just
generator should be undertaken by qualified personnel with above zero at around 100% ; monitor the state of the anti-rust
specialist training in the commissioning, servicing and protection on unpainted parts.
maintenance of electrical and mechanical machinery. This For storage over an extended period, the machine can be
maintenance manual should be retained for the whole of the placed in a sealed enclosure (heatshrunk plastic, for
machine's life and be handed over with the contractual file. example) with dehydrating sachets inside, away from
The various operations described in this manual are significant and frequent variations in temperature to avoid any
accompanied by recommendations or symbols to alert the condensation during storage.
user to the risk of accidents. It is vital that you understand and
take notice of the different safety symbols opposite.

WARNING
Safety symbol for an operation capable of damaging or
destroying the machine or surrounding equipment.

Safety symbol for general danger to personnel.

Safety symbol for electrical danger to personnel.

1.2 - Checks
On receipt of your alternator, check that it has not suffered
any damage in transit.
If there are obvious signs of knocks, contact the transporter
(you may be able to claim on their insurance) and after a
visual check, turn the machine by hand (if twin bearing) to
detect any malfunction.

1.3 - Identification
The alternator is identified by means of a nameplate fixed

3
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ALTERNATORS
TECHNICAL CHARACTERISTICS

2 - TECHNICAL CHARACTERISTICS
2.1 - Electrical characteristics
The 8100 - 9100 series alternators are machines without
sliprings and revolving field brushes, wound as "2/3 pitch",6
wire, with class H insulation and a field excitation system
available in either "AREP+PMI" or "PMG" (see drawings).

MAIN FIELD STATOR

Aux. windings
EXCITER
AREP+PMI T1 T2 T3

Surge suppressor
Armature
sytem with R 449

5+ 6- T4 T5 T6
Field

R 449 Voltage reference

MAIN FIELD STATOR

EXCITER

T1 T2 T3
Surge suppressor

Armature

PMG
PMG sytem with
R 449

5+ 6- T4 T5 T6
Field

R 449 Voltage reference

Interference suppression conforms with standard EN 55011, - Mounting arrangement

group 1, class B. MD 35 : single bearing, with standard feet and SAE coupling
discs
2.1.1 - Options B 34 : two bearing feet mounted with standard bare shaft
key wayed
- Stator temperature detection probes
- Drip-proof machine, self-cooled
- Space heaters
- Degree of protection: IP 22

2.2 - Mechanical characteristics 2.2.1 - Options

- Steel frame - Air input filter, air output filter
- End shields in cast iron
- Greasable ball bearings

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ALTERNATORS
TECHNICAL CHARACTERISTICS

2.3 - Excitation system - max. excitation current adjustment via P5: 4.5 to 15A
- 50/60 Hz selection via strap ST3
For an AREP+PMI and PMG field excitation , the alternator - 2 voltage recovery mods (normal/fast) selected via ST2 and
voltage regulator is the R 449 adjusted via P3 (stability).

ST5 With LAM W/o LAM 5+ Field 6-

Response time Pwr supply

ST2 normal fast (see 2.3.2)
200 x 140 mm
ST3 50Hz 60Hz
4 x 5.8 x 175 x 115
Frequency

P5 X2
Excitation Z1
With AREP excitation, the electronic A.V.R. R 449 is ceiling
X1
powered by two auxiliary windings which are independent of Z2
the voltage detection circuit. The first winding (X1,X2) has a P4 E+
Under-
voltage in proportion with the output voltage of the alternator speed E-
L3
(Shunt characteristic), the second (Z1,Z2) has a voltage in
proportion with the stator current (compound characteristic:
Booster effect). The power supply voltage is rectified and
P3
R449 0V
110
220
(W)

filtered before being used by the regulator monitoring Stability

380
transistor. The result is the alternator has a short circuit
capability (3 In/10s) and a good immunity to distortions. P2
Voltage
With the PMG excitation the system is built with the fitting of
a PMG (Permanent Magnet Generator) on the machine. The ST1
3 phase PMG is fitted at the rear end of the alternator and
Single-phase
detection
P1
Quad droop
supplies a voltage to the A.V.R. R449.
3-ph detection
The PMG provides to the AVR constant power which is L2(V)
independant of the main stator load. The result is the C.T.
Option 340-520V
alternator has a short circuit capability (3 In/10s) and a good R731 ST4 Option S1 S2
immunity to distortions. 170-260V
External potentiometer
By checking the voltage sensing circuit, the AVR adjust the ST4 for adjusting the voltage
or connecting R 726
Option 85-140V
excitation current required for maintaining the right voltage.

