User and maintenance manual for generating sets R230U 33504078701NE_0_1
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of 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.
1. Preface........................................................................................................................................................................... 3 1.1. General recommendations ................................................................................................................................ 3 1.2. Pictograms and their meanings ......................................................................................................................... 4 1.3.
6. Using the generator set................................................................................................................................................33 6.1. Pre-Start Inspection .........................................................................................................................................33 6.2. Generator set with NEXYS control panel .........................................................................................................36 6.2.
1. Preface 1.1. General recommendations Thank you for choosing an electrical generating set from our company. This manual has been designed to help you operate and maintain your electrical generating set correctly. The information contained in this manual is taken from technical data available at the time of print. In line with our policy of continually improving the quality of our products, this information may be amended without warning.
1.2. Pictograms and their meanings Safety notices are clearly mounted on the equipment to draw the operator's or maintenance technician's attention to the potential dangers and explain the action to be taken in the interest of safety. These notices are reproduced in this publication for ease of identification by the operator. Replace any notice that is missing or illegible.
WARNING: DANGER This symbol warns of a safety hazard. The presence of this symbol indicates a risk of injury. Observe the safety instructions and precautions for use. Important: Carefully read the instructions supplied with the generating set before using or servicing the equipment. WARNING: DANGER Risk of electrocution Do not touch the cables or connections when the generating set is in operation. Switch off the generating set for maintenance operations. DANGER Use diesel fuel only.
WARNING: DANGER Hot coolant can cause serious burns. Switch off the engine. Do not remove the filler cap until it is completely cold. Do not open the radiator when it is hot. DANGER Rotating parts can cause serious injury. Do not operate the generating set with the doors open. Do not remove the enclosures. 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.
WARNING: DANGER A poor earth connection can lead to serious injuries or death. Always connect the earth terminal of the generating 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.
1.3. Instructions and safety regulations THESE SAFETY GUIDELINES ARE IMPORTANT If you do not understand or have any questions about any point in this manual, contact your dealer who will explain it to you or give you a demonstration. A list of risks and precautionary measures to take follows. You should also refer to any local and national regulations that apply in accordance with your own jurisdiction.
Environment The operator must take the necessary measures to comply with the aesthetics of the site of use. The whole site must be maintained in a good state of cleanliness. The premises must be kept clean, and be regularly cleaned so as to avoid accumulation of dangerous materials or pollutants and dust, which could ignite or cause an explosion. The cleaning equipment must be suited to the risks posed by the products and dust.
1.3.3 Risks related to toxic products Warning Glycol is a toxic product and dangerous if absorbed. The corrosion inhibitor contains alkali. Avoid all contact with the skin and eyes. Read the Do not swallow it. instructions on the packaging. This substance should not come into contact with the eyes. In the event of contact with the eyes, rinse immediately with plenty of water for at least 15 minutes. Avoid prolonged or repeated contact with the skin.
1.3.5 Risks related to electrical networks The electrical equipment supplied with the generating set complies with standard NF C15.100 (France), or with the standards of the countries in question. The earth connection must be installed in accordance with the standards in force in each country in question, and with the neutral system sold. Read the manufacturer's identification plate carefully. The values for voltage, power, current and frequency are shown. Check that these values match the supply use.
1.4. Identifying sets Generating sets and their components are identified by means 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.
Alternator Cabinet Figure 1.
2. General description 2.1. Description Overview 3 2 1 2 3 Circuit breakers Control unit External emergency stop 4 5 6 Battery charge alternator Protective grilles Filling with fuel External fuel supply combined tap (optional) 1 5 4 7 7 6 Figure 2.
8 10 9 11 8 9 Circuit breaker Starter battery 10 11 Connection termination box Chassis Figure 2.
Sockets ( voltage 208/120V ) 16/209
2.2. Technical specifications RENTAL POWER / R230U Range / Generating set type Weights and Dimensions Dimensions with standard tank Dimensions l x w x h : 3508 mm x 1200 mm x 1830 mm Weight : 2540 kg dry weight 2890 kg in operating configuration Hood : M226C Noise level (measurement uncertainty) : 82 dB @ 1 m (0.70) 72 dB @ 7 m (0.
Fuel Fuel type Standard fuel tank High autonomy fuel tank Diesel 340 L 868 L Lubrication Oil capacity with filter Min. Oil pressure Nominal oil pressure Oil consumption (100 % load) Oil sump capacity Type of lubricant 34 L 2 bar 4 bar 0,09 L/h 31 L Genlub Cooling Engine capacity with radiator Max coolant temperature Fan power Refrigerant type Thermostat 35,8 L 105°C 3,4 kW Gencool 87-102°C Alternator data ● Compliant with NEMA MG21 standards, UTE NF C51.111, VDE 0530, BS 4999, IEC 34.
2.3. Fuel and consumables All specifications (product features) are given in the motor and alternator maintenance manuals attached to this manual. In addition, we recommend the consumables to be used in the "specifications" section. 2.3.1 Specifications 2.3.1.1.
2.3.1.2. Specifications of coolants Engine Coolants Make John Deere Type All MITSUBISHI All Volvo All Make GenPARTS Mitsubishi GenPARTS GenPARTS Type GENCOOL PC -26°C LLC GENCOOL PC -26°C GENCOOL PC -26°C GenCOOL PC -26 High-protection coolant, approved by manufacturers. GenCOOL PC -26 is a ready-to-use, highly protective coolant which is produced from an antifreeze recommended by the majority of European manufacturers. It is made from antifreeze and G 48 inhibitors. It protects up to -26°C.
RECOMMENDATIONS FOR USE: Compatible with the original fluid. It is recommended that the cooling system is completely drained when replacing the fluid. UNITS SPECIFIED VALUES TRIAL METHODS kg/m3 1,059 +/- 3 R 15-602-1 pH pH 7.5 to 8.5 NF T 78-103 Alkalinity reserve ml >=10 NF T 78-101 Boiling point °C 105 +/- 2 R 15-602-4 °C -26 +/- 2 NF T 78-102 SPECIFICATIONS Density at 20°C Freezing point: Glassware corrosion (test with antifreeze) : mg/test piece R 15-602-7 - Copper +/- 2.
3.1.2.2. Fork lift truck Position the forklift arms under the base frame (except with generating sets fitted with "forklift pockets", in which case position the forklift arms in these pockets), making sure that only its cross-members are resting on the arms. Lift the equipment, handling it gently. Set down the generating set in its unloading position. Figure 3.1 : Transporting a generating set using a forklift truck 3.2.
Figure 3.3 : Offset fluid retention container underneath the generating set chassis. Figure 3.4 : Offset fluid retention container integrated into the chassis and tank. Generating sets fitted with the offset tank option (DW) above also have 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).
3.3. Choice of location It should be determined on the basis of use. There are no specific rules governing the choice of location, other than proximity to the electric distribution panel and disturbances caused by the noise. However, fuel supply, burnt gas evacuation, and the direction of these gases and the noises emitted should be taken into account.
3.4. Electricity a) Connections - general information As with low voltage electrical installations, use and maintenance is governed by standard NFC 15.100 (France) or by the standards in the relevant country, based on international standard IEC 60364-6-61. They must also adhere to the regulations in the NFC 15.401 application guide (France) or to the regulations and standards in the relevant country. b) Power cables These can be unipolar or multipolar according to the power of the generating set.
d) Safety guidelines References: NFC 15-100:2002 (France) - IEC: 60364-5-54 In order to protect personnel against electric shocks, this generating set is equipped with a differential residual current protector "factory" set to trigger instantly, with a sensitivity of 30 mA. Important Any modification to this setting could endanger personnel. Any modification would render the user liable, and must only be performed by qualified and authorised personnel.
