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GTS DWG Series Installation And Operating Manual

Synchronous generators
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Synchronous generators of series
DGG, DWG and WG
Models BG 132 and BG 160
Installation and operating manual
English 05/2013
Issue 05/2013

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Summary of Contents for GTS DWG Series

  • Page 1 Synchronous generators of series DGG, DWG and WG Models BG 132 and BG 160 Installation and operating manual English 05/2013 Issue 05/2013...

  • Page 2: Legend, Safety Instructions

    Legend, safety instructions Legend, safety instructions This operating manual contains information you must observe for your own personal safety and to prevent material or property damage. The information concerning your own personal safety is emphasised with a warning triangle. Information about material or property damage without personal injury appears without a warning triangle.

  • Page 3: Table Of Contents

    Legend, safety instructions Contents Contents Legend, safety instructions Important information and notes Qualified personnel Intended use Validity of the manual Copyright General safety instruction Manufacturer's address Warranty Safety instructions References to norms and directives Description Models (BG 132 and BG 160) 4.1.1 Features and options of the models General functions Generator 4.3.1...
  • Page 4 Legend, safety instructions Contents Holes for condensation water discharge Installation of single-bearing generators 6.6.1 Delivery scope 6.6.2 Installation dimensions 6.6.3 Minimum clearances and cooling provisions 6.6.4 Assembly to engine 6.6.5 Additional assembly instructions for shaft attachment with tension bolt Installation of dual-bearing generators (BG 132) 6.7.1 Installation dimensions and assembly 6.7.2...
  • Page 5 Legend, safety instructions Contents Repairs 10 Disassembly 10.1 Safety instructions 10.2 Disassembly 10.3 Disassembly of dual-bearing generators (BG 132 and BG 160 models) 10.4 Disassembly of single-bearing generators 10.4.1 Disassembly of single-bearing brush generators 10.4.2 Disassembly of brushless single-bearing generators 11 Transport and storage 11.1 Generator 12 Decommissioning, storage after disassembly of, disposal...

  • Page 6: Important Information And Notes

    Important information and notes Important information and notes Qualified personnel The unit or system may be installed and operated in connection with this manual. Installation, commissioning and operation of a unit or system must only be performed by qualified personnel. Qualified personnel within the meaning of the technical safety information in this manual are persons with the authorization to put devices, systems and circuits into service, to ground them, and to label them, according to technical safety standards.

  • Page 7: Validity Of The Manual

    Important information and notes Validity of the manual This operating manual applies for synchronous generators with the type designations DGG (three phase AC generators), DWG (AC-DC generators) and WG (AC generators). For reasons of clarity, only AC generators are indicated in the operating manual and explicitly named.

  • Page 8: Copyright

    Ziegelfeldstraße 62 + 65 73563 Mögglingen (Germany) Tel +49 (0) 7174 8 98 00-0 Fax +49 (0) 7174 8 98 00-25 www.gts-generator.com info@gts-generator.com Warranty We provide a warranty on generators of the series described here, according to the latest version of the “General for products and services of the electronic industry”...
  • Page 9 Generator. Technik. Systeme. GmbH & Co. KG is a technically leading manufacturer of generators from 3.2 to 40 kVA and electronic control units of its own design. GTS generators are highly durable and of the highest quality. They are maintenance-free, long-lasting, precise and robust. Only high-quality parts that meet the requirements of VDE tests and DIN and European norms are used in the manufacture of the generator.

  • Page 10: Safety Instructions

    Safety instructions Safety instructions This section contains a compilation of generally valid safety instructions. Please read and heed the safety instructions before installation, commissioning and operation of the generator carefully. This safety instructions also appears in the relevant areas of the text in the manual. Important ►...
  • Page 11 Safety instructions Danger Danger to life through electric shock A grounding of the neutral conductor of the generator (N, neutral conductor) invalidates the “electrical separation” protective measure. Never ground the neutral conductor of the generator. ► Danger Danger to life through electric shock Insulation monitors can mutually influence each other.
  • Page 12 Safety instructions Warning Risk of injury When protective coverings are not in use, there is a risk of injury through electric shock, moving parts and hot surfaces. Only operate the generator with the fitted protective ► coverings proscribed for the drive in the regulations. Warning Risk of explosion A discharge of sparks during operation is possible.
  • Page 13 Safety instructions Caution Burn hazard Parts of the generator can become very hot during and after the operation. Allow the generator or parts of the generator to cool down ► before you touch them. Important These generators are not suitable for supplies to fixed distribution networks.

