ALTERNATORS

Rf. 3120 - 4.33/a - 09.99

P5
P4

P3

P2 P1

PART NUMBER : 277 - 821

8000 - 9000
ALTERNATORS
Installation and maintenance
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS

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

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

2
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
RECEIPT

1 - RECEIPT 1.3 - Identification

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

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

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

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.

3
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
TECHNICAL CHARACTERISTICS

2 - TECHNICAL
CHARACTERISTICS
2.1 - Electrical characteristics
The 8000 - 9000 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" or "PMG" (see drawings).

MAIN FIELD STATOR

Aux. windings
EXCITER
T1 T2 T3
Armature
AREP sytem with

Varistor
R 449

5+ 6- T4 T5 T6
Field

R 449 Voltage sensing

MAIN FIELD STATOR

EXCITER

T1 T2 T3
Armature
Varistor

PMG
PMG sytem with
R 449
5+ 6- T4 T5 T6
Field

R 449 Voltage sensing

- Mounting arrangement
Interference suppression conforms with standard EN 55011,
MD 35 : single bearing, with standard feet and SAE coupling
group 1, class B.
discs
B 34 : two bearing feet mounted with standard bare shaft
2.1.1 - Options 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

4
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
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 and PMG field excitation , the alternator voltage - 2 voltage recovery mods (normal/fast) selected via ST2 and
regulator is the R 449 adjusted via P3 (stability).

ST5 With LAM W/O LAM 5+ Exciter field 6-

ST2 normal rapid

Supply
(see 2.3.2)
Response time

50Hz 60Hz 200 x 140 mm

ST3 4 x fl5.8 x 175 x 115
Frequency

With AREP excitation, the electronic A.V.R. R 449 is P5 X2

powered by two auxiliary windings which are independent of Excitation Z1
ceiling
the voltage detection circuit. The first winding (X1,X2) has a X1
Z2
voltage in proportion with the output voltage of the alternator P4 E+
(Shunt characteristic), the second (Z1,Z2) has a voltage in Under
speed E-
proportion with the stator current (compound characteristic: L3

Booster effect). The power supply voltage is rectified and

filtered before being used by the regulator monitoring
P3
R449 0V
110
220
(W)

transistor. The result is the alternator has a short circuit Stability

380
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
3 phase PMG is fitted at the rear end of the alternator and
supplies a voltage to the A.V.R. R449. ST1
The PMG provides to the AVR constant power which is
Single phase
detection
P1
Quadrature
independant of the main stator load. The result is the droop
3 phase detection
alternator has a short circuit capability (3 In/10s) and a good
T.I.
immunity to distortions. Option L2(V)
R731 ST4 Option S1 S2
340-520V
By checking the voltage sensing circuit, the AVR adjust the
excitation current required for maintaining the right voltage. 170-260V
ST4
Option
External potentiometer
for voltage adjustment
2.3.1 - R 449 regulator or for R 726 connexion
85-140V

- continuous rated current : 8A

- rated overload current: 15A - 10s
- electronic protection (overload, short-circuit): excitation 2.3.2 - R 449 supply connection
ceiling current for 10 seconds then return to approx. 2A
The alternator must be stopped (or the power switched off, AREP field excitation
see 3.5.3.) in order to reset the protection.
- fuses outside AVR Yellow
- voltage detection: 5 VA isolated via transformer R 449 X2
Red
- 110 V terminals = 85 to 140 V Z1
Green Auxiliary wind.
- 220 V terminals = 170 to 260 V X1
- 380 V terminals = 340 to 520 V Black
Z2
other voltages via step down transformer (Option)
- voltage regulation 0,5% E+ 5+ 6-
- voltage adjustment via potentiometer P2 E-
- current detection: (parallel operation): C.T. 10 VA CL1, Exciter field
secondary 1,2 A (Option)
- quadrature droop adjustment via potentiometer P1.
- underspeed protection (U/f) and LAM: frequency threshold
adjustable via potentiometer P4

5
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
TECHNICAL CHARACTERISTICS