3.5. Special arrangements Generating sets are not fitted with protection against power surges caused by drops in atmospheric pressure or manoeuvring. The company does not accept any responsibility regarding damage caused by these occurrences. However, lightning conductors can be installed, on the understanding that this does not give total protection. 4. Trailer 4.1. Trailer linkage Before attaching the trailer, check the trailer hook on the tow vehicle; it should fit the trailer ring perfectly.
4.3. Operation "On-site" trailer These trailers are not fitted with a main brake, and so cannot be braked in motion; the tyres allow for a maximum speed of 27 km/h. So it is absolutely prohibited to exceed this speed. Nor are these trailers fitted with signalling lights. On-road use is prohibited. "On-road" trailer The driving speed must be suited to the condition of the road and the handling of the trailer.
4.5. Implementation for installation Operations to be carried out: Ensure that the ground is strong enough for the assembly not to sink into it. Unhitch the trailer. Immobilise the trailer by placing chocks under the wheels. Fully engage the parking brake (if fitted). Using the front wheel, position the generating set as close to horizontal as possible. Lower the stands (if fitted), and lock them. 4.6. Break transmission adjustment - The handbrake is used only as a parking brake.
Figure 4.3 : Braking transmission Figure 4.4 : Cross bar fitting Figure 4.
4.7.
4.8. Electrical connection diagram Figure 4.6 : Electrical connection diagram 4.9.
5. Preparation before operating the set The inspections referred to in this section enable the electrical generator set to operate. Specific skills are required to carry out these operations. They must only be entrusted to personnel with the necessary skills. Failure to follow these instructions in any way could result in malfunction or very serious accidents. Danger 5.1. Installation checks Check that the general recommendations given in the installation section (ventilation, exhaust, fluids, etc.
Coolant level, check Do not open the filler cap when the engine is hot, except in an emergency. Boiling liquid or vapour may be ejected. Warning The system must be filled up with liquid which has identical proportions to that already contained in the cooling system Important Check the coolant level daily, before starting the equipment. Top up if necessary. The coolant level should be approximately 5 cm below the edge of the filler cap seal.
Checking the fuel pre-filter The fuel is highly flammable and its vapours are combustible. The fuel pre-filter must only be bled when the engine is stopped and cold. Danger Check that there is no water or sediment at the bottom of the pre-filter. If necessary, drain the pre-filter using the following procedure: Undo the drain plug (A) at the bottom of the pre-filter by two or three turns. Collect the water and/or sediment in a suitable container. When fuel starts to flow out, tighten the drain plug.
6.2. Generator set with NEXYS control panel 6.2.1 Control panel presentation 9 7 1 9 10 2 3 6 9 5 8 9 4 Figure 6.
1 2 3 4 5 Figure 6.2 : Description of the LEDs A lit LED indicates: Module being supplied (green, lights up and remains lit) Emergency stop activated (control panel or external emergency stop) (red, lights up and remains lit) Visualisation of starting phase and speed/voltage stabilisation (flashing) and generating set operating OK or set ready to generate (green, lights up and remains lit) General alarm (orange, flashing) General fault (red, flashing). 6.2.1.1.
6.2.2 Manual starting Check that the generating set circuit breaker has triggered. Danger Connect the generating set battery. Turn the key switch to the ON position (without forcing it) All of the LEDs light up for 2 seconds, to confirm that they are operating correctly. If the LEDs do not light up, check the protection fuse and replace it if necessary. All the items on the screen are displayed for 2 seconds. Only the "ON" LED remains lit to indicate that the module is powered up.
6.2.3 Switching off Trigger the circuit breaker located at the base of the centre console. Let the motor run under no load for 1 to 2 minutes to allow it to cool. Press the "STOP" button to stop the generating set. Switch off the MICS Nexys module by switching the key to "OFF" (without forcing it). 6.2.4 Alarms and faults The appearance of a fault or an alarm causes the following screen to be displayed (one or more pictograms or a fault code along with the SOS message are displayed).
6.2.5 Faults and alarms - Details List of faults which will cause the generating set to stop and generate a pictogram Associated pictogram Oil pressure fault: Indicates that the oil pressure is incorrect Associated pictogram Engine temperature fault: temperature is too high. Indicates that the engine Associated pictogram Non-starting fault: Indicates that there have been three consecutive unsuccessful starting attempts.
List of faults which will cause the generating set to stop and generate a fault code Associated message Low coolant level fault: indicates that the level of coolant is low in the radiator (linked to a two second time delay). Or Overload or short-circuit fault (optional): with the circuit breaker SD contact closing (overload or short-circuit), the generating set switches off immediately also causing the main circuit breaker to be triggered.
List of alarms associated with a pictogram Associated pictogram Low fuel level alarm: Indicates the need to fill up with fuel. Associated pictogram "Alternator charging fault" alarm indicates a problem affecting the alternator charging rate.
6.3. Generator set with TELYS control panel 6.3.1 Control panel presentation 6.3.1.1. View of the front panel 9 1 13 6 7 9 5 12 2 3 9 8 10 11 4 9 Figure 6.4 : View of the front panel 1 2 3 4 5 6 7 8 9 10 11 12 13 Emergency stop button (AU) for switching off the generating set in the event of a fault which could endanger personnel or damage equipment. Key switch for switching the module on/off. Electronic board protection fuse.
1 2 3 Figure 6.5 : Description of the LEDs A lit LED indicates: 1 Alarm activated (flashing yellow). 2 Fault found (flashing red). 3 Module on (green, on continuously). 1 2 3 Figure 6.6 : Close-up of USB ports 1 2 3 USB key connection (HOST): file transfer between USB key and TELYS and vice versa. Connection for microcomputer (DEVICE): file transfer between PC and TELYS and vice versa, main module power supply. Protective cover.
6.3.1.2. Description of the screen The screen is backlit and requires no contrast adjustments. This screen is divided into 4 zones. SERIAL No.: 08030010000 SOFTWARE: 5.3.5 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS Figure 6.
6.3.1.3.
6.3.1.4. Description of the pictograms in zone 2 Alarm and fault pictograms in zone 2 All the pictograms in this zone are activated when TELYS is initialised.
6.3.1.5. Description of the pictograms in zone 3 Pictograms in zone 3 All the pictograms in these zones are activated when TELYS is initialised. The pictograms below are given as examples. Generating set stopped Screen no.
Generating set started Screen no.
Screen no. Pictograms Data displayed Single phase Alternator current indicator Two phase Alternator current indicator P8 Three phase Alternator current indicator Neutral Alternator current indicator Total Active Power Indicator Total Reactive Power Indicator P9 Total Effective Power Indicator Total Power Factor Indicator (lagging or leading) Fuel Level Indicator P10 Indication of Battery Voltage Indication of Battery Amps Screen order of appearance according to network type with the generating set on.
6.3.1.6. Display of messages in zone 4 The display (zone 4), among other things, displays messages relating to the operation of the generating set. The messages are as follows: Initialisation of TELYS Screen no. Screen Data displayed Initialisation of TELYS when the power is switched on and/or when loading a configuration G1 G2 SERIAL No.: 08030010000 SOFTWARE: 6.1.0 NOMINAL VOLTAGE: 400V FREQUENCY: 50Hz NOMINAL KW: 320kW EARTH SYSTEM: TNS Generating set serial no.
Generating set stopped Screen no.
Generating set start-up Screen no. G6 Screen Data displayed START-UP IN PROGRESS 24/08/2005 Operating phase - generating set in starting phase Date and time (depending on settings) 13:12 AIR PREHEATING Operating phase - air preheating prior to starting generating set Countdown for air preheating delay Date and time (depending on settings) G7 10 seconds 24/08/2005 13:12 Generating set started Screen no.
Generating setstop Screen no. G 11 Screen Data displayed OFF IN PROGRESS 24/08/2005 Generating set stop in progress Date and time (depending on settings) 13:16 Operating mode changeover (switching from Manual Mode to Auto Mode following auto start demand) Screen no.
