KWG -DVR Operating Instructions Manual

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KWG-DVR

Generator regulator

Operating instructions

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Page 1 Powerful. Innovative. KWG-DVR Generator regulator Operating instructions...
Page 2: Manufacturer Address
Operating instructions Imprint Document type: Operating instructions Document name: KWG_DVR_Operating_Manual_V2-0_EN Version: V2.0 Language: Number of pages: 46 Pages Created by: Tim Kurz Created on: 20.06.2024 Modified by: Tim Kurz Modified on: 28.06.2024 Copyright Copyright © 2024 KW-Generator GmbH All rights reserved. Manufacturer address KW-Generator GmbH Bänglesäcker 24...
Page 3: List Of Changes
Operating instructions List of changes Index Modified by Stand Amendment V2.0 Tim Kurz 07/2024 New layout; adaptation of texts Version: V2.0 Doc.name: KWG_DVR_Operating_Manual_V2-0 page 3 from 46...
Page 4 IST OF ILLUSTRATIONS IST OF TABLES OREWORD AND GENERAL INFORMATION BOUT THESE OPERATING INSTRUCTIONS RESENTATION OF WARNINGS RESENTATION CONVENTIONS 2.3.1 XTENDED SYMBOLISM KWG-DVR NTENDED USE OF THE GENERATOR CONTROLLER 2.4.1 TANDARDS AND REGULATIONS ARRANTY UARANTEE AFETY INSTRUCTIONS UALIFICATION OF STAFF...
Page 5 Operating instructions 1 - Table of contents VOIDING DAMAGE DURING THE INSULATION TEST ONTROLLER CIRCUIT DIAGRAMS 7.4.1 ONTROLLER ASSIGNMENT DIAGRAM 7.4.2 ONTROLLER PORTS BLOCK DIAGRAM 7.4.3 10 V LOCK DIAGRAM OF EXTERNAL CIRCUIT 7.4.4 LOCK DIAGRAM NALOG CIRCUIT 7.4.5 LOCK DIAGRAM OF RELAY CIRCUIT ONNECTION OF THE GENERATOR CONTROLLER 7.5.1 LTERNATOR WITH THREE...
Page 6 Figure 8: Connection: Generator with three-phase winding and DVR controller ......34 Figure 9: Connection: Generator with single-phase winding and DVR controller ......35 Figure 10: Interface to the KWG iso-monitor / optional current transformer equipment ...37 Figure 11: Connection with current transformer assembly ............38 Figure 12: Connection with current transformer equipment and insulation monitoring ....39...
Page 7 Operating instructions 1 - Table of contents 1.2 List of tables Table 1: Controller structure overview ..................19 Table 2: Parameter set, software version, serial number (example) ..........20 Table 3: Technical data - functional features ................21 Table 4: Technical data - Operating characteristics ..............22 Table 5: Technical data - Mechanical features ................23 Table 6: Protection classes - 1st digit: Protection against contact and foreign bodies ....24 Table 7: Protection classes - 2nd digit: Protection against water ..........25...
Page 8 2.1 About these operating instructions These operating instructions refer to the KWG-DVR series regulators and are intended to familiarize you with these KWG-DVR generator regulators and their intended use and to install and operate them safely, properly and efficiently. Following the instructions in this operating manual helps to avoid hazards, unnecessary repair costs and downtime that could result from incorrect installation or operation.
Page 9 Operating instructions 2 - Foreword and general information 2.2 Display of warnings For better differentiation, hazardous risks are identified in the instructions by the following warning signs and signal words. DANGER Disregarding such warnings can lead to serious injury or even death. WARNING Disregarding such warnings can lead to serious injury or even death.
Page 10 Operating instructions 2 - Foreword and general information 2.3 Presentation conventions The following presentation conventions are used: Name Representation Function Instruction for action 1), 2) etc. Prompts an action. 1st level Instruction for action a), b) etc. Designates a section in a sequence of 2nd level actions.
Page 11 Operating instructions 2 - Foreword and general information Intended use of the KWG-DVR generator regulator The controllers are components of machines and systems that are intended for industrial and professional use and therefore cannot be treated as retail goods. The controllers have primarily been developed and designed for KWG generator systems.
Page 12: Standards And Regulations
For cleaning and maintenance, see chapter 8 "Maintenance" on page 40 2.4.1 Standards and regulations The KWG controller systems comply with DIN EN 60034 / VDE0530 and are RoHS compliant. Warranty The controllers may only be used for the applications specified here and only in accordance with the information in these operating instructions.
Page 13: Safety Instructions
Operating instructions 3 - Safety instructions AFETY INSTRUCTIONS Always observe the safety instructions listed in this chapter when working with the controllers. These are supplemented by additional specific warnings that only apply to certain actions and activities. These specific warnings are indicated at the relevant points in the manual and highlighted accordingly.