  • Page 14: References To Norms And Directives

    References to norms and directives References to norms and directives The generator has been manufactured in accordance with the following norms and directives. y DIN 6280-10, Reciprocating internal combustion engines; generating sets with reciprocating internal combustion engines; small power generating sets;...

  • Page 15: Description

    Description Models (BG 132 and BG 160) Description Models (BG 132 and BG 160) Depending on their nominal output and number of poles, the generators are constructed in two different versions: BG 132 model means 132 mm measured from the base up to the shaft center; and 160 mm for model 160. BG 132 model y 2-pole generators (drive speed 3000 1/min) with rated output of 3.2 kVA up to 20 kVA...

  • Page 16: Features And Options Of The Models

    Description Models (BG 132 and BG 160) 4.1.1 Features and options of the models Variant / option BG 132 BG 160 BG132 2-pole to 20 kVA 4-pole to 15 kVA BG160 1-pole from 20 kVA 4-pole from 10 kVA Generator attached directly onto engine The type of the seal depends on the drive motor used. Direct coupling via flange Driven by belts or hydraulic system “Brushless”...

  • Page 17: General Functions

    Description General functions General functions These generator series are self-excited synchronous inner-pole generators. The generator comprises a functional group consisting of the main machine, exciter machine and, on brushless generators, co-rotating rectifiers. These groups are housed together in one housing. The electronic generator controller can be housed in a terminal box attached to the generator or in an external switch box.

  • Page 18: Fig. 1 Mains Configuration Of Generator, Principle Circuit Diagram, Electrical Separation

    Description Generator Generator without the “insulation monitor with disconnection” option With this option, the generator meets the protective measure “electrical separation with potential equalization connector” according to VDE 0100, Part 410. The mains configuration is the IT network with neutral conductor N and protective earth conductor PE.

  • Page 19: Generator Controller

    Description Generator 4.3.2 Generator controller Fig. 2 Block circuit diagram, DWG-brushless generator with generator controller LCAR4BASIC Issue 05/2013 Page 19...

  • Page 20: Fig. 3 Block Circuit Diagram, Dwg Generator With Brushes And Generator Controller Lcar4Std (With Connected Electronic Idling Mechanism)

    Description Generator Fig. 3 Block circuit diagram, DWG generator with brushes and generator controller LCAR4STD (with connected electronic idling mechanism) Page 20 Issue 05/2013...

  • Page 21: Mechanical Versions

    Description Variants for the electrical connection 4.3.3 Mechanical versions Depending on their nominal output, the generators are constructed in various model sizes. Ö Models (BG 132 and BG 160), page 15 Variants for the electrical connection Ö Generator with attached terminal box (standard version), page 21 Ö...

  • Page 22: Fig. 5 Terminal Box With Terminal Board, Generator Controller And Noise Filter

    Description Variants for the electrical connection Terminal box The fully potted generator controller is housed in the cover of the terminal box. The generator controller can be replaced by an optional extended generator controller with automatic idling mode. Ö Generator controller, page 19 Generator controller Terminal box Noise filter (option)

  • Page 23: Generator With Attached Corrugated Pipe, Controller Electronics Installed Externally

    Description Variants for the electrical connection 4.4.2 Generator with attached corrugated pipe, controller electronics installed externally All connection lines of the generator, including the lines for the generator controller, are lead out through a corrugated pipe from the generator housing. This variant offers the advantage that the generator can also be used in relatively constrained spaces.

  • Page 24: Fig. 6 Switch Box With Installed Options Operating Hours Counter And Insulation Monitor

    Description Variants for the electrical connection If an insulation fault is detected at a connected device or in an extension cable, the insulation monitor will de-energize all power sockets immediately and the red signal lamp “INSULATION FAULT” will light up. In this case, the faulty unit will be put out of service and will reset the insulation monitor.

  • Page 25: Drive Types

    Description Drive types Drive types 4.5.1 Single-bearing generators (only BG 132) Single-bearing generators are designed exclusively for direct attachment to the drive unit. The shafts of generator and drive unit are directly connected to each other and the bearing of the drive unit serves as a second bearing for the generator.

  • Page 26: Drive Via Belt Pulley

    Description Drive types 4.5.5 Drive via belt pulley The generator is joined to the drive unit via a belt pulley and a belt. The belt drive is an especially simple and cost-effective means of transmission. It also offers the advantage that, by selecting the transmission ratio, it is possible to optimally adjust the speeds of the drive unit and generator to each other.