6.3.2 Starting Check that the generating set circuit breaker has triggered.
6.3.3 Switching off Open the circuit breaker manually OR by selecting menu 12 "CONTROL LOAD" The following display will disappear (supply stopped) Press the STOP button The following screen is displayed and the generating set will stop OFF IN PROGRESS 24/08/2005 13:12 Switch TELYS off by turning the key to "OFF" (without forcing it to the "OFF" position).
6.3.4 Alarms and faults 6.3.4.1. Viewing alarms and faults Alarms and faults are displayed as follows: Alarms All alarms will cause: the yellow LED to flash "General alarm".
6.3.4.2. Activation of an alarm or fault The appearance of an alarm or a fault causes the corresponding screen to be displayed (examples below) FAULT FAULT ALARM Low coolant Level 06/10/06 10:30 FAULT Emergency Stop 06/10/06 15:30 Esc=RESET OK=HELP 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 active, it is reset automatically (cause disappears).
6.3.4.3. Activation of an alarm and a fault The appearance of an alarm and a fault causes: The yellow and red LEDs to flash the related screen to be displayed (example below) FAULTS 1/2 FAULT Emergency Stop 25/12/05 15:30 Esc=RESET If several faults are present, the number of faults is displayed at the top of the screen.
6.3.4.4. Engine fault codes display Certain alarms and engine faults generate specific fault codes. These codes are standardised according to the J1939 and/or J1587 standards, except for MTU engines that have a specific transmission protocol (see appendix, if applicable). Terminology used by the SAE CAN J1939 standard SPN: Suspect Parameter Number This represents the system or component at fault, for example: SPN 100, indicates an oil pressure problem or a problem with the oil pressure sensor.
In the event of a fault, the screen will display the following message: FAULT ALARM ENGINE GENERAL 110 18 25/12/2005 15:30 OK=HELP Engine fault code. Pressing OK will display fault finding information. In addition, appendix D indicate the meaning of the code. The checking and maintenance operations to carry out in order to solve the fault are included in the user and maintenance manuals of the engines supplied with the generating set documentation.
7. Maintenance schedule 7.1. Reminder of use The maintenance interval frequency and the operations to be carried out are outlined in the maintenance schedule, given as a guideline. N.B. the environment in which the generating set is operating determines this schedule.
8. Battery Fit the battery so that it is properly ventilated. Maintenance should only be carried out by qualified personnel. If replacing the batteries, use the same type of batteries. Do not throw the old battery in the fire. Only use insulated tools (the operator should not be wearing a watch, chain or any metal object). Never use sulphuric acid or acid water to top up the electrolyte level. Use an approved battery fluid. Batteries release oxygen and hydrogen gas, which are flammable.
8.2. Battery setting into service Batteries filled with acid have a density of 1.28 g/ml and are charged. In the case of dry batteries, fill each battery cell with acid up to the maximum level mark or to 15 mm above the plates. Let the battery 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.
8.4. Load preconization Highly discharged or sulphated batteries (formation of whitish lead sulphate deposit on the plates, which becomes hard and insoluble to acid; this deposit reduce the active surface of the plates, and increases their internal resistance) can no longer regenerate or be charged in a generating set. A discharged battery should be recharged immediately, or else it will suffer irreparable damage.
8.5.
9. Appendix 9.1.
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User's guide and maintenance manual VOLVO DIESEL ENGINE TAD 733 33522077701_0_1 69/209
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OPERATOR’S MANUAL p Generating set and industrial engines 4-7 liter (EDC 4) 71/209
Foreword Volvo Penta industrial engines are relied upon throughout the world, in both mobile and stationary applications, under some of the most rigorous conditions imaginable. This is not by chance. After more than 90 years of producing engines the name Volvo Penta has come to symbolize reliability, technical ingenuity, first-class performance and longevity. We believe that these characteristics are also ultimately your requirements and expectations for new Volvo Penta industrial engines.
Table of contents Safety information ................................................. 2 Safety rules for operation and maintenance .......... 3 Maintenance schedule ........................................ 18 Maintenance schedule ........................................ 18 Introduction ........................................................... Environmental responsibility ................................. Running in ............................................................. Fuel and oils ............
Safety information Read this chapter very carefully. It has to do with your safety. This describes how safety information is presented in the instruction book and on the product. It also gives you an introduction to the basic safety rules for using and looking after the engine. Check that you heave received the correct instruction book before you read on. If not, please contact your Volvo Penta dealer. Incorrect operation can lead to personal injury and damage to products or property.
Safety information Safety rules for operation and maintenance Daily checks Ignition lock Make it a habit to give the engine and engine bay a visual check before operating (before starting the engine) and after operation (when you have stopped the engine). This helps you to quickly discover whether any leakage of fuel, coolant, oil or any other abnormal event has happened, or is about to happen,.
Safety information Safety rules for operation and maintenance (contd.) Lifting the engine Batteries The existing lugs on the engine should be used for lifting. Always check that the lifting devices are in good condition and that they have the correct capacity for the lift (engine weight together with auxiliaries, if fitted). The engine should be lifted with an adjustable lifting boom for safe handling.
Safety information Electric welding Cooling system Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out at the same time as the pressure built up is lost. Remove the positive and negative cables from the batteries. Then disconnect all cables connected to the alternator. If the filler cap, coolant hose etc.
Introduction This instruction book has been prepared to give you the greatest possible benefit from your Volvo Penta industrial engine. It contains the information you need to be able to operate and maintain the engine safely and correctly. Please read the instruction book carefully and learn to handle the engine, controls and other equipment in a safe manner before you start the engine. IMPORTANT! This instruction book describes the engine and equipment sold by Volvo Penta.
Introduction Certified engines • If you own an emission certified engine, which is used in an area where exhaust emissions are regulated by law, it is important to be aware of the following: The engine must not be converted or modified, except for the accessories and service kits which Volvo Penta has developed for the engine. • No installation changes to the exhaust pipe and engine air inlet ducts may be done. • No seals may be broken by unauthorized personnel.
Presentation TD420VE, TAD420VE, TD520GE, TAD530/531GE and TAD520VE are in-line, direct injected, 4-cylinder industrial diesel engines. TAD620VE, TD720GE, TAD730/731GE, TAD720VE, TAD732GE, TAD721VE, TAD733GE and TAD722VE are inline, direct injected, 6-cylinder industrial diesel engines. All engines are equipped with electronically controlled fuel management (EDC4), turbocharger, thermostatically controlled cooling systems and electronic speed control. All TAD engines are also equipped with an intercooler.
Presentation TD420VE, TAD420VE, TAD620VE TD520GE, TAD530GE, TAD531GE, TAD532GE, TAD520VE TD720GE, TAD730/731GE, TAD732/733GE TAD720VE, TAD721VE, TAD722VE 9 81/209
Presentation Identification numbers Location of engine signs The engines are supplied with two engine signs, of which one is installed on the right side of the engine block. Engine plate 1. 2. 3. 4. 5. 6. 7. 8. Engine model Engine specification number Engine series number (10 digits) Engine power, peak, without fan Engine speed Injection advance and type of camshaft Manufacturer’s identification code Indication of standard and/or specification 9.
Presentation EDC 4 EDC 4 (Electronic Diesel Control) and is an electronic system with CAN (Controller Area Network) or potentiometer communication for diesel engine control. The system includes fuel management and diagnostic functions. Summary Diagnostic function The system includes sensors, control unit and an engine speed regulator.
Instruments The engines are not supplied with instruments and controls. The choice of instrument type and controls is made by the customer. The functions available are described below. A. Engine speed potentiometer (throttle control) B. CAN interface SAE J 1939 C. VODIA input D. Droop contact E. 1500 / 1800 rpm switch F. Diagnostic button G. Tachometer H. Warning lamp, oil pressure J. Diagnostic lamp K. Warning lamp, high coolant temperature L. Fuse 15 A M. Main switch N. Battery (24(12 V).