2.3.1 - R 449 regulator

- continuous rated current : 7A
2.3.2 - R 449 supply connection
- rated overload current: 15A - 10s AREP field excitation
- electronic protection (overload, short-circuit): excitation
ceiling current for 10 seconds then return to approx. 2A Yellow
R449 X2
The alternator must be stopped (or the power switched off, Red
see 3.5.3.) in order to reset the protection. Z1
Green Aux. windings
- fuses outside AVR 16A - 500 V X1
Black
- voltage detection: 5 VA isolated via transformer Z2
- 110 V terminals = 85 to 130 V E+ 5+ 6-
- 220 V terminals = 170 to 260 V E-
- 380 V terminals = 340 to 520 V
other voltages via step down transformer (Option) Exciter field
- voltage regulation 0,5% (steady state)
- voltage adjustment via potentiometer P2
- current detection: (parallel operation): C.T. 10 VA CL1,
secondary 1,2 A (Option)
- quadrature droop adjustment via potentiometer P1.
- underspeed protection (U/f) and LAM: frequency threshold
adjustable via potentiometer P4

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ALTERNATORS
TECHNICAL CHARACTERISTICS

PMG field excitation

14 Voltage
X2
15 Transient voltage drop
Z1 PMG
UN
16
X1
Z2
5+ 6-
E+ 0.9
E- (U/f)
2.3.3 - Frequency compared with voltage 0.8 LAM
(W/O LAM).
Frequency
Voltage Bend 57.5 Hz
Max. speed drop
LAM
U/UN 48 Hz fN
100 %
50 Hz
60 Hz 0.9

0.8

Power
Frequency LAM
50 Hz 60 Hz Hz
Load on the
shaft (kW)

2.3.4 - LAM characteristics Variation in the load

The LAM system is integrated as standard in the R 449

regulator. It can be activated by closing strap ST5. Load shedding due to "LAM"
Time
Role of the "LAM" (Load Adjustment Module): (s)
On load impact, the rotation speed of the generator set 0 1s 2s 3s
decreases. When it passes below the preset frequency
threshold, the "LAM" causes the voltage to droop by Typical effects of the "LAM" with a diesel engine -
approximately 15% and consequently the amount of active with LAM without LAM (U/F only)
load applied is reduced by approximately 25%, until the
speed reaches its rated value again.
Hence the "LAM" can be used either to reduce the speed 2.3.5 - R 449 A.V.R. options
variation (frequency) and its duration for a given applied load,
or to increase the applied load possible for one speed - Current transformer for parallel operation
variation (turbo-charged engine). of ....../1,2 A - 10 VA CL 1 (see schematic included with this
To avoid voltage oscillations, the trip threshold for the "LAM" manual).
function should be set approximately 2 Hz below the lowest - Remote voltage adjustment potentiometer :
frequency in steady state. 470 , 3 W min: adjustment range 5% (range limited via
internal voltage potentiometer P2). Remove ST4 to connect
Voltage Underspeed and LAM the potentiometer. (A 1 k potentiometer can also be used
ST5 disconnected to extend the adjustment range to 10%)
UN Voltage - R 731 module : detection of 3-phase voltage 200 to 480 V,
P2
compatible with parallel operation. Cut ST1 to connect the
U/f module; set the voltage via the module potentiometer.
0.85 UN LAM - R 726 module : regulation system changed to 4 F :
(see R 726 maintenance manual and connection drawing)
- P4 trip threshold
for LAM or U/F P.F. regulation (2F)
P4 (factory preset). Balance (equalization) of voltages before paralleling (U =
U) (3F).
48 or 57.5 Hz 50 or 60 Hz Possibility of coupling to the mains of alternators already
0 fC
ST3 fN running in parallel (4F).
R 726 module connected in place of ST4.

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ALTERNATORS
INSTALLATION

3 - INSTALLATION 3.1.3 - Location

Ensure that the ambient temperature in the room where the
3.1 - Assembly alternator is placed cannot exceed 40 C for standard power
ratings (for temperatures above 40 C, apply a derating
coefficient). Fresh air, free from damp and dust, must be able
to circulate freely around the air input louvres on the opposite
side from the coupling. It is essential to prevent not only the
recycling of hot air from the machine or engine, but also
All mechanical handling operations must be undertaken
exhaust fumes.
using approved equipment.
While being handled, the machine should remain
horizontal. 3.2 - Inspection prior to first use
3.2.1 - Electrical checks
3.1.1 - Handling
The generously-sized lifting rings are for handling the
alternator alone. They must not be used to lift the genset.
Choose a lifting system which respects the positionning of the
rings .
Under no circumstances should an alternator, new or
otherwise, be operated if the isolation is less than 1
megohm for the stator and 100,000 ohms for the other
windings.
There are three possible methods for restoring the above
minimum values.
a) Dry out the machine for 24 hours in a drying oven at a
temperature of approximately 110 C.
b) Blow hot air into the air input, having made sure that the
machine is rotating with the exciter field disconnected.
c) Run in short-circuit mode (disconnect the AVR) :
- Short-circuit the output phases using connections capable
of supporting the rated current (try not to exceed 6 A/mm2).
- Insert a clamp ammeter to monitor the current passing
through the short-circuit connections.
- Connect a 72 Volt battery in series with a rheostat of
3.1.2 - Coupling approximately 40 ohms (2000 Watts), to the exciter field
terminals, respecting the polarity.
3.1.2.1 - Single bearing alternator
- Open fully all the alternator openings.
Before coupling to the prime mover, check that both are
- Run the alternator at rated speed. Adjust the exciter field
compatible by:
current using the rheostat to obtain the rated output current in
- Undertaking a torsional analysis of the transmission.
the short-circuit connections.
- Checking the dimensions of the flywheel and its housing, the
Note: Prolonged standstill: In order to avoid these problems,
flange, coupling discs and offset.
we recommend the use of space heaters, as well as turning
over the machine from time to time. Space heaters are only
WARNING
really effective if they are working continuously while the
When coupling the alternator to the prime mover, the machine is stopped.
holes of the coupling discs should be aligned with the
flywheel holes by cranking the engine. 3.2.2 - Physical and visual checks
Do not use the alternator fan to turn the rotor.
Tighten the coupling discs screws to the recommended Before starting the machine for the first time, check that:
torque (see section 4.6.2.) and check that there is lateral play - the fixing bolts on the feet are tight
on the crankshaft. - the cooling air is drawn in freely
3.1.2.2 - Two-bearing alternator - the protective louvres and housing are correctly in place
- Semi-flexible coupling - the standard direction of rotation is clockwise as seen from
Careful alignement of the machines by measuring the the shaft end (phase rotation in order 1 - 2 - 3).
concentricity and parallelism of the two parts of the coupling For anti-clockwise rotation, swap 2 and 3.
is recommended, the difference between the readings should - the winding connection corresponds to the site operating
not exceed the specified values (say 0.1 mm). voltage (see section 3.3).