PMG field excitation

Voltage
X2
Transient voltage dip
Z1 PMG UN
X1
Z2
5+ 6- 0,9
E+
E- (U/f)

0,8 LAM

2.3.3 - Frequency compared with voltage Frequency

(W/O LAM). Max speed dip
LAM
fN
Knee-point 48 Hz 57.5 Hz
100 % 0,9
Voltage 50 Hz
U/UN 60 Hz 0,8

Power
LAM
Frequency
Load on the
shaft (kW)

50 Hz 60 Hz Hz
Load variation

2.3.4 - LAM characteristics Load shedding due to "LAM"

Time
The LAM system is integrated as standard in the R 449
(s)
regulator. It can be activated by closing strap ST5.
0 1s 2s 3s
Role of the "LAM" (Load Adjustment Module):
On load impact, the rotation speed of the generator set
Typical effects of the "LAM" with a diesel engine -
decreases. When it passes below the preset frequency With LAM W/O LAM (U/F only)
threshold, the "LAM" causes the voltage to droop by
approximately 15% and consequently the amount of active
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
variation (frequency) and its duration for a given applied load, 2.3.5 - R 449 A.V.R. options
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
the potentiometer. (A 1 k potentiometer can also be used
Underspeed to extend the adjustment range to 10%)
Voltage and LAM
ST5 cut - R 731 module : detection of 3-phase voltage 200 to 500 V,
UN P2 compatible with parallel operation. Cut ST1 to connect the
Voltage
module; set the voltage via the module potentiometer.
U/f - R 726 module : regulation system changed to 4 F :
0.85 UN LAM
(see R 726 maintenance manual and connection drawing)
- P4 LAM or U/F P.F. regulation (2F)
frequency threshold,
P4 factory set.
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 running in parallel (4F).
ST3 fC fN
R 726 module connected in place of ST4.

6
 INSTALLATION AND MAINTENANCE
8000 - 9000
ALTERNATORS
INSTALLATION
3 - INSTALLATION
3.1 - Assembly
All mechanical handling operations must be undertaken
using approved equipment.
While being handled, the machine should remain
horizontal.
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 .
3.1.2 - Coupling
3.1.2.1 - Single bearing alternator
Before coupling to the prime mover, check that both are
compatible by:
- Undertaking a torsional analysis of the transmission.
- Checking the dimensions of the flywheel and its housing, the
flange, coupling discs and offset.
WARNING
When coupling the alternator to the prime mover, the
holes of the coupling discs should be aligned with the
flywheel holes by cranking the engine.
Do not use the alternator fan to turn the rotor.
Tighten the coupling discs screws to the recommended
torque (see section 4.6.2.) and check that there is lateral play
on the crankshaft.
3.1.2.2 - Two-bearing alternator
- Semi-flexible coupling
Careful alignement of the machines by measuring the
concentricity and parallelism of the two parts of the coupling
is recommended, the difference between the readings should
not exceed the specified values (say 0.1 mm).
WARNING
This alternator has been balanced with a 1/2 key.
Rf. 3120 - 4.33/a - 09.99
3.1.3 - Location
Ensure that the ambient temperature in the room where the
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
exhaust fumes.
3.2 - Inspection prior to first use
3.2.1 - Electrical checks
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
approximately 40 ohms (2000 Watts), to the exciter field
terminals, respecting the polarity.
- Open fully all the alternator openings.
- Run the alternator at rated speed. Adjust the exciter field
current using the rheostat to obtain the rated output current in
the short-circuit connections.
Note: Prolonged standstill: In order to avoid these problems,
we recommend the use of space heaters, as well as turning
over the machine from time to time. Space heaters are only
really effective if they are working continuously while the
machine is stopped.
3.2.2 - Physical and visual checks
Before starting the machine for the first time, check that:
- the fixing bolts on the feet are tight
- the cooling air is drawn in freely
- the protective louvres and housing are correctly in place
- the standard direction of rotation is clockwise as seen from
the shaft end (phase rotation in order 1 - 2 - 3).
For anti-clockwise rotation, swap 2 and 3.
- the winding connection corresponds to the site operating
voltage (see section 3.3).
7
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8000 - 9000
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 8000 / 9000