  • Page 27: Technical Data

    Technical data Generators Technical data Generators Generator technical data Technical data for your product are available from GTS upon request. Generator rating plate Ö Designation system for generator types, page 115. Switch box Protection class IP54 (all covers sealed and locked)

  • Page 28: Installation Of Generator

    Installation of generator General safety instructions, installation Installation of generator Depending on the model, nominal output, and drive type, there installation may vary. Reference is made to these deviations in the corresponding sections of this manual. Carefully read and follow the safety instructions and all applicable sections of this chapter and the instructions and notes contained therein before installation and commissioning and during operation of the generator.
  • Page 29 Installation of generator General safety instructions, installation Danger Risk of injury and risk of damage! Opening or disassembling the generator puts the system at risk and compromises the safety of the user. Never open or dismantle the generator. ► The generator may only be opened by the ►...

  • Page 30: Requirements On The Installation Position

    Installation of generator Requirements on the installation position Warning Risk of injury When protective coverings are not in use, there is a risk of injury through electric shock, moving parts and hot surfaces. Only operate the generator with the fitted protective ►...

  • Page 31: General Provisions For Installation

    Installation of generator General provisions for installation Important A cooling air feed above 40 °C can lead to power restrictions; in extreme cases it can cause damage to the generator. The temperature of the supplied cooling air should not ► exceed 40 °C. Observe the necessary minimum clearances.
  • Page 32 The neutral conductor N must be secured. Coordinate the type and nominal current of the protective circuit breakers with the generator manufacturer GTS. y For generators without factory-installed switch box that contains electrical safety devices and power sockets, check the generator, the switch...

  • Page 33: Permissible Installation Positions

    Installation of generator Permissible installation positions Permissible installation positions 6.4.1 Single-bearing generators Single-bearing generators are exclusively for direct attachment to the drive unit. A horizontal installation position is required by the drive motor. Please indicate the position of the terminal box (or depending on the version, the cable outlet or switch box) when ordering the generator.

  • Page 34: Dual-Bearing Generators (Bg 132 An Bg 160)

    > Replace the screws with screws of the same grade. Replacement screws of the same grade are supplied by GTS. > The screws must be tightened to the correct torque. y Torque 25 Nm for grade 8.8 y Torque 35 Nm for grade 10.9 Other installation positions are not permitted.

  • Page 35: Holes For Condensation Water Discharge

    Installation of generator Holes for condensation water discharge Holes for condensation water discharge The drain holes for condensation water are not available for all generators; they may be omitted depending on the intended area of application. Important Under unfavorable circumstances, condensate water may form within the generator.
  • Page 36 Installation of generator Holes for condensation water discharge y Check whether the holes on the sides and on the upper side are sealed with screws. For rotated generator installation > Remove the screws on the bottom in order to open the condensate water drain. >...

  • Page 37: Installation Of Single-Bearing Generators

    Installation of generator Installation of single-bearing generators Installation of single-bearing generators y To install the single-bearing generators, proceed according to the descriptions in this section. y Before installation, read the chapter on intended use, the general safety instructions and the safety information in this chapter carefully and follow the instructions and regulations given therein.

  • Page 38: Installation Dimensions

    Installation of generator Installation of single-bearing generators 6.6.2 Installation dimensions Generator dimension The generators vary according to the output and model. IF needed, request the drawing for your generator from Generator.Technik.Systeme GmbH & Co. KG. Important ► Do not attach any third party parts to the mounting profiles on the generator housing.
  • Page 39 Installation of generator Installation of single-bearing generators Temperature and pressures of the cooling air Important A cooling air feed above 40 °C can lead to power restrictions; in extreme cases it can cause damage to the generator. The temperature of the supplied cooling air should not ►...

  • Page 40: Assembly To Engine

    Installation of generator Installation of single-bearing generators 6.6.4 Assembly to engine During assembly, observe the minimum clearances and specifications for cooling. Ö Installation of single-bearing generators, page 37 Ö Installation of dual-bearing generators (BG 132), page 52 Ö Installation of dual-bearing generators (BG 160), page 64 6.6.4.1 Generator seal to the drive motor Use a seal between generator and drive motor during assembly.

  • Page 41: Fig. 7 Preparatory Disassembly For Assembling Single-Bearing Brush Generators

    Installation of generator Installation of single-bearing generators 6.6.4.2 Assembly of brush generators Preparatory disassembly and removal of carbon brush holder Ö Fig. 7, Preparatory disassembly for assembling single-bearing brush generators, page 41 > Unscrew two M8 x 45 screws, wrench size 10 mm, [2]. >...
  • Page 42 Installation of generator Installation of single-bearing generators 6.6.4.3 Shaft attachment assembly via grub screw Ö Fig. 8, Assembly of single-bearing brush generators on the drive motor, page 43 Ö Additional assembly instructions for shaft attachment with tension bolt, page 48 > Thread the provided grub screw [1] into the shaft of the drive motor as far as the stop with a hexagon socket wrench.