WARNING
This alternator has been balanced with a 1/2 key.

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ALTERNATORS
INSTALLATION

3.3 - Terminal connection diagrams

To modify the connection, change the position of the terminal
cables. The winding code is specified on the nameplate.

3.3.1 - Terminal connection 8100 / 9100

Any intervention on the alternator terminals during

reconnection or checks should be performed with the
machine stopped

Connection code Voltage L-L

Ph1-L1
D T1-U1
Winding 50 Hz 60Hz
Star
3 PH T4-U2
6S 380 - 415 380 - 480
Factory connection
T6-W2 T5-V2 8S 347 380 - 416

T3-W1 T2-V1
AVR connector 0 - 380 V
Ph3-L3 Ph2-L2

Ph1-L1
C Winding
50 Hz 60Hz
T6 -W2 T1-U1
Delta
6S 220 - 240 220 - 255 Connection using optional kit
3 PH
T4-U2 8S 200 220 - 240
T3-W1 Consult the factory
T5-V2 T2-V1 AVR connector 0 - 220 V
Ph3-L3 Ph2-L2

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ALTERNATORS
INSTALLATION

3.3.2 - Connection checks On application of the load, the machine should maintain its
rated speed and voltage; however, in the event of abnormal
operation, the machine setting can be altered (follow the
adjustment procedure in section 3.5). If the machine still
operates incorrectly, the cause of the malfunction must be
located (see section 4.4) .
Electrical installations must comply with the current
legislation in force in the country of use. 3.5 - Setting up
Check that:
- the differential circuit-breaker conforms to legislation on
protection of persons, in force in the country of use, and has
been correctly installed on the alternator power output as
close as possible to the alternator. (Disconnect the wire of the The various adjustments during tests must be made by a
interference suppression module linking the neutral). qualified engineer. Take care that the drive speed
- any protective devices in place have not tripped, specified on the nameplate is reached before
- if there is an external regulator, the connections between the commencing adjustment. After operational testing,
alternator and the cubicle are made in accordance with the replace all access panels or covers.
connection diagram. The A.V.R. is used to make any adjustments to the machine.
- there is no short-circuit between phase or phase-neutral
between the alternator output terminals and the generator set 3.5.1 - R 449 main adjustments
control cabinet (part of the circuit not protected by circuit-
breakers or cubicle relays)
- the machine should be connected with bar of one another as
shown in the terminal connection diagrams
.

3.3.3 - Electrical checks on the A.V.R.

- Check that all connections have been made properly as
a) Initial potentiometer settings (see table below) remote
shown in the attached connection diagram.
voltage adjustment potentiometer: centre (ST4 strap
- Check that the frequency selection strap "ST3" is on the
removed).
correct frequency setting.
- Check whether strap ST4 or the remote adjustment
Action Factory setting Pot.
potentiometer have been connected.
- Optional operating modes
Voltage 400V - 50 Hz
Strap ST1: cut to connect the R 731 3-phase detection
minimum fully anti-clockwise (Input 0 - 380 V) P2
module.
Strap ST2: cut for rapid response time.
Strap ST5: cut to suppress the L.A.M. function Not set
Stability
(centre position) P3

3.4 - Commissioning Threshold/LAM or U/F

Underspeed protection IfST3 = 50 Hz
and "LAM" trip threshold (factory) = 48 Hz
Maximum frequency fully If ST3 = 60 Hz P4
anti-clockwise (factory) = 57.5 Hz

Voltage quadrature droop Not set

The machine can only be started up and used if the (// operation with C.T.) (fully anti-
installation is in accordance with the instructions and - 0 quadrature droop fully clockwise.) P1
advices defined in this manual. anti-clockwise.
The machine is tested and set at the factory. When first used Excitation ceiling
with no load, make sure that the drive speed is correct and Limit of excitation ceiling 15 A
and short-circuit current, (fully clockwise) P5
stable (see the nameplate). It is recommanded to grease the
bearing(s) at the time of commissionning (see 4.2.3). minimum fully anti-clockwise