Any intervention on the alternator terminals during

reconnection or checks should be performed with the
machine stopped

Connection code Voltage L-L Factory connection

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

T3-W1 T2-V1 AVR terminals 0 - 380 V

Ph3-L3 Ph2-L2

Ph1-L1
C Winding
50 Hz 60Hz
T6 -W2 T1-U1
Delta
6S 220 - 240 220 - 255
3 PH
T4-U2 8S 200 220 - 240
T3-W1

T5-V2 T2-V1 AVR terminals 0 - 220 V

Ph3-L3 Ph2-L2

8
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
INSTALLATION

3.3.2 - Connection checks bearing(s) at the time of commissionning (see 4.2.3).

On application of the load, the machine should maintain its

Electrical installations must comply with the current
legislation in force in the country of use.
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) .

Check that: 3.5 - Setting up

- 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
interference suppression module linking the neutral). The various adjustments during tests must be made by a
- any protective devices in place have not tripped, qualified engineer. Take care that the drive speed
- if there is an external regulator, the connections between the specified on the nameplate is reached before
alternator and the cubicle are made in accordance with the commencing adjustment. After operational testing,
connection diagram. replace all access panels or covers.
- there is no short-circuit between phase or phase-neutral The A.V.R. is used to make any adjustments to the machine.
between the alternator output terminals and the generator set
control cabinet (part of the circuit not protected by circuit- 3.5.1 - R 449 main adjustments
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.

a) Initial potentiometer settings (see table below) remote
- Check that all connections have been made properly as voltage adjustment potentiometer: centre (ST4 strap
shown in the attached connection diagram. removed).
- Check that the frequency selection strap "ST3" is on the
correct frequency setting. Action Factory adjust. Pot.
- Check whether strap ST4 or the remote adjustment
potentiometer have been connected. Voltage 400V - 50 Hz
- Optional operating modes minimum fully CCW ( 0 - 380 V) P2
Strap ST1: cut to connect the R 731 3-phase detection
module. Not adjusted
Strap ST2: cut for rapid response time. Stability ( middle) P3
Strap ST5: cut to suppress the L.A.M. function
Threshold/LAM or U/f ST3 on 50 Hz
Threshold for underspeed (factory=48 Hz)
protection U/f and LAM ST3 on 60 Hz
3.4 - Commissioning function (factory=57,5Hz)
P4

Quadrature voltage droop

Not adjusted
(Parallel operation with C.T.)
(fully CCW) P1
No droop fully CCW

The machine can only be started up and used if the Ceiling excitation current
installation is in accordance with the instructions and Excitation current and short 15 A
advices defined in this manual. circuit current limitation, (fully CW) P5
The machine is tested and set at the factory. When first used minimum fully CCW
with no load, make sure that the drive speed is correct and
stable (see the nameplate). It is recommanded to grease the

9
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
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
frequency (50 or 60 Hz). (excitation ceiling)
d) Voltage potentiometer P2 at minimum, fully anti-clockwise. Max. excitation
according to 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 Exciter field ~ 10 ohms
P4
Z2
g) Start the engine and set its speed to a frequency of 47,5 Hz E+
P3 R 449 - +
for 50 Hz, or 57 for 60 Hz. 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
ST4 220V
- 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 Adjustment of the current limit
cutting or replacing the ST2 strap (normal /rapid). by potentiometer P5 ( fuse rating: 16A - 10 seconds).

i) Check LAM operation : ST5 closed
j)Turn potentiometer P4 slowly anti-clockwise until there is a
significant voltage drop.
k) Vary the frequency (speed) a bit above 47,5 or 57 Hz
according to the operating frequency, and check the change
in voltage to the previously observed.
The factory setting corresponds to that of the excitation
current required to obtain a 3-phase short-circuit current of
approximately 3 x In at 50 Hz for industrial power, unless
otherwise specified.(*)
It is possible to reduce the maximum excitation level by a
static method which is safer for the alternator and the
network. Disconnect power supply wires X1,X2 and Z1,Z2,
and the sensing leads (0-110V-220V-380V) on the alternator.