  • Page 43: Fig. 8 Assembly Of Single-Bearing Brush Generators On The Drive Motor

    Installation of generator Installation of single-bearing generators Install a appropriate seal for the drive motor Fig. 8 Assembly of single-bearing brush generators on the drive motor 6.6.4.4 Installation of carbon brush holder Ö Fig. 9, Installation of carbon brush holder, page 44 >...

  • Page 44: Fig. 9 Installation Of Carbon Brush Holder

    Installation of generator Installation of single-bearing generators > Place the collar [3] and clamp securely with two screws [2]. > Attach the fan wheel cover [1] Flange shown rotated by 45° Fig. 9 Installation of carbon brush holder Page 44 Issue 05/2013...

  • Page 45: Fig. 10 Preparatory Disassembly For Assembling Brushless Single-Bearing Brush Generators

    Installation of generator Installation of single-bearing generators 6.6.4.5 Assembly of brushless generators Preparatory disassembly Ö Fig. 10, Preparatory disassembly for assembling brushless single-bearing brush generators, page 45 > Remove the fan wheel cover [1] on the generator. > On the generator, unscrew the four mounting screws [3] and remove the front bearing plate [2].
  • Page 46 Installation of generator Installation of single-bearing generators 6.6.4.6 Shaft attachment assembly via grub screw Ö Fig. 11, Assembly of brushless single-bearing generators on the motor (1), page 47 Ö Fig. 12, Assembly of brushless single-bearing generators on the motor (2), page 47 Ö...

  • Page 47: Fig. 11 Assembly Of Brushless Single-Bearing Generators On The Motor (1)

    Installation of generator Installation of single-bearing generators > Secure the bearing plate to the generator with the four mounting screws [2] (Figure 12). > Attach the fan wheel cover [1] (Figure 12). Install a appropriate seal for the drive motor Fig. 11 Assembly of brushless single-bearing generators on the motor (1) Fig.

  • Page 48: Additional Assembly Instructions For Shaft Attachment With Tension Bolt

    Installation of generator Installation of single-bearing generators 6.6.5 Additional assembly instructions for shaft attachment with tension bolt A tension bolt can optionally be used for the connection of the shafts. The generator shaft has a hollow bore. In this case, proceed as follows instead of the relevant assembly of description.

  • Page 49: Fig. 13 Assembly Of Single-Bearing Brush Generators With Tension Bolts

    Installation of generator Installation of single-bearing generators Install a appropriate seal for the drive motor Fig. 13 Assembly of single-bearing brush generators with tension bolts 6.6.5.2 Assembly of brushless generators Ö Fig. 14, Assembly of brushless single-bearing generators with tension bolts (1), page 50, Ö...

  • Page 50: Fig. 14 Assembly Of Brushless Single-Bearing Generators With Tension Bolts (1)

    Installation of generator Installation of single-bearing generators > Align the generator in front of the drive motor so that the generator shaft lies in a line with the shaft of the drive motor. If necessary, install a spacer below the generator as appropriate. >...

  • Page 51: Fig. 15 Assembly Of Brushless Single-Bearing Generators With Tension Bolts (2)

    Installation of generator Installation of single-bearing generators Fig. 15 Assembly of brushless single-bearing generators with tension bolts (2) Issue 05/2013 Page 51...

  • Page 52: Installation Of Dual-Bearing Generators (Bg 132)

    Installation of generator Installation of dual-bearing generators (BG 132) Installation of dual-bearing generators (BG 132) y To install the dual-bearing generators with BG 132 model, proceed according to the descriptions in this section. y Before installation, read the chapter on intended use, the general safety instructions and the safety information in this chapter carefully and follow the instructions and regulations given therein.

  • Page 53: Minimum Clearances And Cooling Provisions

    Installation of generator Installation of dual-bearing generators (BG 132) Permissible load of the shaft y Standard bearing plate (shaft ø 28 mm)  = 2,000 N (measured in 50 mm axial clearance from the point where the shaft exits the bearing plate) Fa = 200 N y Reinforced bearing plate (shaft ø 32 mm): = 3,000 N (measured in 50 mm axial max ...
  • Page 54 Installation of generator Installation of dual-bearing generators (BG 132) Cooling Observe the following instructions for the cooling of the generator. = 4 Pa Risk of overheating. The temperature of the supplied cooling air should not exceed 40 °C. = 7 Pa A maximum underpressure of P = 4 Pa is allowed in the suction path of the cooling air, otherwise, a sufficient quantity of cooling air...