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ALTERNATORS
INSTALLATION

Adjustments in islanded operation reactive load is available)

- By altering the speed drop, equalize the kW (or divide the
b) Install a D.C. analogue voltmeter (needle dial) cal. 100V on rated power of the units proportionally).
terminals E+, E- and an A.C. voltmeter cal. 300 - 500 or - By altering the quadrature droop potentiometer P1, equalize
1000V on the alternator output terminals. or divide the currents.

c) Make sure that the ST3 strap is positioned on the desired 3.5.2 - Max. excitation adjustment (excitation
frequency (50 or 60 Hz). ceiling)
d) Voltage potentiometer P2 at minimum, fully anti-clockwise. Max. excitation depending on the mains frequency
ST3
e) Turn the U/f potentiometer P4, fully clockwise.
X2
P5 50Hz 60Hz
A
Z1
f) Stability potentiometer P3 approximately in the middle.
X1 Field ~ 10 ohms
P4
Z2
g) Start the engine and set its speed to a frequency of 47,5 Hz E+
R 449 - +
for 50 Hz, or 57 for 60 Hz. P3
E- A
0V 15A DC
h) Adjust the output voltage to the desired value using P2. 110 V
- rated voltage Un for solo operation (eg. 400 V) P2 220V
ST4
- or Un + 2 to 4% for parallel operation with C.T. (eg. 410V ) 380V
If the voltage oscillates, use P3 to make adjustments (try both D
directions) observing the voltage between E+ and E- (approx. Voltage
10V D.C.). The best response times are obtained at the limit
of the instability. If no stable position can be obtained, try
cutting or replacing the ST2 strap (normal /rapid). Adjustment of the current limit
by potentiometer P5 .
i) Check LAM operation : ST5 closed The factory setting is maximum fully clockwise.
It is possible to reduce the maximum excitation level by a
j)Turn potentiometer P4 slowly anti-clockwise until there is a static method which is safer for the alternator and the
significant voltage drop. network. Disconnect power supply wires X1,X2 and Z1,Z2,
and the sensing leads (0-110V-220V-380V) on the alternator.
k) Vary the frequency (speed) a bit above 47,5 or 57 Hz
according to the operating frequency, and check the change Connect the mains power supply (200-240V) as indicated
in voltage to the previously observed. (X1,X2). Install a 20A D.C. ammeter in series with the exciter
field. Turn P5 fully C.C.W. and activate the power supply(A
l) Readjust the speed of the unit to its rated no-load value. and D). If there is no output current from the A.V.R., turn
potentiometer P2 (voltage) C.W. until the ammeter indicates
Adjustments in parallel operation a stable current. Switch the power supply off, then on again,
turn P5 C.W until the required max. current is obtained (no
Before any intervention on the alternator, make sure that more than 15 A).
the speed droop is identical for all engines.
Checking the internal protection:
m) Preset for parallel operation (with C.T. connected to S1, Open switch (D): the excitation current should increase to its
S2): preset ceiling, remain at that level for about 10 seconds and
- potentiometer P1 (quadrature droop) in centre position then drop to below < 2A.
Apply the rated load (P.F. = 0.8 inductive). To reset, switch off the power supply by opening switch (A).
The voltage should drop by 2 to 3 %. If it increases, swap the
2 incoming wires of the C.T. secondary. Note: After setting the excitation ceiling as described, adjust
the voltage again (see section 3.5.2.) by P2.
n) The no-load voltages should be identical for all the
alternators intended to run in parallel. (*): A short-circuit current of 3 x In is a legal requirement in
- Couple the machines in parallel. some countries so as to offer selective protection.
- By adjusting the speed, try to obtain 0 Kw power exchange.
- By altering the voltage setting P2 or Rhe on one of the
machines, try to cancel (or minimise) the current circulating
between the machines.

From now on, do not touch the voltage settings.

o) Apply the available load (the setting is only correct if a

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ALTERNATORS
INSTALLATION

3.5.3 - Special type of use

- Field de-energizing

X2 AREP / PMG
Z1
X1
Z2
E+

The exciter is switched off by disconnecting the AVR power

supply (1 wire on each auxiliary winding) contact rating 16A -
250V A.C.
Connection is identical for resetting the AVR internal
protection.

- Field forcing
(400V - 10A) Diode
X2
R 449

Z1 t - +
X1 Battery (B Volt)
Z2
E+
~ 10 ohms
E-
Exciter field

Forced excitation
B Volt

Time

Applications B volts Time t

Guaranteed voltage build up 12 (1A) 1-2 s
Parallel operation, de-energized 12 (1A) 1-2 s
Parallel operation, at standstill 24 (2A) 5 - 10 s
Battery starting 24 (4A) 5 - 10 s
Sustained voltage on over load 24 (4A) 5 - 10 s

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ALTERNATORS
SERVICING - MAINTENANCE

4 - SERVICING - MAINTENANCE Before using another grease, check for compatibility with the
original one.
4.1 - Safety measures Monitor the temperature rise in the bearings, which should not
exceed 50C above the ambient temperature. Should this
value be exceeded, the machine must be stopped and
checks carried out.