l) Readjust the speed of the unit to its rated no-load value.
Adjustments in parallel operation
Before any intervention on the alternator, make sure that
the speed droop is identical for all engines.
m) Preset for parallel operation (with C.T. connected to S1,
S2):
- potentiometer P1 (quadrature droop) in centre position
Apply the rated load (P.F. = 0.8 inductive).
The voltage should drop by 2 to 3 %. If it increases, swap the
2 incoming wires of the C.T. secondary.
n) The no-load voltages should be identical for all the
alternators intended to run in parallel.
- Couple the machines in parallel.
- 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.
Connect the mains power supply (200-240V) as indicated
(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
and D). If there is no output current from the A.V.R., turn
potentiometer P2 (voltage) C.W. until the ammeter indicates
a stable current. Switch the power supply off, then on again,
turn P5 C.W until the required max. current is obtained (no
more than 15 A).
Checking the internal protection:
Open switch (D): the excitation current should increase to its
preset ceiling, remain at that level for about 10 seconds and
then drop to below < 2A.
To reset, switch off the power supply by opening switch (A).
Note: After setting the excitation ceiling as described, adjust
the voltage again (see section 3.5.2.) by P2.
(*): A short-circuit current of 3 x In is a legal requirement in
some countries so as to offer selective protection.

From now on, do not touch the voltage settings.

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

10
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
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 48 (4A) 5 - 10 s
Sustained voltage on over load 48 (4A) 5 - 10 s

11
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8000 - 9000
ALTERNATORS
SERVICING - MAINTENANCE

4 - SERVICING - MAINTENANCE original one.

Monitor the temperature rise in the bearings, which should not
4.1 - Safety measures 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 WARNING
state. DO NOT USE: TRICHLORETHYLENE,
PERCHLORETHYLENE, TRICHLOROETHANE and ANY
ALKALINE PRODUCTS.

Certain strictly defined pure volatile degreasing products can

All such operations performed on the alternator should
be used, such as:
be undertaken by personnel with training in
- Normal petrol (without additives)
commissioning, servicing and maintenance of electrical
- Toluene (slightly toxic); flammable
and mechanical components.
- Benzene (or benzine, toxic); flammable
Before any intervention on the machine, ensure that it cannot
- Ciclohexare (non toxic); flammable
be started by a manual or automatic system and that you
have understood the operating principles of the system.
Cleaning of the stator, rotor, exciter and diode bridge

4.2 - Regular maintenance
4.2.1 - Checks after start-up
After approximately 20 hours of operation, check that all fixing
screws on the machine are still tight, plus the general state of
the machine and the various electrical connections in the
installation.
The insulating components and the impregnation system are
not at risk of damage from solvents (see the list of authorised
products above).
Avoid letting the cleaning product run into the slots.
Apply the product with a brush, sponging frequently to avoid
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,
WARNING
grease, etc.
Water and/or Pressure wash are strictly prohibited. Any
problems caused by such treatement are not covered by
4.2.3 - Bearings our warranty.
The bearings are greasable. Degreasing : Use a brush and detergent (adapted to paint).
It is recommanded to grease the machine when rotating. Dusting : Use an air gun.
Time intervals and quantity of grease are given in the If a machine is fitted with air inlet and outlet filters, in order to
following table. ensure correct ventilation, a regular cleaning of the filters
must be done according to the environment conditions.
Bearing 6226 C3
After cleaning the alternator, it is essential to check the
Quantity of grease 50 g insulation of the windings (see sections 3.2. and 4.8).
Lubrication time 3600 H
Bearing 6232 MC3 4.3 - Fault detection
Quantity of grease 70 g If, when first commissioned, the alternator does not work
Lubrication time 1700 H normally, the source of the malfunction must be identified.
Bearing NU 1028 MC3 To do this, check that:
- the protective devices are fitted correctly
Quantity of grease 35 g
- all connections comply with the diagrams in the manuals
Lubrication time 2000 H supplied with the machine.
- the speed of the unit is correct (see section 1.3.).
Lubrication time intervals are given for a grease of grade: Repeat the operations defined in section 3.
LITHIUM - standard - NLGI 3.
The factory lubrication is done with grease :
SHELL - ALVANIA R3.
Before using another grease, check for compatibility with the