  • Page 55: Assembly Instructions For Belt Drive

    Installation of generator Installation of dual-bearing generators (BG 132) 6.7.3 Assembly instructions for belt drive Warning Risk of accident Open drive belts and pulleys are a hazard. Never operate the generator without ► a protective covering. Never reach into a drive belt while it is ►...
  • Page 56 Installation of generator Installation of dual-bearing generators (BG 132) Important Loose belts can spring off and do not reliably transmit the drive power. The drive belt must not sag ► loosely. When using narrow belt pulleys of type SPA, the clearance between the axes must not exceed 600 mm.

  • Page 57: Fig. 16 Preparatory Disassembly Of For Flange Mount (Dual-Bearing, Bg 132 Model With Standard Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 132) 6.7.4 Assembly instructions for flange mount 6.7.4.1 Flange mount BG 132 with standard bearing plate Preparatory disassembly > Unscrew two M8 x 45 screws, wrench size 10 mm, [2]. > Remove the sleeve [1]. > Unscrew and remove four screws M12 x 12 [3], along with the washers. Fig.

  • Page 58: Fig. 17 Assembly Of Flange Mount (Dual-Bearing, Bg 132 Model With Standard Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 132) Assembly > Apply Loctite to the screw thread and place a toothed washer [4b] underneath the screw head. > Place toothed washers [2b] underneath the nuts. > Place the flange [1] onto the generator and secure with four screws [4a] nuts [3a] to a tightening torque of 47 Nm.

  • Page 59: Fig. 18 Preparatory Disassembly Of Flange Mount (Dual-Bearing, Bg 132 Model With Reinforced Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 132) 6.7.4.2 flange mount BG 132 model with reinforced bearing plate Preparatory disassembly > Unscrew the four grub screws M12 x 25 [1]. Fig. 18 Preparatory disassembly of flange mount (dual-bearing, BG 132 model with reinforced bearing plate) Issue 05/2013 Page 59...

  • Page 60: Fig. 19 Assembly Of Flange Mount (Dual-Bearing, Bg 132 Model With Reinforced Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 132) Assembly Ö Fig. 19, Assembly of flange mount (dual-bearing, BG 132 model with reinforced bearing plate), page 60 > Apply Loctite to the screw thread of the four screws [2a] and place a toothed washer [2b] underneath the screw. >...

  • Page 61: Assembly Instructions For Hydraulic Drive

    Installation of generator Installation of dual-bearing generators (BG 132) 6.7.5 Assembly instructions for hydraulic drive 6.7.5.1 Hydraulic drive for BG 132 model with standard bearing plate Preparatory disassembly > Carry out the preparatory disassembly on the generator. Ö Preparatory disassembly, page 57 Ö Fig. 16, Preparatory disassembly of for flange mount (dual-bearing, BG 132 model with standard bearing plate), page 57 Assembly Ö...

  • Page 62: Fig. 20 Assembly Of Flange Mount For Hydraulic Drive (Dual-Bearing, Bg 132 Model With Standard Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 132) M8 DIN 985 A8 DIN 125 M8 x 45 DIN 912 VH 8 DIN 128 M8 x 20 DIN 912 VH 8 DIN 128 Fig. 20 Assembly of flange mount for hydraulic drive (dual-bearing, BG 132 model with standard bearing plate) Page 62 Issue 05/2013...
  • Page 63 Installation of generator Installation of dual-bearing generators (BG 132) 6.7.5.2 BG 132 hydraulic drive with reinforced bearing plate Preparatory disassembly > Carry out the preparatory disassembly on the generator. Ö Preparatory disassembly, page 59 Ö Fig. 18, Preparatory disassembly of flange mount (dual-bearing, BG 132 model with reinforced bearing plate), page 59 Assembly Ö...

  • Page 64: Fig. 21 Assembly Of Flange Mount Hydraulic Drive (Dual-Bearing, Bg 132 Model With Reinforced Bearing Plate)

    Installation of generator Installation of dual-bearing generators (BG 160) M12 x 35 DIN 912 VH 12 DIN 128 M8 x 30 DIN 912 VH 8 DIN 128 Fig. 21 Assembly of flange mount hydraulic drive (dual-bearing, BG 132 model with reinforced bearing plate) Installation of dual-bearing generators (BG 160) y To install the dual-bearing generators with BG 160 model, proceed according to the descriptions in this section.