4.2.4 - Electrical servicing

Servicing or troubleshooting must be carried out strictly
Cleaning product for the windings
in accordance with instructions so as to avoid the risk of
accidents and to maintain the machine in its original
state. WARNING
DO NOT USE: TRICHLORETHYLENE,
PERCHLORETHYLENE, TRICHLOROETHANE and ANY
ALKALINE PRODUCTS.
All such operations performed on the alternator should Certain strictly defined pure volatile degreasing products can
be undertaken by personnel with training in be used, such as:
commissioning, servicing and maintenance of electrical - Normal petrol (without additives); flammable
and mechanical components. - Toluene (slightly toxic); flammable
Before any intervention on the machine, ensure that it cannot - Benzene (or benzine, toxic); flammable
be started by a manual or automatic system and that you - Ciclohexare (non toxic); flammable
have understood the operating principles of the system.
Cleaning of the stator, rotor, exciter and diode bridge
4.2 - Regular maintenance
The insulating components and the impregnation system are
4.2.1 - Checks after start-up not at risk of damage from solvents (see the list of authorised
After approximately 20 hours of operation, check that all fixing products above).
screws on the machine are still tight, plus the general state of Avoid letting the cleaning product run into the slots.
the machine and the various electrical connections in the Apply the product with a brush, sponging frequently to avoid
installation. accumulation in the housing. Dry the winding with a dry cloth.
Let any traces evaporate before reassembling the machine.
4.2.2 - Cooling circuit
4.2.5 - Mechanical maintenance
It is advisable to check that circulation of air is not reduced by
partial blocking of the air inlet and outlet louvres: mud, fibre,
grease, etc. WARNING

4.2.3 - Bearings Water and/or Pressure wash are strictly prohibited. Any
problems caused by such treatement are not covered by
The bearings are greasable. our warranty.
It is recommanded to grease the machine when rotating. Degreasing : Use a brush and detergent (adapted to paint).
Time intervals and quantity of grease are given in the Dusting : Use an air gun.
following table. If a machine is fitted with air inlet and outlet filters, in order to
Bearing 6226 C3 ensure correct ventilation, a regular cleaning of the filters
Quantity of grease 50 g must be done according to the environment conditions.
After cleaning the alternator, it is essential to check the
Lubrication time 3600 H (or once a year)
insulation of the windings (see sections 3.2. and 4.8).
Bearing 6232 MC3
Quantity of grease 70 g 4.3 - Fault detection
Lubrication time 1700 H (or once a year)
If, when first commissioned, the alternator does not work
Bearing NU 1028 MC3 normally, the source of the malfunction must be identified.
Quantity of grease 35 g To do this, check that:
Lubrication time 2000 H (or once a year) - the protective devices are fitted correctly
- all connections comply with the diagrams in the manuals
supplied with the machine.
Lubrication time intervals are given for a grease of grade:
- the speed of the unit is correct (see section 1.3.).
LITHIUM - standard - NLGI 3.
Repeat the operations defined in section 3.
The factory lubrication is done with grease :
SHELL - ALVANIA G3.

12
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SERVICING - MAINTENANCE

4.4 - Mechanical defects

Fault Cause / action
Excessive overheating of one or both bea-- If the bearing has turned blue or if the grease has turned black, change the
Bearing defect rings (temp of bearings over 50C above bearing.
ambient) (With of without abnormal bea- - Bearing race badly locked (moving in its housing)
ring noise) - Bracket misalignment.
- Air flow (Inlet - outlet) partially clogged or hot air is being recycled either from
Excessive overheating of alternator frame alternator or prime move
Overheating (temperature rise of more than 40 C - Aternator is functionning at too high a voltage (over 105 % of rated voltage on
above ambient) load).
- Alternator overloaded.
- Misalignment (coupling)
Too much vibration - Defective mounting or play in coupling
Vibration problem - Incorrect balancing of shaft (Engine - Alternator)
Excessive vibration and humming noise - Three phase alternator is single phase loaded in excess of acceptable level.
coming from the alternator - Short-circuit in the alternator stator
- System short-circuit
- Mis paralleling
Alternator damaged by a significant Possible consequences (according to the seriousness of the above faults):
Abnormal noises impact which is followed by humming and - Broken or damaged coupling.
vibration - Broken or bent shaft end.
- Shifting and short circuit of main field rotor.
- Fractured fan or coming loose on shaft.
- Blown up rotating diodes, or and A.V.R.