Page 14 Operating instructions 3 - Safety instructions CAUTION Hot surfaces Risk of burns ➢ The generators and regulators can be very hot during and after operation. Do not touch the generator during operation and allow the generator and controller to cool down completely after use. ATTENTION Never expose the generator and the regulator to jets from high-pressure cleaners.
Page 15 Operating instructions 3 - Safety instructions 3.3.2 Safety instructions for installation, maintenance and repair DANGER Non-compliance with warnings and safety instructions Death or serious injury ➢ All safety and warning instructions must be followed! ➢ Before carrying out any work on the appliance, switch it off completely and secure it against unintentional restarting.
Page 16: Personal Protective Equipment
Operating instructions 3 - Safety instructions WARNING Rotating machine parts Death or serious injury from being pulled in ➢ Before working on the appliance, it must be disconnected from the power supply! ➢ Work on electrical systems and generators/controllers may only be carried out when they are switched off and de-energized.
Page 17 Operating instructions 3 - Safety instructions Commandment Meaning Explanation sign Use hand Safety gloves must be used wherever injuries caused by protection M009 stabs, cuts, burns or hypothermia as well as other harmful effects such as substances that can permanently damage the skin and, above all, severely damage the hands.
Page 18: General Structure
1-phase or 3-phase current transformer, or via other additional modules. An analogue input is also provided for a temperature sensor (KWG-NTC), which can be used to parameterize additional protective functions. The controller supply must be a 3-phase voltage. For generators with 3-phase output windings (three-phase voltage system), the 3-phase regulator supply is also used for actual value measurement.
Page 19 Connection of the generator (supply) (optional) Relay output CAN connection Connection for the CAN connection NTC connection Connection of the KWG-NTC temperature sensor Programming plug Connection for programming the controller Table 1: Controller structure overview For a detailed description see  Table 4 Version: V2.0...
Page 20 Operating instructions 4 - Description 4.2 Type designations and serial numbers Each KWG controller has an individual serial number, a software version and a parameter set. These can be found on the type plate. NOTE Please have the serial number, software version and parameter set ready in case of queries, repeat orders or spare parts orders.
Page 21 Operating instructions 4 - Description 4.3 Technical data The following table provides an overview of the general data of KWG controllers. If no other data is listed in the type-specific data sheet, the data of the  Table 3, Validity.
Page 22 60 x 10 Switching cycles permissible temperature sensor: KWG-NTC SAE J1939 Broadcast J1939-75 CAN: Peer-to-peer KWG additional data Baud rate: 250 kbps flashes slowly at controller temperature limit lights up when the generator temperature is limited Yellow Lights up when f/U characteristic active...
Page 23 4x M5 Fastening: Hole spacing: 152 x 96 mm Screw tightening torque: 5 Nm Chill casting AL239 Heat sink (also potting cover): KWG drawing: KZ002-001-001 Suitable seal: KWG no: PTZ-348 Potting material: 2-component PU casting compound Vibration resistant: Table 5Technical data - Mechanical features Version: V2.0...
Page 24 Operating instructions 4 - Description 4.4 Overview of protection classes (IP code) NOTE Here is an excerpt from the EN 60529 standard (degrees of protection provided by enclosures (IP code)). Further information on the protection classes can be found in the current version of the EN 60529 standard.
Page 25 Operating instructions 4 - Description Protection from water: 2. code Designation - Explanation number No protection. Protected against dripping water: Vertically falling drops must not have any harmful effects. Protected against dripping water when the housing is tilted up to 15°: Vertically falling drops must not have any harmful effects if the housing is inclined by an angle of up to 15°...
Page 26: Transportation And Storage
Operating instructions 5 - Transportation and storage RANSPORTATION AND STORAGE The regulator is supplied with the generator ready for installation. If the regulator is supplied already attached to the generator, the components are sealed with a protective film to protect them from water and dirt.
Page 27: General Functions
6 - Functional description of the generator regulator UNCTIONAL DESCRIPTION OF THE GENERATOR REGULATOR A KWG generator regulator must be used for safe operation of the KWG generator. The voltage regulator is matched to the respective generator type for safe and stable operation. The system is stable in all operating positions and ensures compliance with the guidelines and the requirements of the application.
Page 28: Installation And Commissioning
Operating instructions 7 - Installation and commissioning NSTALLATION AND COMMISSIONING This chapter describes the installation and initial commissioning of the generator/controller. Before installing and commissioning the controller, carefully read the chapter 3 "Safety instructions". DANGER Non-compliance with warnings and safety instructions Death or serious injury ➢...
Page 29: Before Installation
Operating instructions 7 - Installation and commissioning Before installation Before installation, check that: • the controller is suitable for the generator type. • the plug connections on the controller are correctly plugged in and firmly engaged. • the mechanical assembly is correct. •...
Page 30 Operating instructions 7 - Installation and commissioning 7.3 Avoiding damage during the insulation test During an insulation test, the generator system is subjected to a withstand voltage (HV) or a surge test. ATTENTION Damage due to insulation test. ➢ Before carrying out an insulation test, the controller must be completely disconnected from all connections to prevent damage to the controller.