Starting the engine Make it a habit to check the engine and engine room before starting. This will help you to discover quickly if anything abnormal has happened, or is about to happen. Also check that instruments show normal values after starting. Before starting • Check that the oil level is between the MAX and MIN marks. Please refer to the “Maintenance, lubrication system” chapter: • • Open the fuel taps. • Check the air filter pressure drop indicator.
Starting the engine Starting in extreme cold Certain preparations must be made to facilitate engine starting, and in some cases to make starting possible at all. Use a winter grade fuel (of a well-known make) which has been approved for the relevant temperature. This reduces the risk of wax deposits in the fuel system. At extremely low temperatures, the use of a fuel heater is recommended.
Starting the engine Never use start spray WARNING! Never use start spray or similar products as a starting aid. Explosions could occur in the inlet manifold. The consequence could be personal injury. Starting with auxiliary batteries WARNING! Batteries (especially auxiliary batteries) contain hydrogen which is highly explosive in contact with air. A spark, which can be formed if the auxiliary batteries are wrongly connected, is enough to make a battery explode and cause damage. 1.
Operation Correct operation technique is very important for both fuel economy and engine life. Always let the engine warm up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at high engine speeds. Checking instruments Engine speed control Check all instruments directly after starting, and then regularly during operation. Avoid sudden and violent throttle opening.
Stopping the engine During longer breaks in operation, the engine must be warmed up at least once every fortnight. This prevents corrosion damage in the engine. If you expect the engine to be unused for two months or more, it must be laid up: Please refer to the “Laying up” chapter. IMPORTANT! If there is a risk of frost, the coolant in the cooling system must have sufficient frost protection. Please refer to the “Maintenance, cooling system” chapter: A poorly charged battery can freeze and burst.
Maintenance schedule General It is important that the engine receives regular care & maintenance, to achieve maximum reliability and service life. By following the service recommendations, engine performance is sustained and unnecessary environmental impact is avoided. MAINTENANCE SCHEDULE WARNING! Before you start to do any maintenance work, read the “Maintenance” chapter carefully. This contains instructions for doing work in a safe and correct manner.
Maintenance schedule Every 50-600 hours or at least every 12 months • 1) Engine oil and oil filter, change 1) .............................................................. page 22-23 Oil change intervals vary, depending on oil grade and sulfur content of the fuel. page 26. Every 500 hours • • Fuel tank (sludge trap), drain ..................................................................... not shown Drive belts, inspection/adjustment ..............................................................
Maintenance This chapter describes how the specified maintenance points should be done. Read them carefully before starting work. The times when maintenance points need to be attended to are given in the previous chapter: Maintenance schedule WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work. WARNING! Care and maintenance work should be done with the engine stopped unless otherwise specified.
Maintenance Drive belts. Inspection/adjustment Inspection and any adjustment should be done after operation, when the belts are hot. Loosen the screws (A) before tensioning the alternator belts. It should be possible to press the belts down about 10 mm (3/16 “) between the pulleys. Worn belts which operate in pairs should be changed together. On TD420VE, TAD420VE and TAD620VE, the fan belts have an automatic belt tensioner and do not need to be adjusted.
Maintenance Lubrication system Oil change intervals can vary from 40 to 500 hours, depending on oil grade and sulfur content of the fuel. Note that oil change intervals must never exceed a period of 12 months. If you want longer oil change intervals than given in the table below, the condition of the oil must be checked by the oil manufacturers through regular oil testing.
Maintenance Viscosity Select the viscosity from the table below, for the appropriate continuous ambient air temperature. * Refers to synthetic or semi-synthetic oils. Oil change volume Please refer to the “Technical Data” chapter. Oil level. Inspection Make sure that the oil level is between the MAX and MIN marks. IMPORTANT! In continuous operation, the oil level should be checked every 8 hours. WARNING! Working with, or going close to a running engine is a safety risk.
Maintenance Oil and oil filters. Change Always follow the recommended oil change interval and always change the oil filter during oil changes. On stationary engines, the bottom plug should not be removed. Use an oil drain pump to suck the oil up. 1. Clean the oil filter holder thoroughly to avoid dirt entry when the new filter(s) is/are installed. 2. Warm the engine up. WARNING! Hot oil and hot surfaces can cause burns. 3. Remove the bottom plug. Drain the oil. 4. Install the bottom plug with a new gasket.
Maintenance Cooling system The cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system and must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against internal corrosion, cavitation and damage caused by freezing. We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (concentrated) mixed with pure water according to spec, see “Coolant. Mixture”.
Maintenance Coolant. Mixture WARNING! All glycol is hazardous and harmful to the environment. Do not consume! Glycol is flammable. IMPORTANT! Ethylene glycol must not be mixed with other types of glycol. Mix: 40 % “Volvo Penta Coolant” (conc. coolant) 60 % water This mixture protects the engine against internal corrosion, cavitation and frost damage down to -28 °C (18°F). (Using 60 % glycol lowers the freezing point to -54 °C (65°F)).
Maintenance Coolant. Checking and filling WARNING! Do not open the filler cap when the engine is warm, except in emergencies. Steam or hot fluid could spray out. Check the coolant level daily before starting. Top the coolant up as necessary. The level should be about 50 mm (2”) below the sealing plane of the filler cap, or between the MIN and MAX markings, if a separate expansion tank is installed. IMPORTANT! Topping up should be done with the same type of mixture as is already in the cooling system.
Maintenance Coolant. Draining. The engine must be stopped before draining, and the filler cap unscrewed. WARNING! Do not open the filler cap when the engine is warm, except in emergencies. Steam or hot fluid could spray out. Open the drain taps and remove the drain plugs (positions are shown below). Unscrew and empty the coolant filter if installed. IMPORTANT! Deposits, which must be cleared away, may be found inside the drain plugs/taps. Check that all coolant really does drain out. Drain/vent taps.
Maintenance Cooling system Flushing Cooling performance is reduced by deposits in the radiator and cooling galleries. The cooling system should be flushed when the coolant is changed. 1. Drain the coolant, as in the description on the previous paragraph. 2. Insert a hose into the filler hole in the radiator, and flush with fresh water until the water which runs out is completely clear. 3. Close the drain taps and plugs. Fill up with fresh coolant, as in the instructions in the chapter entitled “Coolant.
Maintenance Fuel system Only use the grades of fuel recommended in the fuel specification below. Always observe the greatest cleanliness during re-fueling and work on the fuel system. All work on the injection system of the engine must be done by an authorized workshop. If the seal on the injection pump is broken by an unauthorized person, all warranties are void. WARNING! Fire hazard. Work on the fuel system must be done with the engine cold.
Maintenance Fuel filter. Change Cleanliness! No dirt must be allowed to get into the fuel system. WARNING! Fuel filters must be changed when the engine is cold, to avoid the risk of fire due to spilled fuel on hot surfaces. Remove the filters. Wipe a film of oil on the gaskets of the new filters. Screw the filters on by hand until the gaskets just touch the mating surface. Then tighten a further half turn, no more. Vent the fuel system.
Maintenance Electrical system WARNING! Before any work is done on the electrical system, the engine must be stopped and the current cut by switching off the main switch. Battery chargers or other auxiliary equipment installed on the engine must be disconnected. Fuses No fuses or circuit breakers are supplied with the engine. Customers have to install the electrical system on the side of the vehicle themselves. Fuses cut the current if the electrical system is overloaded.
Maintenance Battery. Maintenance WARNING! Fire and explosion hazard. Batteries must never be exposed to open flames or sparks. WARNING! Never confuse the positive and negative poles on the batteries. Risk of arcing and explosion. WARNING! Battery electrolyte is highly corrosive. Always protect your eyes, skin and clothes when handling batteries. Always use protective goggles and gloves. If acid comes into contact with your skin, wash at once with soap and a lot of water.