4.5 - Electrical faults

Fault Action Symptoms Cause
The alternator builds up and voltage is - Lack of residual magnetism
correct when the battery is removed - fuse defect
The alternator builds up but voltage but - Check the connection of the sensing leads to the
Connect a battery of 4 to 12 does not reach nominal value when the A.V. R
No voltage at no volts to terminals E+ or E- battery is removed - Faulty rotating diode
load or start up respecting the polarity on - Short-circuit on rotor windings
the A.V.R.for 2 to 3 seconds The alternator builds up but voltage col- - Faulty A.V.R
lapses when the battery is removed - Exciter windings shorted or open circuit (check win-
ding)
- Main field winding open circuit (check resistance)
Check AVR connections (possible AVR failure)
- Exciter field short-circuited
Correct speed - Rotating diode(s) burnt out
Voltage too low Check the prime mover - Main field rotor short-circuited - Check the resistance
speed Increase the speed of prime mover
Speed too low (Do not touch the AVR voltage pot. (P2) before running
at the correct speed)
Voltage too high Adjust potentiometer Adjustment without action AVR faulty
voltage
Voltage oscilla- Adjust the stability potentio- If no effect : change recovery mode nor- - Check speed for possible cyclic irregularity
tions meter on A.V.R. mal / rapid (ST2) - Loose connections
- Faulty A.V.R.
- Speed below nominal on load (or LAM set too high)
Voltage between E+ and E- (DC)
Voltage correct Run on no-load and check AREP / PMG < 10V - Check speed (or LAM set too high)
on no load too voltage between E+ and E- Voltage between E+ and E- - Faulty rotating diodes faulty
low on load AREP / PMG > 15V - Short-circuit in the main field. Check resistance.
- Faulty exciter armature. Check resistance.
Voltage collap- Check the AVR, the surge The output voltage does not return the - Exciter winding open circuit
ses during nor- suppressor, the rotating rated value . - Faulty exciter armature
mal operation diodes and replace any - Faulty AVR
defective part - Main field rotor winding open circuit or short circuit

13
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SERVICING - MAINTENANCE

4.5.1 - Checking the windings Assembly A: Connect a 24 V battery in series with a rheostat
of approximately 50 ohms - 300 W and a diode on both exciter
You can check the winding insulation making a high voltage field wires (5+) and (6-).
test. In this case, you must disconnect all AVR wires.

WARNING ASSEMBLY A
6 - Exciter field 5 +
Damages occuring to A.V.R. in such conditions will not Rh. 50 -300W
5A diode
be taken into account in a warranty claim.

4.5.2 - Checking the diode bridge +

-
DIODE BRIDGE
Anode 24V battery
Cathode
A
C
A diode in good
working order must
allow the current Assembly B: Connect a "Variac" variable power supply and
to flow from the anode a diode bridge on both exciter field wires (5+) and (6-).
to the cathode.
These two systems should have characteristics which are
compatible with the exciter field excitation power of the
machine (see the nameplate).
- +
C C C A C 3) Run the unit at its rated speed.

4) Gradually increase the exciter field current by adjusting the

A A A rheostat or the variac and measure the output voltages on L1
+ ~ ~ ~ +
- L2 - L3, checking the excitation voltage and current at no
load (see machine nameplate or ask for the factory test
report).
- ~ ~ ~ - - +
A
C
C C C When the output voltage is at its rated value and balanced
within 1%, for the rated excitation level and rated speed, then
the machine is in good working order.
A A A The fault must therefore come from the A.V.R. or its
associated wiring (i.e. sensing, auxiliary windings)

4.5.3 - Checking the windings and rotating ASSEMBLY B

diodes using separate excitation
Variac 6 - Exciter field 5+

40
50 60 +
30

70

5A diode
20

80

During this procedure, make sure that the alternator is

10

90

disconnected from any external load and inspect the 0 100

terminal box to check that the connections are fully DC

tightened. AC -
24V
1) Stop the unit, disconnect and isolate the AVR wires. 220V
2) There are are two ways of carrying out a separate
excitation.

14
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SERVICING - MAINTENANCE

4.6 - Dismantling, reassembly 4.6.4 - Access to connections and regulation

(see section 5.4.1. & 5.4.2.) system
Access by removing the box lid (48) and the left side panel
During the warranty period, this operation should only be
(59).
carried out in an approved workshop or in our factory,
otherwise the warranty may be invalidated.The machine
must be horizontal when handled.
4.6.5 - N.D.E. ball bearing replacing on single
bearing alternator (8100)
36

78

349

72

79

70

- remove the air inlet screen (47)

- disconnect the diodes bridge (106) : 5 leads
- remove the 3 screws of the diode bridge on the shaft
- remove the diodes bridge
4.6.1 - Tools required - remove the 4 screws of the inner bearing cap (78)
To fully dismantle the machine, we recommend to have the - remove the 6 screws of the bracket (36) on the stator (1)
tools listed below : - tap off the NDE bracket (36) together with the exciter field
- one three arms ratchet spanner with extension (90) from the stator (1)
- one torque wrench - extract the ball bearing (for 8100 series) or the roller bearing
- one set of flat spanners : 8, 10, 18, 19 mm inner ring (9100 series) with the suitable puller
- one set of socket : 8, 10, 13, 16, 18, 19, 21, 24, 30 mm - check the "O" ring (349) and the wavy washer (79) and
- one 5 mm Allen key replace them if necessary (8100 series only)
- one puller (U35), (U32/350) - position the new ball bearing (8100 series) or new roller
bearing inner ring (9100 series) after heating it, by induction
4.6.2 - Screw tightening torque system, at 80C.