12
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
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
correct when the battery is removed - Lack of residual magnetism
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

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8000 - 9000
ALTERNATORS
SERVICING - MAINTENANCE

4.5.1 - Checking the windings

You can check the winding insulation making a high voltage
test. In this case, you must disconnect all AVR wires.

WARNING

Damages occuring to A.V.R. in such conditions will not

be taken into account in a warranty claim.

4.5.2 - Checking the diode bridge

- +
C C C A C
DIODE BRIDGE
Anode
A A A A
C + ~ ~ ~ +
Cathode

A diode in a good condition - ~ ~ ~ - - +

A
C
enables the current to flow C C C
in only one direction, from
anode to cathode.
A A A

4.5.3 - Checking the windings and rotating Assembly B: Connect a "Variac" variable power supply and
diodes using separate excitation a diode bridge on both exciter field wires (5+) and (6-).

These two systems should have characteristics which are

compatible with the exciter field excitation power of the
machine (see the nameplate).
During this procedure, make sure that the alternator is
3) Run the unit at its rated speed.
disconnected from any external load and inspect the
terminal box to check that the connections are fully
4) Gradually increase the exciter field current by adjusting the
tightened.
rheostat or the variac and measure the output voltages on L1
1) Stop the unit, disconnect and isolate the AVR wires.
- L2 - L3, checking the excitation voltage and current at no
2) There are are two ways of carrying out a separate
load (see machine nameplate or ask for the factory test
excitation.
report).
Assembly A: Connect a 24 V battery in series with a rheostat
When the output voltage is at its rated value and balanced
of approximately 50 ohms - 300 W and a diode on both exciter
within 1%, for the rated excitation level and rated speed, then
field wires (5+) and (6-).
the machine is in good working order.
The fault must therefore come from the A.V.R. or its
associated wiring (i.e. sensing, auxiliary windings)

ASSEMBLY A ASSEMBLY B
6 - Exciter field 5+
Variac 6 - Exciter field 5+
Diode 5A Rh. 50 -300W
40
50 60 +
30

70

Diode 5A
20

80

+
-
10

90

0 100

- DC
AC 24V
24V battery
220V

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 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SERVICING - MAINTENANCE

4.6 - Dismantling, reassembly 4.6.4 - Access to connections and

(see section 5.4.1. & 5.4.2.)
During the warranty period, this operation should only be
carried out in an approved workshop or in our factory,
otherwise the warranty may be invalidated.The machine
must be horizontal when handled.
regulation system
Access by removing the box lid (48) and the left side panel
(59).
4.6.5 - N.D.E. ball bearing replacing on
single bearing alternator
- 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
- remove the 4 screws of the inner bearing cap (78)
- remove the 6 screws of the bracket (36) on the stator (1)
- tap off the NDE bracket (36) together with the exciter field
(90) from the stator (1)
- extract the ball bearing (for 8000 series) or the roller bearing
inner ring (9000 series) with the suitable puller
- check the "O" ring (349) and the wavy washer (79) and
replace them if necessary (8000 series only)
- position the new ball bearing (8000 series) or new roller
bearing inner ring (9000 series) after heating it, by induction
system, at 80C.