Maintenance Batteries, charging WARNING! Explosion risk! Hydrogen is given off when batteries are charged. This forms an explosive mixture with air. A short circuit, open flame or spark could cause a violent explosion. Ventilate well. WARNING! Battery electrolyte is highly corrosive. Protect your eyes, skin and clothes. Always use protective goggles and gloves. If acid comes into contact with your skin, wash at once with soap and a lot of water.
Maintenance Component location 1. Speed sensor, camshaft 2. Speed regulator / Actuator 3. Coolant temperature sensor 4. Charge pressure sensor, 3 pin* 5. Charge pressure sensor, 4 pin* 6. Connection to control unit 7. Fuel temperature sensor 8. Oil pressure sensor * Only one type of sensor is used.
Skötsel Laying up The engine must be laid up to prevent damage if it is not used for two months or more. It is important that this is done in the correct manner, and nothing is forgotten. For this reason, we have compiled a check list of the most important points. Before laying up for a long period of time, an authorized Volvo Penta workshop should check over the engine and other equipment. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the next start.
Fault tracing A number of symptoms and possible causes of engine malfunctions are described in the table below. Always contact your Volvo Penta dealer if any problems occur which you can not solve by yourself. WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work. Symptoms and possible causes The diagnosis button lamp flashes. Please refer to the “Diagnostic information” chapter. Engine can not be stopped.
Diagnostic function The diagnostic function monitors and checks that the EDC 4 system functions normally. Diagnostic function Effect on engine The diagnostic function has the following tasks: The diagnostic function affects the engine in the following ways: • • • • Discover and localize malfunctions. Notify that malfunctions have been discovered. Give advice in fault finding. 1. The diagnostic function has discovered a minor malfunction which does not damage the engine.
Operation During starting Reading fault codes When the ignition is turned on, the diagnostic lamp lights up for two seconds, together with the warning lamps for oil pressure and coolant. This is to check the lamp function. Fault codes can either be read via: - The VODIA tool (including the Penta EDC4 software). Please refer to the “VODIA User’s Guide” for advice on use. If the diagnostic lamp flashes after the two seconds, this indicates a serious fault and the engine can not be started.
Diagnostic function Fault codes WARNING! Read through the safety advice for care and maintenance work in the “Safety information” chapter before starting work. Code 2.0.0 PID 91, Code 2.2.1 Accelerator pedal sensor No faults There are no active faults. Reason: Faulty sensor, connector or cable. Reaction: The engine goes into “limp home” mode. PID 190, Code 2.1.1 Engine speed sensor, camshaft Reason: Faulty sensor, connector, cables or incorrect distance to cam wheel. High frequency interference.
Fault codes PID 102, Code 2.2.3 Charge pressure sensor PID 174, Code 2.2.7 Fuel temperature sensor Reason: Faulty sensor, connector or cable. Reason: Faulty sensor, connector or cable. Reaction: A fault code is generated. Reaction: A fault code is generated. Action: Action: • Check the sensor cable for breaks and short circuits. • Check the sensor cable for breaks and short circuits. • Check sensor function. Change the sensor as necessary. • Check sensor function.
Fault codes PID 111, Code 2.3.5 Warning, coolant level PID 174, Code 2.3.7 Warning, fuel temperature Reason: Coolant level too low Reason: Excessive fuel temperature. Reaction: A fault code is generated. Reaction: A fault code is generated. The fault code disappears when the fuel temperature falls below the recuperation value. Action: • Check the coolant level. Action: • Check the sensor cable for breaks and short circuits. • Check the fuel. • Check sensor function (if installed).
Fault codes PID 111, Code 2.3.5 Emergency stop, coolant level SID 23, Code 2.5.1 Control rod position sensor, difference Reason: Low coolant level Reaction: The engine is emergency stopped and can not be re-started until the fault is rectified. Reaction: A fault code is generated. The fault code disappears when the difference between control rod current value and nominal value falls below 10%. Action: • Check coolant level. • Check the sensor cable for breaks and short circuits.
Fault codes SID 252, Code 2.8.1 Parameter programming Reason: Memory fault Reaction: The engine is emergency stopped and can not be re-started until the fault is rectified. Action: Turn the ignition off and on, and check if the fault code remains. • SID 240, Code 2.8.1 Cyclical program test PID 158, Code 2.8.2 Reference voltage 2 Reason: Reference voltage for actuator exceeds permissible limit values. Reaction: A fault code is generated.
PID 48, Code 2.9.2 Atmospheric pressure SID 240, Code 2.10.1 Stack overflow Reason: Air pressure is outside permissible values. Reason: Internal calculation fault. Reaction: A fault code is generated. The fault code disappears when the pressure returns to normal. Monitoring function for air pressure is activated. Reaction: The engine is emergency stopped and can not be re-started until the fault is rectified. Action: Action: • Turn the ignition off and on, and check if the fault code remains.
Felkoder Technical data General Type designation .................................................... TD420VE Direction of rotation (seen from flywheel) ............... Anti- clockwise No. of cylinders ...................................................... 4 Cylinder bore mm (inch) ......................................... 101 (3.97”) Stroke mm (inch) ................................................... 126 (4.96”) Cylinder volume liter (inch 3 ) ................................... 4.04 (246.5) No.
Technical data Type designation ............................................. Direction of rotation, seen from flywheel: ........ No. of cylinders ............................................... Cylinder bore mm (inch) .................................. Stroke mm (inch) ............................................ Cylinder volume liter (inch 3 ) ............................ No. of valves ................................................... Compression ratio: EPA1 .............................................
Technical data Type designation ................................ Direction of rotation (seen from flywheel) No. of cylinders .................................. Cylinder bore mm (inch) ...................... Stroke mm (inch) ................................ Cylinder volume liter (inch 3 ) ............... No. of valves ...................................... Compression ratio: EPA1 ............................................... EPA2 ............................................... EU2 .........................
Technical data Lubrication system Oil Change volume, including filter change, TD420VE/TAD420VE: ............................................. TD520GE/TAD530/531GE/TAD520VE,TAD532GE: TAD620VE: ............................................................. TAD720VE/TAD721VE/TD720GE/TAD730/731GE: TAD722VE: ............................................................. TAD732GE/TAD733GE: .......................................... 10 liter (2.64 US gal) 13 liter (3.43 US gal) 16 liter (4.
Technical data Fuel system Injection sequence TD420VE/TAD420VE/TD520GE/ TAD530/531GE/TAD520VE,TAD532GE: ................ TAD620VE/TD720GE/TAD730/731GE/ TAD720VE/TAD732GE/TAD721VE/TAD733GE TAD722VE: ............................................................. Feed pump Supply pressure: ........................................................ Supply pressure after fuel filter at 1500 rpm: Min ......................................................... By-pass valve Opening pressure ...........................
Technical data Cooling system Type .......................................................................... Pressurized, sealed Pressure cap, max. opening pressure: TD420VE/TAD420VE/TAD620VE/ TD520GE/TAD530/531GE/ TAD520VE/TAD720VE/TAD732GE TAD721VE/TAD733GE/TAD722VE: ....................... 90 kPa (13 psi)1) TD720GE/TAD730/731GE, TAD532GE: ................. 60 kPa (8.7 psi) 1) Refers to VE engines which are not equipped with a pressure valve at the factory. Volume (engine) TD420VE/TAD420VE: ............
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✂ Yes please, I would like an operator’s manual in English at no charge. Orders can also be placed via the Internet: http://www.volvopenta.com/ manual/coupon Publication number: 7745131 42200/615001/155099900192 Post or fax this coupon to: Document & Distribution Center Order Department ARU 2, Dept.
✂ Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español. El pedido puede hacerse también por internet: http://www.volvopenta.com/ manual/coupon Número de publicación: 7745205 42200/615001/155099900192 Franquear o enviar fax a: Document & Distribution Center Order Department ARU 2, Dept. 64620 SE-405 08 Göteborg Suecia Fax: +46 31 545 772 Nombre Dirección País Observe que la oferta es válida durante 12 meses a partir de la fecha de entrega del motor.