  • Page 65: Installation Dimensions And Assembly

    Installation of generator Installation of dual-bearing generators (BG 160) 6.8.1 Installation dimensions and assembly > During assembly, observe the minimum clearances and specifications for cooling. Ö Minimum clearances and cooling provisions, page 66 The generators vary according to the output and model. If needed, request the drawing for your generator from Generator.Technik.Systeme GmbH & Co.

  • Page 66: Minimum Clearances And Cooling Provisions

    Installation of generator Installation of dual-bearing generators (BG 160) 6.8.2 Minimum clearances and cooling provisions The generator needs sufficient ventilation for cooling. The cooling air is drawn through the cooling profiles by the fan wheel on the rear side of the generator and across the housing, towards the front side.

  • Page 67: Assembly Instructions Belt Drive

    Installation of generator Installation of dual-bearing generators (BG 160) 6.8.3 Assembly instructions belt drive Warning Risk of accident Open drive belts and pulleys are a hazard. Never operate the generator without ► a protective covering. Never reach into a drive belt while it is ►...
  • Page 68 Installation of generator Installation of dual-bearing generators (BG 160) Important Loose belts can spring off and do not reliably transmit the drive power. The drive belt must not sag ► loosely. When using narrow belt pulleys of type SPA, the clearance between the axes must not exceed 800 mm.

  • Page 69: Fig. 22 Preparatory Disassembly Of Flange Mount (Bg 160 Model)

    Installation of generator Installation of dual-bearing generators (BG 160) 6.8.4 Assembly instructions for flange mount Preparatory disassembly > Unscrew the four grub screws M12 x 25 [1]. Fig. 22 Preparatory disassembly of flange mount (BG 160 model) Issue 05/2013 Page 69...

  • Page 70: Fig. 23 Assembly Of Flange Mount (Bg 160 Model)

    Installation of generator Installation of dual-bearing generators (BG 160) Assembly Ö Fig. 23, Assembly of flange mount (BG 160 model), page 70 > Place the flange [1] onto the generator and secure with four screws [2a] a tightening torque of 75 Nm. > Apply Loctite to the screw thread on the four screws [2a] and place a toothed...

  • Page 71: Assembly Instructions Hydraulic Drive

    Installation of generator Installation of dual-bearing generators (BG 160) 6.8.5 Assembly instructions hydraulic drive Preparatory disassembly > Carry out the preparatory disassembly on the generator. Ö Preparatory disassembly, page 69 Ö Fig. 22, Preparatory disassembly of flange mount (BG 160 model), page 69 Assembly Ö Fig. 24, Assembly of flange mount hydraulic drive (BG 160 model), page 72 >...

  • Page 72: Fig. 24 Assembly Of Flange Mount Hydraulic Drive (Bg 160 Model)

    Installation of generator Installation of dual-bearing generators (BG 160) M12 x 35 DIN 912 VH 12 DIN 128 M8 x 30 DIN 912 VH 8 DIN 128 Fig. 24 Assembly of flange mount hydraulic drive (BG 160 model) Page 72 Issue 05/2013...

  • Page 73: Electrical Generator Connection

    Installation of generator Electrical generator connection Electrical generator connection Carefully read the safety instructions before installing, commissioning and operating the generator, and follow the instructions and heed the information. Ö General safety instructions, installation, page 28 This section is only relevant for generators that are not fitted with a switch box in the factory.

  • Page 74: General

    Installation of generator Electrical generator connection 6.9.1 General On generators without a factory-installed switch box, install suitable safety devices in a separate switch cabinet in order to protect the circuits (power sockets) connected to the generator: y Short circuit tripping characteristics: “B” characteristic y Protection against overcurrent: as per nominal current y The neutral conductor N must be secured.

  • Page 75: Fig. 25 Terminal Boxes, Connection Assignment On Terminal Board

    Installation of generator Electrical generator connection Fig. 25 Terminal boxes, connection assignment on terminal board 6.9.3 Version without terminal box, cable is routed in the tube Optionally, the generator can also be delivered without an attached terminal box. In this case, the connection lines are lead out of the generator through a tube.