4.6.1 - Tools required

To fully dismantle the machine, we recommend to have the
tools listed below :
- one three arms ratchet spanner with extension
- one torque wrench
- one set of flat spanners : 8, 10, 18 mm
- one set of socket : 8, 10, 13, 16, 18, 21, 24, 30 mm
- one 5 mm Allen key
- one puller (U35), (U32/350)

4.6.2 - Screw tightening torque

CAUTION : IF THE BEARING NEEDS TO BE REMOVED
IDENTIFICATION screw Torque N.m
FOR ANY REASON, ALWAYS INSTALL A NEW BEARING.
Diode bridge screw M6 5,6
Diode nut M 12 10 4.6.6 - D.E. ball bearing replacing on two
Bracket / Frame screw M 12 62 bearings alternator
Discs / Hub screw M 20 300
- remove 6 screws (411) and the 4 screws (62)
Earthing screw M 12 46
- tap off the D.E. bracket (410) from the stator (1)
Air inlet screen M 12 46 - extract ball bearing (60) with suitable puller
Terminal box screws M6 5,6 - position the new ball bearing after heating it, by induction
Terminal bars screws M 12 46 system at 80 C

4.6.3 - Access to diodes

WARNING
- Remove the air inlet screen (47)
- Disconnect the diodes and recheck diodes either by
ohmeter or battery lamp ( 4.5.2). CAUTION : IF THE BEARING NEEDS TO BE REMOVED
- If failed remove the surge suppressor FOR ANY REASON, ALWAYS INSTALL A NEW BEARING.
- Replace reconnect and reassemble.

15
 INSTALLATION AND MAINTENANCE
8000 - 9000
ALTERNATORS
SERVICING - MAINTENANCE
4.6.7 - Complete dismantling
- remove the 6 screws (411)
- support the rotor (4) DE by a crane
- remove the NDE bracket (36) ( 4.6.5)
- support the rotor NDE with a tube shaft extension
- push the rotor out of the stator from the NDE, with care
- if necessary, then, dismantle the half coupling and the DE
bracket (410)
4.6.8 - End shield reassembling
- place the "O" ring (349) and the wavy washer (79) into the
recess of the bearing housing in the NDE bracket (36) (8000
series only).
- 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).
4.6.9 - Rotor reassembling
See 4.6.7 and 4.6.8
Note : If the rotor has been rewound, it must be
rebalanced.
After final adjustments, the access panels or cover
should be refitted.
16
Rf. 3120 - 4.33/a - 09.99
4.7 - Installation and maintenance
of PMG
The PMG reference for 8000/9000 series is PMG 4
4.7.1 - Mechanical fitting
It is pointing out the following :
- an adaptation shaft (centring of the rotor PMG on alternator
shaft)(291).
- a tie rod M20 with screw, washer and nut (295 and 296).
- a rotor with 16 magnets (292).
- a bare stator with leads (293)
- a stator support clock (290)
- a spacer for the air inlet screen (265) (8000 series only)
The PMG mechanical assembly order is as follows :
- remove the air inlet screen (47)
- put the rotor with magnets on the adaptation shaft
- put the whole on the shaft (4) with the washers and tie rod
and tighten the M20 nut
- place the stator inside the clock and tighten the screws and
washers
- slide the stator along the rotor into the NDE bracket (36)
- secure and tighten the screws of the clock into the NDE
bracket
- connect the PMG stator leads and secure the leads
- put in place the spacer for air inlet screen (8000 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.
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.
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SERVICING - MAINTENANCE

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 ()
8000 B H L P
STATOR L/N 0,0021 0,00175 0,00135 0,0011
ROTOR 0,284 0,33 0,368 0,408
Excit. Field 9,25 9,25 9,25 9,25
Excit. armat. 0,015 0,015 0,02 0,02

9000 - H L -
STATOR L/N - 0,0008 0,0006 -
ROTOR - 0,314 0,352 -
Excit. Field - 11,35 11,35 -
Excit. armat. - 0,022 0,022 -

AREP auxiliary winding resistances at 20C ()

8000 B H L P
Auxil. WDG 0,093 0,085 0,075 0,078
X1, X2
Auxil. WDG 0,22 0,19 0,16 0,18
Z1, Z2

9000 - H L -
Auxil. WDG - 0,08 0,085 -
X1, X2
Auxil. WDG - 0,125 0,14 -
Z1, Z2

Field excitation current i exc (A)

Symbols : "i exc": excitation current of the exciter field.
8000 B H L P
At load 4,71 4,31 5,35 5,54
At no load 1,18 1,16 1,54 1,5

9000 H L
At load 3,93 3,56
At no load 0,98 0,94

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

10 % less.