✂ Ja graag, Ik wil kosteloos een instructieboek in het Nederlands ontvangen. U kunt ook bestellen via internet: http://www.volvopenta.com/ manual/coupon Publicatienummer: 7745208 42200/615001/155099900192 Stuur of fax de coupon naar: Document & Distribution Center Order Department ARU 2, Dept. 64620 SE-405 08 Göteborg Zweden Fax: +46 31 545 772 Naam Adres Land Denk eraan dat de aanbieding geldt tot 12 maanden na levering van de motor, daarna nog slechts indien beschikbaar.
✂ Íáé, Èá Þèåëá Ýíá áíôßôõðï ôïõ åã÷åéñéäßïõ ÷ñÞóçò óôçí áããëéêÞ ãëþóóá ÷ùñßò êáìéÜ ÷ñÝùóç. Ìðïñåßôå åðßóçò íá äþóåôå ôçí ðáñáããåëßá óáò ìÝóù ôïõ Internet, óôç äéåýèõíóç: http://www.volvopenta.com/ manual/coupon Áñéèìüò Ýêäïóçò: 7745210 ¼íïìá Äéåýèõíóç ×þñá Ðáñáêáëïýìå óçìåéþóôå üôé áõôÞ ç ðñïóöïñÜ éó÷ýåé ãéá 12 ìÞíåò áðü ôçí çìåñïìçíßá ðáñÜäïóçò ôçò ìç÷áíÞò. ÌåôÜ èá åßíáé èÝìá äéáèåóéìüôçôáò.
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132/209 7745131 English 06-2007
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User guide and maintenance manual LEROY SOMER Alternator LSA46.2 L6 - L9 LSA46.
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3856 en - 2011.01 / h 371 364 367 49 48 124 120 122 177 198 41 466 15 n ive be g o t s i ual d user man n This to the e 322 325 320 30 321 1 31 37 347 323 33 34 4 343 100 78 28 LSA 46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. SAFETY MEASURES WARNING SYMBOLS Before using your machine for the first time, it is important to read the whole of this installation and maintenance manual.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS CONTENTS 1 - RECEIPT.............................................................................................................................4 1.1 - Standards and safety measures....................................................................................4 1.2 - Inspection......................................................................................................................4 1.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 1 - RECEIPT 1.1 - Standards and safety measures • C : excitation system (C : AREP / J : SHUNT or PMG / E : COMPOUND) • 6/4 : winding number / number of poles. 1.2 - Inspection 1.3.1 - Nameplate So that you can identify your machine quickly and accurately, we suggest you write its specifications on the nameplate below. On receipt of your alternator, check that it has not suffered any damage in transit.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 2 - TECHNICAL CHARACTERISTICS 1.1 - Electrical characteristics The LSA 46.2 alternator is a machine without sliprings or revolving armature brushes, wound as “2/3 pitch”, 6 or 12wire, with class H insulation and a field excitation system available in either SHUNT, AREP or «PMG» version (see diagrams and AVR manuals). 2.1.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3 - INSTALLATION Personnel undertaking the various operations indicated in this section must wear personal protective equipment appropriate for mechanical and electrical hazards. 3.1 - Assembly 3.1.2 - Coupling 3.1.2.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS There are 2 possible methods for restoring the above minimum values. a) Dry out the machine for 24 hours in a drying oven at a temperature of 110 °C (without the regulator). b) Blow hot air into the air intake, having made sure that the machine is rotating with the exciter field disconnected.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Connection codes Voltage L.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.2 - Terminal connection: 6 wire (not possible with the R 250) Connection codes Voltage L.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 3.3.4 - Connection checks 3.4 - Commissioning Electrical installations must comply with the current legislation in force in the country of use. Check that: - The residual circuit-breaker conforms to legislation on protection of personnel, in force in the country of use, and has been correctly installed on the alternator power output as close as possible to the alternator.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4 - SERVICING - MAINTENANCE 4.1 - Safety measures Servicing or troubleshooting must be carried out strictly in accordance with instructions so as to avoid the risk of accidents and to maintain the machine in its original state.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.5.1 - Checking the winding You can check the winding insulation by performing a high voltage test. In this case, you must disconnect all AVR wires. 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-). ASSEMBLY A WARNING Diode 1A Damage caused to the AVR in such conditions is not covered by our warranty.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.6 - Dismantling, reassembly (see sections 5.4.1. & 5.4.2.) WARNING During the warranty period, this operation should only be carried out in an LEROY-SOMER approved workshop or in our factory, otherwise the warranty may be invalidated. Whilst being handled, the machine should remain horizontal (rotor not locked in position). Check how much the machine weighs (see 4.8.3) before choosing the lifting method. 4.6.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS - Slide the threaded rod into the shield hole to make it easier to assemble (see basic diagram). 4 78 36 Threaded rod Dowel Nut - 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). - Refit the air outlet grille (33). 4.6.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS If using a single-bearing or double-bearing machine with the regreasable bearing option: - Mount the new preloading (wavy) washer (79) + the new “O” ring seal (349) in the shield (36). - Screw a threaded rod into the thrust bearing (78). - Refit the shield (36) on the machine using a dowel and nut in the shaft extension (see diagram).
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 4.8 - Table of characteristics Table of average values Alternator - 4 poles - 50 Hz - Standard winding No. 6. (400V 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 to within ± 10% and may be changed without prior notification (for exact values, consult the test report). 4.8.1 - LSA46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5 - SPARE PARTS 5.1 - First maintenance parts Emergency repair kits are available as an option.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 5.4 - Exploded view, parts list and tightening torque 323 37 31 1 322 325 320 15 30 321 466 41 198 177 371 364 33 48 34 49 4 28 347 343 100 78 70 349 79 367 91 124 90 120 36 122 51 365 72 21 71 53 5.4.1 - LSA 46.
Installation and maintenance LEROY-SOMER 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS 34 37 62 30 33 284 60 22 1 31 466 41 198 177 371 364 68 48 15 49 4 28 343 347 100 70 349 79 367 91 124 90 120 36 122 51 365 71 53 21 5.4.2 - LSA 46.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Screw Torque Screw Torque Ref. Qty Description Ø N.m Ø N.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.2 - 4 POLES ALTERNATORS Electric Power Generation Division Declaration of CE compliance and incorporation This Declaration applies to the generators designed to be incorporated into machines complying with the Machinery Directive Nr 2006/42/CE dated 17 May 2006. MOTEURS LEROY-SOMER Boulevard Marcellin Leroy 16015 ANGOULEME France MLS HOLICE STLO.
LEROY-SOMER Installation and maintenance 3856 en - 2011.01/ h LSA 46.
LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME www.leroy-somer.
4067 en - 2009.05 / b STATOR : 12 wires (marking T1 to T12) MAIN FIELD T1 T7 T2 T8 T3 T4 T5 T11 T6 Varistor SHUNT SYSTEM 5+ Induced 6- Field T10 75 mm R 250 P1 Voltage ST4 Stability Option R250 A.V.R. Installation and maintenance 161/209 KNEE 65Hz LAM OFF KNEE 57Hz LAM OFF External potentiometrer for voltage adjusting 9 LAM OFF SPECIAL 8 7 50Hz o 901 6 1 23 P2 KNEE 47.5Hz 78 Slow fuse 250V 8 A 5 4 60Hz LAM OFF 2 3 13% 25% OFF 13% 25% LAM FREQ. & L.A.M.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. This manual concerns the alternator A.V.R. which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your A.V.R., you can look forward to many years of trouble-free operation.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. SUMMARY 1 - SUPPLY...............................................................................................................................4 1.1 - SHUNT excitation system.............................................................................................4 2 - R250 A.V.R..........................................................................................................................5 2.1 - Characteristics...
LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 1 - SUPPLY 1.1 - SHUNT excitation system The regulator controls the excitation current according to the alternator’s output voltage. With a very simple conception, the SHUNT excitation alternator does not have a short circuit capacity. The SHUNT excitation alternator is autoexcited with a R 250 voltage regulator.
Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2 - R250 A.V.R. 2.1 - Characteristics The threshhold position and LAM fonction settings are done with the jumper. - Storage: -55°C; +85°C - Operation: -40°C; +70°C - Voltage regulation: around ± 0,5 %. - Supply range/voltage detection 85 to 139 V (50/60Hz). - Rapid response time (500 ms) for a transient voltage variation amplitude of ± 20 %. - Voltage setting P1. - Stability setting P2.
LEROY-SOMER Installation and maintenance 4067 en - 2009.05 / b R250 A.V.R. 2.3 - R250 A.V.R. option Potentiometer for voltage setting, 1000 W / 0,5 W min: setting range ± 5 %. - Remove the ST4 jumper. It is advised to use the “LAM” at 25% for load impacts > at 70% of the genset rated power. Voltage Voltage UN 0,85 UN For wiring up the external potentiometer; the “earth” wires must be isolated as well as the potentiometer terminals (wires at the same voltage as the power). 2.
Installation and maintenance LEROY-SOMER R250 4067 en - 2009.05 / b A.V.R. 2.5 - Typical effects of the LAM with a diesel engine or without a LAM (U/F only) 2.5.1 - Voltage Transient voltage drop UN 0,9 (U/f) without LAM with LAM 0,8 1s 0 Time 2s 3s 2.5.2 - Frequency Max speed drop fN with LAM 0,9 without LAM 0,8 1s 0 2s Time 3s 2.5.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3 - INSTALLATION COMMISSIONING 3.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check that the position of the jumper corresponds to the operating frequency. - Check whether the ST4 jumper or the remote adjustment potentiometer have been connected. 3.2.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R. 3.3 - Electrical faults Fault Action Connect a new battery No voltage at of 4 to 12 volts to no load on terminals E- and E+ start-up respecting the polarity for 2 to 3 seconds Voltage too low Effect - Lack of residual magnetism The alternator starts up but its voltage disappears when the battery is removed - Faulty A.V.R. - Exciter field short-circuited - Short-circuit in the main field.
Installation and maintenance LEROY-SOMER R250 A.V.R. 4 - SPARE PARTS 4.1 - Designation Description A.V.R. Type R 250 Code AEM 110 RE 019 4.2 - Technical support service Our technical support service will be pleased to help you with any information needed. 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.
LEROY-SOMER Installation and maintenance R250 4067 en - 2009.05 / b A.V.R.
MOTEURS LEROY-SOMER 16015 ANGOULÊME CEDEX - FRANCE 338 567 258 RCS ANGOULÊME S.A. au capital de 62 779 000 ¤ www.leroy-somer.
3 LAM OFF LAM MODE 1 LAM MODE 2 LAM OFF LAM MODE 1 LAM STAB. I EXC 1 4 2 50Hz 0 90 1 23 6 4 56 VOLT. 7 8 EXT.FREQ. SET. 9 LAM ON LAM OFF KNEE ONLY FOR SPECIAL CONFIG. SERIES 0 SERIES 0 LSA 46.2/47.2 5000/6000 LSA 46.2/47.2 1 5000/6000 LEDS FUSIBLES / FUSES Installation & maintenance manual : www.leroy-somer.com VOIR NOTICE SEE NOTICE Installation and maintenance 5 MODE 2 65Hz LAM OFF 60Hz 1 PHASE SENSING 2 3 STAT. AVRs SERIES 3 7000/8000 2 SERIES 7000/8000 LSA 49.1/50.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs This manual concerns the alternator AVR which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. By following certain important points during installation, use and servicing of your AVR, you can look forward to many years of trouble-free operation.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs CONTENTS 1 - GENERAL INFORMATION ................................................................................................4 1.1 - Description.................................................................................................................... 4 1.2 - Characteristic................................................................................................................ 4 2 - POWER SUPPLY................
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 1 - GENERAL INFORMATION 1.1 - Description 1.2 - Characteristic The connection is realised by “Faston” connectors and the voltage sensing is single - phase. The R450 AVR is supplied in a casing designed to be mounted on a panel with dampers. - Operating temperature: - 30°C to + 65° C. - Storage temperature: - 55°C to + 85°C. - Shocks on the base: 9 g depending on the 3 axes.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2 - POWER SUPPLY characteristic), the second one has a voltage proportional to the stator current (compound characteristic : Booster effect). The power supply voltage is rectified and filtered before being used by the AVR monitoring transistor. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s. The rotating switch should be in the AREP position (see 3.2.3).
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.2 - PMG excitation system The AVR monitors the alternator output voltage by adjusting the excitation current. The rotating switch should be in the PMG position (see 3.2.3). With PMG excitation, a permanent magnet generator (PMG) added to the alternator supplies the AVR with voltage which is independent of the main alternator winding. This system provides the machine with a short-circuit current capacity of 3 IN for 10 s.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 2.3 - SHUNT or separate excitation system With SHUNT excitation, the AVR is powered by the main winding (100V to 140V 50/60 Hz ) by using X1, X2 on the AVR. The rotating switch should be in the SHUNT/ AREP position (see 3.2.3).
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3 - TECHNICAL CHARACTERISTICS 3.1 - Electrical characteristics - maximum power supply: 150V - 50/60 Hz - Rated overload current: 10 A - 10 s - Electronic protection: - In the case of a short-circuit, the excitation current is reduced to a value less than 1A after 10 s - In the event of loss of voltage reference, the excitation current is reduced to a value less than 1A after 1s for AREP/SHUNT, 10 s for PMG.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs excitation current must be limited to 9 A ± 0.5 A. WARNING The limitation threshold must be adjustable between 1 and 5.5 A. The genset breaker must be open during the short circuit. If the genset is restarted in short circuit, there is a excitation build up during 10s again at the maximum value. Operation between 3 and 6 In when short-circuited: The excitation current ceiling during a short-circuit equals 2.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs I exc(A) 2.9x I threshold (max. 9.5 A) 9.5 Diagram 2 (Maximum current I exc) P3 I threshold (1...5.5A) Shutdown 0.5 ~ 0.7 t(s) Activation of 90 s. tempo 90 s.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs KNEE 65Hz LAM OFF 78 456 7 6 2 5 3 4 60Hz RAPIDE 3 FAST RAPIDE FAST 2 For Pavers and hydraulic applications, select positions 0 (50 Hz) or 3 (60 Hz). 0 NORMAL NORMAL PMG NORMAL 1 NORMAL 0: AREP excitation and normal time response. 3: AREP excitation and fast time response. 1: PMG excitation and normal time response. 2: PMG excitation and fast time response. For SHUNT applications, AREP excitation must be selected.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.3 - U/F and LAM function 3.3.1 - Frequency variation compared with voltage (without LAM) Bend Voltage 48 Hz 100 % U/UN 57.5 Hz 50 Hz 60 Hz Frequency 50 Hz 60 Hz Hz 3.3.2.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 3.4.3 - Power • Equalization of voltages before paralleling (3 F). • Possibility of coupling to the mains of alternators already running in parallel (4F). Load on the shaft (kW) LAM 0 - R729 module: same as R726 with additional functions. • Detection of a diode fault. • 4-20 mA input. • Possibility of kVAR regulation. Variation in the load Load shedding due to LAM 1s 2s Time 3s 3.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4-INSTALLATION-COMMISSIONING 4.1 - Electrical checks on the AVR - Check that all connections have been made properly as shown in the attached wiring diagram. - Check the rotating switches selections - frequency, - type of alternator, - normal position (response time), - external potentiometer, - rated voltage, - secondary current of the CT used, - type of excitation. - R450 optional operating modes 4.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs i) Vary the frequency (speed) around 48 or 58 Hz according to the operating frequency, and check the change in voltage from that observed previously (~ 15%). j) Readjust the speed of the genset to its rated no-load value. Adjustments in parallel operation Before starting work on the alternator, make sure that the speed droop is identical for all engines. k) Preset for parallel operation (with C.T.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs When the excitation current is set to the rated value, a voltage dip is observed in excitation current limit when the limitation is activated and the current limit is reached. 4.2.3 - Special type of use WARNING The excitation circuit F+, F- must not be left open when the machine is running: this will irreparably damage the AVR.