Page 31 Operating instructions 7 - Installation and commissioning 7.4 Controller circuit diagrams 7.4.1 Controller assignment diagram Illustration 3Controller assignment diagram Version: V2.0 Doc.name: KWG_DVR_Operating_Manual_V2-0 Page 31 from 46...
Page 32 Operating instructions 7 - Installation and commissioning 7.4.2 Controller I/O ports block diagram Circuit of the optocoupler I/O ports: Illustration 4Controller I/O ports block diagram 7.4.3 Block diagram of external 10 V circuit Illustration 5Block diagram of external 10 V circuit 7.4.4 Block diagram Analog IN circuit Illustration 6Block diagram Analog IN circuit page 32 from 46...
Page 33 Operating instructions 7 - Installation and commissioning 7.4.5 Block diagram of relay circuit Illustration 7Block diagram of relay circuit Version: V2.0 Doc.name: KWG_DVR_Operating_Manual_V2-0 Page 33 from 46...
Page 34 Operating instructions 7 - Installation and commissioning 7.5 Connection of the generator controller NOTE The illustrations shown in the current chapter are symbolic images. 7.5.1 Generator with three-phase winding and DVR regulator Illustration 8Connection: Generator with three-phase winding and DVR regulator page 34 from 46 Doc.name: KWG_DVR_Operating_Manual_V2-0 Version: V2.0...
Page 35 Operating instructions 7 - Installation and commissioning 7.5.2 Generator with single-phase winding and DVR regulator Illustration 9Connection: Generator with single-phase winding and DVR regulator Version: V2.0 Doc.name: KWG_DVR_Operating_Manual_V2-0 Page 35 from 46...
Page 36 Operating instructions 7 - Installation and commissioning 7.5.3 Generator regulator pin assignment DVR controller Generator interface 1 = F1 2 = F2 3 = ZW 4 = ZV 5 = CLOSED 6 = N (optional when using the current measurement module and CAN J1939 broadcast data) CAN interface 1 = CAN_LOW...
Page 37 KWG generator controller. The insulation value is output via the CAN BUS. At the same time, the insulation value can be further processed in the KWG generator controller and used to control relays, for example. When the 3-phase current transformer is fitted, the current is measured and data is output via the CAN bus.
Page 38 Operating instructions 7 - Installation and commissioning 7.5.5 Connection with current transformer equipment Illustration 11Connection with current transformer equipment page 38 from 46 Doc.name: KWG_DVR_Operating_Manual_V2-0 Version: V2.0...
Page 39 Operating instructions 7 - Installation and commissioning 7.5.6 Connection with current transformer equipment and insulation monitoring Illustration 12Connection with current transformer equipment and insulation monitoring Version: V2.0 Doc.name: KWG_DVR_Operating_Manual_V2-0 Page 39 from 46...
Page 40: Maintenance
Operating instructions 8 - Maintenance AINTENANCE DANGER Dangerous electrical voltage Death or serious injury due to electric shock ➢ Visual inspections and cleaning work on the generator/regulator for maintenance purposes must never be carried out during operation. CAUTION Hot surfaces Risk of burns ➢...
Page 41 Operating instructions 8 - Maintenance It may be necessary to carry out checks on the drive system in accordance with the specifications and regulations of the respective drive/system manufacturer. This also includes fitted protective covers. Observe the maintenance instructions of the drive or system manufacturer. The generator may only be opened by KW-Generator GmbH or an authorized service centre.
Page 42: Troubleshooting
Operating instructions 9 - Troubleshooting ROUBLESHOOTING DANGER Dangerous electrical voltage Death or serious injury due to electric shock ➢ All troubleshooting/repair work on the generator system may only be carried out by a qualified electrician. 9.1 Troubleshooting Detailed information on troubleshooting can be found in the operating instructions "KWG_Generator_Operating-Manual"...
Page 43 Operating instructions 10 - Repair 10 R EPAIR No repair or maintenance work can be carried out on the components of the controller by the user. We strongly recommend that you remove the controller for this work and send it to KW- Generator GmbH.
Page 44 Operating instructions 11 - Decommissioning, uninstallation 11 D ECOMMISSIONING UNINSTALLATION DANGER Dangerous electrical voltage Death or serious injury due to electric shock ➢ Before working on the appliance, it must be disconnected from the power supply and de-energized! ➢ Work on electrical systems and generators may only be carried out when they are switched off and de-energized.
Page 45: Waste Disposal
Operating instructions 12 - Waste disposal 12 W ASTE DISPOSAL Observe the applicable legal regulations when disposing of or recycling generator systems that are no longer functional. If necessary, commission a disposal company. Further information can be obtained from the responsible environmental authorities or from KW-Generator GmbH as well as from the type-specific data sheet.
Page 46 Operating instructions 13 - Spare parts 13 S PARE PARTS Please contact KW-Generator GmbH directly for spare parts due to the wide range of possible variants. page 46 from 46 Doc.name: KWG_DVR_Operating_Manual_V2-0 Version: V2.0...