17
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SPARE PARTS

5 - SPARE PARTS 15 1 Fan

17 1 Fan key
5.1 - First maintenance parts 18 1 Balancing discs
Emergency repair kits are available as an option. 22 1 Key
They contain the following items 33 1 Air exit screen
34 1 Bolts
Rep Description Qty 8000 Ref 36 1 N.D.E. Bracket
Emergency kit 1 954 - 238 41 2 Terminal box panel
198 Voltage regulator (AVR) 1 R 449 954 - 233 47 1 Air inlet box cover
106 Diode bridge assembly 1 - 954 - 234 48 1 Terminal box cover
112 Resistor 954 - 235 49 - Bolts
50 2 Terminal box spacer
Others spare parts
59 2 Removable access panels
60 D.E. bearing 1 6226 C3 954 - 236
60 1 D.E bearing
70 N.D.E. bearing 1 6226 C3 954 - 237
62 4 Bolts
68 1 Inner bearing cap
Rep Description Qty 9000 Ref 70 1 N.D.E bearing
Emergency kit 1 954 - 243 72 4 Bolts
198 Voltage regulator (AVR) 1 R 449 954 - 233 78 1 Inner bearing cap
106 Diode bridge assembly 1 - 954 - 239 79 1 Wavy washer
112 Resistor 954 - 240 90 1 Wound exciter field
91 5 Bolts
Others spare parts 100 1 Wound exciter armature
60 D.E. bearing 1 6232 954 - 241 106 1 Rotating diode bridge assembly
MC3
190 1 A.V.R. support stirrup
70 N.D.E. bearing 1 NU 1028 954 - 242
193 1 Terminal box spacer
MC3
198 1 A.V.R
: 203 1 Optional module.
5.2 - Technical support service 205 1 Terminal strip
265 1 Spacer for screen
Our technical support service will be happy to provide any
270 4 Connection bar
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 320 1 Driving hub
necessary parts without delay. 321 1 Hub key
To ensure correct operation and the safety of our machines,
322 2 Coupling disc
we recommend the use of original manufacture spare parts.
In the event of failure to comply with this advice, the 323 8 Fixing screw
manufacturer cannot be held responsible for any damage. 325 - Spacer shim
349 1 Rubber "O ring"
410 1 D.E. bracket
5.3 - Exploded view, part list. 411 6 Bolts

5.3.1 - Part list

Rep Qty Description
1 1 Wound stator assembly
4 1 Wound rotor assembly

18
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SPARE PARTS

5.3.2 - Single bearing

41

47
50

106
198

72
203

36
205
190

36
79
193

349
70
78
P1

90
P5
P4

P3

P2

91
100
18
1
4
34
33
15
270

280
279
59

41
49

48

321
320
325
322
323

19
 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SPARE PARTS

5.3.3 - Two bearing

41

47
50

106
198

72
203

36
205
190

79
193

349
70
78
P1

90
P5
P4

P3

P2

91
100
18
1
4
34
33
15
68
60
270

280
279
59

41
49

48

17
22
410
411
62

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 INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

8000 - 9000
ALTERNATORS
SPARE PARTS

5.3.4 - D.E. Bearing mounting (8000) 5.3.6 - PMG mounting

290

410 293

68 292

62 291

295
60

296
4
265

5.3.5 - N.D.E. Bearing mounting (8000)

36

78

349

70

72

79

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8000 - 9000
ALTERNATORS
SPARE PARTS

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INSTALLATION AND MAINTENANCE Rf. 3120 - 4.33/a - 09.99

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ALTERNATORS
SPARE PARTS

23