  • Page 76: Operation

    Operation General safety instructions, operation Operation This chapter describes the operation and control of the generator. Depending on the generator equipment, deviations can arise. Reference is made to these deviations in the corresponding sections of this manual. Before use, read the chapter on intended use, the general safety instructions and the safety information in this chapter carefully and follow the instructions and regulations given therein.
  • Page 77 Operation General safety instructions, operation Danger Risk of injury When protective coverings are not in use, there is a risk of injury through electric shock, moving parts and hot surfaces. Only operate the generator with the fitted protective ► coverings proscribed for the drive in the regulations. Warning Risk of injury and risk of damage! The power generation system must be operated under certain...
  • Page 78 Operation General safety instructions, operation Warning Danger to life caused by electric shock and risk of damage. Jets from a high-pressure cleaner can lead to the destruction of the switch cabinet or electric shock. Never expose the generator or switch ► cabinet with a protection class lower than IP69k to high-pressure cleaner.
  • Page 79 Operation General safety instructions, operation Important These generators are not suitable for supplies to fixed distribution networks. These generators are designed for a certain performance and speed. They can be destroyed by voltage peaks and overloads. Do not use the generator to supply building-site distribution ►...

  • Page 80: Operating Conditions

    Operation Operating conditions Operating conditions The generator may only be used if the following operating conditions are met. y Only connect devices which have voltage and frequency data on their rating plate matching that for the power generation system. The total power draw of all connected units must not exceed the output indicated for the current power generation system.

  • Page 81: Electrical Safety Devices, Safety Measures And Earthing

    Operation Electrical safety devices, safety measures and earthing 7.3.1 Electrical protection and earth / potential equalization Generators without the “insulation monitor with disconnection” option meet the protective measure “electrical separation with potential equalization connector” according to VDE 0100, Part 728. Generators with the “insulation monitor with disconnection” option meet the higher-level protective measure “electrical separation with insulation monitor”...

  • Page 82: Fig. 26 Miniature Circuit Breakers In The Switch Box (Only For Generators 8Kva And 13 Kva)

    Operation Electrical safety devices, safety measures and earthing 7.3.2 Protection against overcurrent On generators with factory-installed switch box, the power sockets are to be protected against overcurrent and short circuits at the attached switch box using line circuit breakers. Line circuit breaker block (protection: 3P + N) Fig.

  • Page 83: Connection To An Existing Distribution Network (E.g. Company Installation)

    Operation Connection to an existing distribution network (e.g. company installation) Danger Danger to life through electric shock In an energy recovery system, there is a danger to life through an electric shock for any persons who may be working on the public power network while it is shut down. The generator can be damaged in mains parallel mode with the public power network, may catch fire or may cause fires in the electrical lines of the installation.

  • Page 84: Working Safely With Electrical Devices

    Operation Working safely with electrical devices Working safely with electrical devices Follow the following operating instructions to work safely with electrical devices. Ö General safety instructions, operation, page 76 Danger Risk of accident and injury There are risks associated with working with power generation systems and electrical equipment.
  • Page 85 Operation Working safely with electrical devices y Depending on the range of use and application, when working with power generation systems, follow the instructions, requirements, provisions or recommendations from Employer's Liability Insurance Associations and trade associations. In particular, the German Equipment Safety Act (GSG) must be followed, as must relevant accident prevention requirements and the mining ordinances of the states.

  • Page 86: Fig. 27 Operating And Control Elements In The Switch Box (Optional)

    Operation Generator operation Generator operation Danger Risk of accident and injury There are risks associated with working with power generation systems and electrical equipment. Before putting the generator into operation: read through ► all sections of this chapter carefully, in particular, the safety instructions in the chapter on “General safety information”.

  • Page 87: Electricity Distribution And The Connection Of Devices

    Operation Generator operation 7.6.2 Electricity distribution and the connection of devices Danger Danger to life through electric shock Insulation monitors can mutually influence each other. Do not connect any other insulation monitors downstream ► of the power generation system. Warning Risk of injury and risk of damage! An even distribution across all three phase conductors of the generator is the ideal scenario.
  • Page 88 Operation Generator operation Important Risk of damage The total power draw of all connected units must not exceed the output indicated for the current power generation system. Only connect as many units as the generator output can ► supply sufficiently. Do not overload the generator.
  • Page 89 Operation Generator operation Generator with attached switch box Important Risk of damage When using several devices on the AC power sockets at the same time (especially on devices with different power consumption ratings), temporary over and undervoltages may arise due to a switch-on delay in the neutral conductor. Do not use the line circuit breakers in the switch cabinet for ►...
  • Page 90 Operation Generator operation Note Equipment powered by electric motors may need start-up currents which can be many factors higher than the indicated operating currents. In case of doubt, please get in touch with the manufacturer. ► > Every work day carry out a check on the insulation monitor to ensure it is suitable for work.

  • Page 91: Check Insulation Monitor

    Operation Generator operation 7.6.3 Check insulation monitor Warning Risk of injury and risk of damage! The insulation monitor must trip. Every work day, check generators with the option ► “insulation monitor with disconnection” to ensure that the insulation monitor is working correctly. Only put the generator into service when the check showed ►...