LEROY-SOMER Installation and maintenance 4531 en - 2012.03 / e R 450 AVRs 4.
LEROY-SOMER Installation and maintenance R 450 AVRs 5 - SPARE PARTS 5.1 - Designation Description Type Voltage regulator R 450 (AVR) Code AEM 110 RE 031 5.2 - Technical support service Our technical support service will be pleased to provide any additional 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.
LEROY-SOMER Installation and maintenance 4531 en - 2012.
www.leroy-somer.
Appendix C - Common spare parts R230U Rental Power ENGINE VOLVO TAD733GE GENLUB 9.3.
GENCOOL x 20 L 330910098 x 60 L 330910099 x 210 L 330910100 X1 330570107 + 330570108 X1 330560196 + 330510016 X1 330560039 X1 ALTERNATOR LEROY-SOMER LSA46.2M5 Note: Diode bridge 330410126 X1 Varistor 330410109 X1 For all technical assistance or spare part requests, contact your nearest SDMO agent.
SID PID PPID FMI 28 97 98 Comment 3 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- Throttle #2 Position 3 Throttle Voltage high, short to V+ Short to V+ 4 Throttle Voltage low, short to V- Short to V- 14 Throttle voltage out of range 84 94 Description Throttle #3 Position 29 91 Perkins CID Volvo SPN Appendix D - List of John Deere - Volvo and Perkins fault codes John Deere 9.4.
100 102 273 PID PPID FMI 100 1 Engine oil pressure extremely low Oil pressure sensor input voltage high Short to V+ 4 Oil pressure sensor input voltage low Short to V- 5 Oil pressure sensor open circuit 17 Engine oil pressure low 18 Engine oil pressure moderately low 31 Oil pressure detected, motor stopped 102 Manifold air pressure sensor 0 Manifold air pressure above normal 1 15 Manifold air pressure below normal Incoherent measurement of the oil pressure Manifold air pressure sens
274 PID PPID FMI 108 3 4 17 110 110 15 Coolant temperature high least severe 16 Coolant temperature moderately high 17 Water temperature very low 31 Coolant temperature high 111 Engine coolant level low 1 Engine coolant level low 3 Coolant level sensor input voltage high 4 Coolant level sensor input voltage low 153 Crankcase pressure sensor 0 1 Value above normal Crankcase pressure sensor input voltage high Crankcase pressure sensor open circuit Fuel pressure sensor in the common r
172 PID PPID FMI 172 4 5 15 16 174 0 15 16 Fuel temperature moderately high 31 Fuel temperature sensor faulty 4 175 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 9 189 190 228 Transmission oil temperature invalid Rated engine speed 190 0 Engine speed de rated 31 Engine speed de rated 190 Engine speed sen
282 285 PID PPID FMI 3 Overspeed output open/short to B+ 4 Overspeed output short to ground 285 4 323 324 286 Oil pressure output open/short to B+ 4 Oil pressure output short to ground 5 Oil pressure output open circuit 323 Shutdown output status 3 Shutdown output open/short to B+ 4 Shutdown output short to ground 5 Shutdown output open circuit 324 Warning output status 3 Warning output open/short to B+ 4 Warning output short to ground 5 Warning output open circuit 0 15 Te
626 PID PPID FMI 45 3 4 5 627 Perkins SID Volvo CID John Deere SPN Description Comment Start enable device (intake heater and ether) Start enable device output short to B+ Not used, the control panel Start enable device output short to is in charge of managing the ground start enable device Start enable device output open circuit Power supply 1 Injector supply voltage problem 4 For 6125HF070 only 628 240 ECU unswitched power missing For 6068HF275 VP44 only Battery voltage below the oper
639 247 231 PID PPID FMI 2 Bus Off error 9 Passive bus error 11 Data registers read back failure 12 Loss of message error 13 Bus CAN error Comment Engine shutdown vehicle status 11 Engine shutdown vehicle request invalid 31 Engine shutdown vehicle request Status of the Turbo with variable geometry Supply voltage of the Turbo actuator low Error in communication between the ECU and the TGV actuator Error in position of the TGV Temperature of the actuator moderately high.
PID 653 3 3 653 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #3 circuit open 6 Cylinder #3 circuit shorted Cylinder #3 balancing error/mechanical failure Cylinder #3 unknown error/mechanical failure Cylinder #4 injector status 7 11 4 4 654 0 Injector outside the specifications 1 Injector outside the specific
PID 656 6 6 656 PPID FMI 0 Injector outside the specifications 1 Injector outside the specifications 2 4 Short circuit high side to B+ Short circuit high side to low side or low side to B+ Short circuit high or low side to ground 5 Cylinder #6 circuit open 6 Cylinder #6 circuit shorted Cylinder #6 balancing error/mechanical failure Cylinder #6 unknown error/mechanical failure Glow plug relay status 7 11 39 677 678 39 3 Glow plug relay voltage high 5 Glow plug relay voltage low 3 3
PID PPID FMI 1069 Comment 2 Tire size error 9 Tire size invalid 31 Tire size error 5 6 Feed pump of the fuel circuit High impedance at the terminals of the pump or open circuit Pump coil short to ground 12 Pump defective 1076 Not possible with Genset application Fuel Injection pump status 0 Pump control valve closure too long Injection DE10 1 Pump control valve closure too short Injection DE10 2 Pump detected defect Injection VP44 3 Pump solenoid current high Injection DE10 5 P
PID PPID FMI 1172 3 4 1180 1184 Input temperature of the TGV compressor Input voltage of the temperature sensor Short to V+ high Input voltage of the temperature sensor Short to Vlow Input temperature of the TGV turbine Turbine temperature extremely high Short to V+ Turbine temperature moderately high Short to V- Exhaust gas temperature sensor Status of the pressure system of the common rail 96 Pump control valve status 3 Pump control valve current high 5 Pump control valve error/mismatch 7
PID PPID FMI 2659 Description Comment Flow level of the EGR valve 2 Calculated EGR flow not valid 15 Calculated EGR flow rather high 17 Calculated EGR flow rather low Air temperature at turbo compressor outlet Temperature at compressor outlet moderately high Statuses of the EGR valve 2790 16 2791 Perkins SID Volvo CID John Deere SPN 19 2 Valve position signal not valid 3 Input voltage of the position sensor high 4 13 Input voltage of the position sensor low Short to VInability of th
SAE J1939-73 : March 2004 FMI and Description FMI=0—DATA VALID BUT ABOVE NORMAL OPERATIONAL RANGE - MOST SEVERE LEVEL The signal communicating information is within a defined acceptable and valid range, but the real world condition is above what would be considered normal as determined by the predefined most severe level limits for that particular measure of the real world condition (Region e of the signal range definition) Broadcast of data values is continued as normal.
FMI=11—ROOT CAUSE NOT KNOWN It has been detected that a failure has occurred in a particular subsystem but the exact nature of the fault is not known. Broadcast of data value is substituted with the “error indicator” value. FMI=12—BAD INTELLIGENT DEVICE OR COMPONENT Internal diagnostic procedures have determined that the failure is one which requires the replacement of the ECU, used here to mean the packaged unit that includes some microprocessor and its associated components and circuits.
FMI=20-30—RESERVED FOR SAE ASSIGNMENT FMI=31—CONDITION EXISTS Used to indicate that the condition that is identified by the SPN exists when no more applicable FMI exists or in 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.