IDENTIFICATION screw Torque N.m

Diode bridge screw M6 5,6
Diode nut M 12 10
Bracket / Frame screw M 12 62
Discs / Hub screw M 20 300
Earthing screw M 12 46
Air inlet screen M 12 46
Terminal box screws M6 5,6
Terminal bars screws M 12 46

CAUTION : IF THE BEARING NEEDS TO BE REMOVED

4.6.3 - Access to diodes FOR ANY REASON, ALWAYS INSTALL A NEW BEARING.
- Remove the air inlet screen (47)
- Disconnect the diodes and recheck diodes either by 4.6.6 - D.E. ball bearing replacing on two
ohmeter or battery lamp ( 4.5.2). bearings alternator
- If failed remove the surge suppressor
- Replace reconnect and reassemble. - remove 6 screws (411) and the 4 screws (62)
- tap off the D.E. bracket (410) from the stator (1)
- extract ball bearing (60) with suitable puller
- position the new ball bearing after heating it, by induction
system at 80 C

15
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SERVICING - MAINTENANCE

4.7 - Installation and maintenance of

WARNING
PMG
The PMG reference for 8100/9100 series is PMG 4

CAUTION : IF THE BEARING NEEDS TO BE REMOVED

FOR ANY REASON, ALWAYS INSTALL A NEW BEARING. 299

4.6.7 - Complete dismantling 290

- remove the 6 screws (411) 293

- support the rotor (4) DE by a crane
- remove the NDE bracket (36) ( 4.6.5) 292
- support the rotor NDE with a tube shaft extension
- push the rotor out of the stator from the NDE, with care 291
- if necessary, dismantle the half coupling and the DE bracket
(410) 295

4.6.8 - End shield reassembling 296

- place the "O" ring (349) and the wavy washer (79) into the 298
recess of the bearing housing in the NDE bracket (36) (8000
series only). 265
- mount the non drive end bracket (36) and drive end bracket
(410) on the stator (1).
- tighten the 12 screws of the brackets into the stator
- for lubrication, positionne the inner bearing cap nick
upwards (68 and 78)
- tighten 4 screws of the inner bearing cap (68 and 78)
- install and connect the diodes bridge ( 4.6.5)
- install the air inlet screen (47). 4.7.1 - Mechanical fitting
It is pointing out the following :
4.6.9 - Rotor reassembling - an adaptation shaft (centring of the rotor PMG on alternator
See 4.6.7 and 4.6.8 shaft)(291).
- a tie rod M20 with screw, washer and nut (295 and 296).
Note : If the rotor has been rewound, it must be - a rotor with 16 magnets (292).
rebalanced. - a bare stator with leads (293)
- a stator support clock (290)
- 5 screws (298)
- a spacer for the air inlet screen (265) (8100 series only)

The PMG mechanical assembly order is as follows :

After final adjustments, the access panels or cover - remove the air inlet screen (47)
should be refitted. - put the rotor with magnets on the adaptation shaft
- put the whole on the shaft (4) with the washers (296) and tie
rod (295) and tighten the M20 nut
- place the stator inside the clock and tighten the screws (298)
and washers
- slide the stator along the rotor into the NDE bracket (36)
- secure and tighten the screws (299) of the clock into the
NDE bracket
- connect the PMG stator leads and secure the leads (4.7.2)
- put in place the spacer (265) for air inlet screen (8100 series
only)
- install the air inlet screen (47)

Note : check carefully the air gap of the PMG.

Note : It is recommended to install the PMG when the rotor is
radially centred in the stator, for example when the gen set is
already assembled.

16
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SERVICING - MAINTENANCE

4.7.2 - Electrical connection

- connect the 3 PMG wires , the 2 exciter field wires (5/6) and
the 2 voltage sensing wires (2/3) into the AVR according the
wiring diagram (see 2.3.2).
Typical electrical values of the PMG 4 :
- stator resistance phase to phase 20C : 1,4
- voltage at no load between phase : 250 V / 1500 R.P.M.

4.8 - Electrical characteristics table

Alternator - 4 pole - 50/60 Hz - No. 6S standard winding.
(400V- 50 Hz for the excitation values)
The voltage and current values are given for no-load
operation and operation at rated load with separate field
excitation. All values are given at 10% (for exact values,
consult the test report) and are subject to change without prior
warning.

Resistances at 20C ()
8100 B H L P
STATOR L/N 0,00195 0,0015 0,0013 0,00095
ROTOR 0,385 0,43 0,46 0,556
Excit. Field 9,35 9,35 9,35 9,35
Excit. armat. 0,052 0,052 0,052 0,065

9100 - H L -
STATOR L/N - 0,0008 0,0006 -
ROTOR - 0,45 0,5 -
Excit. Field - 9,2 9,2 -
Excit. armat. - 0,04 0,04 -

AREP auxiliary winding resistances at 20C ()

8100 B H L P
Auxil. WDG 0,105 0,085 0,085 0,08
X1, X2
Auxil. WDG 0,170 0,185 0,15 0,18
Z1, Z2

9100 - H L -
Auxil. WDG - 0,08 0,09 -
X1, X2
Auxil. WDG - 0,16 0,13 -
Z1, Z2

Field excitation current i exc (A)

Symbols : "i exc": excitation current of the exciter field.
8100 B H L P
At load 5 4,9 4,9 5
At no load 1,05 1,1 1,1 1,3

9100 H L
At load 5,2 5,2
At no load 1,5 1,6

For 60Hz machines the "i exc" values are approximately 5 to

10 % less.

17
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5 - SPARE PARTS 17 1 Fan key

18 1 Balancing discs
5.1 - First maintenance parts 22 1 Key
Emergency repair kits are available as an option. 33 1 Air exit screen
They contain the following items 34 2 Bolts
36 1 N.D.E. Bracket
Rep Description Qty 8100 Ref 41 2 Terminal box panel
Emergency kit 1 954 - 238 47 1 Air inlet box cover
198 Voltage regulator (AVR) 1 R 449 954 - 233 48 1 Terminal box cover
106 Diode bridge assembly 1 - 954 - 234 49 6 Bolts
112 Resistor 954 - 235 50 2 Terminal box spacer
59 2 Removable access panels
Others spare parts
60 1 D.E bearing
60 D.E. bearing 1 6226 C3 954 - 236
62 4 Bolts
70 N.D.E. bearing 1 6226 C3 954 - 237
68 1 Inner bearing cap
70 1 N.D.E bearing
Rep Description Qty 9100 Ref 72 4 Bolts
Emergency kit 1 954 - 243 78 1 Inner bearing cap
198 Voltage regulator (AVR) 1 R 449 954 - 233 79 1 Wavy washer
106 Diode bridge assembly 1 - 954 - 239 90 1 Wound exciter field
112 Resistor 954 - 240 91 5 Bolts
100 1 Wound exciter armature
Others spare parts 106 1 Rotating diode bridge assembly
60 D.E. bearing 1 6232 954 - 241 190 1 A.V.R. support stirrup
MC3
193 1 Terminal box spacer
70 N.D.E. bearing 1 NU 1028 954 - 242
198 1 A.V.R
MC3
203 1 Optional module.
205 1 Terminal strip
5.2 - Technical support service 265 1 Spacer for screen
270 4 Connection bar
Our technical support service will be happy to provide any
271 30 Screws
information you require.
279 6 Connection bar
When ordering spare parts, you should indicate the complete 280 12 Support
machine type, its serial number and the information indicated 290 1 Housing
on the nameplate. 291 1 Adaptation shaft
292 1 Rotor magnets
Address your enquiry to your usual contact.
293 1 Stator
Part numbers should be identified from the exploded views 295 1 Tie rod
and their description in the parts list. 296 1 Washer + nut
Our extensive network of "service stations" can dispatch the 298 5 Screws
necessary parts without delay. 299 5 PMG adaptor screws
To ensure correct operation and the safety of our machines,
300 24 Screws
we recommend the use of original manufacture spare parts.
In the event of failure to comply with this advice, the 320 1 Driving hub
manufacturer cannot be held responsible for any damage. 321 1 Hub key
322 4 Coupling disc
5.3 - Exploded view, part list. 323 12 Fixing screw
325 - Spacer shim
5.3.1 - Part list
349 1 Rubber "O ring"
Rep Qty Description 410 1 D.E. bracket
1 1 Wound stator assembly 411 6 Bolts
4 1 Wound rotor assembly
15 1 Fan

18
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5.3.2 - Single bearing 8100

47
41

106
50

72
198

36
203

36
79
205

349
190
193

70
300

78
90
91
P1
P5
P4

P3

P2

100
18

1
4
34
33
15
320
270

280
279
271
59

49

48

41
17
321
325
322
323

19
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5.3.3 - Two bearing 8100

41

47
50

106
198

72
203

36
205
190

79
193

349
300

70
78
P1

90
P5
P4

P3

P2

91
100
18
1
4
34
33
15
68
60
270

280
271

279
59

41
49

48

17
22
410
411
62

20
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5.3.4 - Single bearing 9100

47
106
36
41

70
72

36
50

78
198

90
203

91
205

100
190

28
193
300

P1
P5
P4

P3

P2

1
4
34
270

279
280
271
59

41
49

48

19
33
30
320
321
15
322
323

21
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5.3.5 - Two bearing

47
106
36
41

70
72

36
50

78
198

90
203

91
205

100
190

28
193
300

P1
P5
P4

P3

P2

1
4
19
320
33
34
279
280
270

271

41
59

49

48

62
321
33
68
60
15
30

22
 INSTALLATION AND MAINTENANCE Rf. 3361 - 4.33/a - 05.00

8100 - 9100
ALTERNATORS
SPARE PARTS

5.3.6 - D.E. Bearing mounting (8100) 5.3.8 - PMG mounting (8100 and 9100)

299

410 290

68 293

62 292

60 291

4 295

296

298

5.3.7 - N.D.E. Bearing mounting (8100) 265

36

78

349

72

79

70

23