  • Page 92: Maintenance And Care

    Maintenance and care Generator operation Maintenance and care All generator components are in principle maintenance-free. However, carry out the maintenance work listed in the maintenance summary regularly and in a timely fashion in order to ensure a reliable operation of the generator. Ö...

  • Page 93: General Safety Instructions, Maintenance And Care

    Maintenance and care General safety instructions, maintenance and care General safety instructions, maintenance and care Danger Danger to life through electric shock During operation, the power generation system generates voltages that are potentially fatal. Work on the electrical systems and equipment must only ►...
  • Page 94 Maintenance and care General safety instructions, maintenance and care Warning Risk of injury and risk of damage! The use of unauthorised third party parts can lead to malfunctions, damage or danger. Only use third party parts expressly approved by the ►...

  • Page 95: Maintenance Overview

    Maintenance and care Maintenance overview Maintenance overview Interval Maintenance work Executed by Insulation monitor every work user > Check where available. Ö Check insulation monitor, page 91 Generator monthly user > Visual inspection for contamination or damage. Clean where necessary. > Check the information and rating plates, where necessary clean or replace them.

  • Page 96: Visual Checks / Cleaning Work, Users

    Maintenance and care Visual checks / cleaning work, users Visual checks / cleaning work, users Read and follow the chapter on safety information, care and maintenance and upkeep as well as the general safety instructions indicated here. Ö General safety instructions, maintenance and care, page 93 Danger Danger to life through electric shock Working on the generator or switch cabinet, visual inspections...

  • Page 97: Maintenance Work, Authorised Technicians

    Maintenance and care Maintenance work, authorised technicians Monthly work, operators > Inspect the generator housing for outwardly visible damage and excess contamination. This can impair the cooling. > Where necessary, clean the generator with a damp cloth. > Check whether the sign attached to the generator for the safety and warning information and the rating plate is easy to read.

  • Page 98: Fig. 28 Removal Of Carbon Brush Holder

    Maintenance and care Maintenance work, authorised technicians 8.4.1 Check / replace carbon brushes (only for brush generators) For brush generators, the carbon brushes must be removed and inspected every 1,000 operating hours by qualified technicians, as described below. If the carbon brushes are run down by more than a half, replace the entire carbon brush holder.

  • Page 99: Fig. 29 Check And Replace Carbon Brushes As Needed

    Maintenance and care Maintenance work, authorised technicians 8.4.2 Check carbon brush holder Replace the carbon brush holder when the carbon brushes have run down by more than a half, i.e. when they extend less than 6 mm from the carbon brush holder. min.

  • Page 100: Fig. 30 Installation Of Carbon Brush Holder

    Maintenance and care Maintenance work, authorised technicians gray Fig. 30 Installation of carbon brush holder 8.4.4 Replacement of the ball bearing Replace the ball bearings of the generator at least every 20,000 operating hours. If rough running noises are detected during the regular check on the ball bearings specified for every 5,000 operating hours, replace the ball bearing earlier.

  • Page 101: Repairs

    Repairs Maintenance work, authorised technicians Repairs Only the work described in Chapter 6 is allowed during maintenance. Additional work may be carried out by the manufacturer only. Danger Risk of injury and risk of damage! Opening or disassembling the generator puts the system at risk and compromises the safety of the user.

  • Page 102: Disassembly

    Disassembly Safety instructions Disassembly 10.1 Safety instructions Danger Danger to life through electric shock Working on the generator or switch cabinet during operation can lead to potentially fatal injuries caused by electric shock. Switch off the drive unit before performing any inspection ►...

  • Page 103: Disassembly Of Single-Bearing Generators

    Disassembly Disassembly Disassembly of dual-bearing generators (BG  1 32  a nd BG  1 60  m odels) Disassembly of dual-bearing generators 10.3 Disassembly of dual-bearing generators (BG 132 and BG 160 models) The disassembly of dual-bearing generator must be carried out according to the descriptions in the Installation chapter. Ö...

  • Page 104: Fig. 31 Preparatory Work, Disassembly Of Single-Bearing Brush Generators

    Disassembly Disassembly of single-bearing generators 10.4.1 Disassembly of single-bearing brush generators Preparatory work and removal of carbon brush holder > Disconnect electrical connection lines of the generator. Ö Installation of generator, page 28 > Unscrew the two M8 x 45 screws, wrench size 10 mm, [2]. >...

  • Page 105: Fig. 32 Disassembly Of Single-Bearing Brush Generators (1)

    Disassembly Disassembly of single-bearing generators Disassembly of shaft attachment via the grub screw Ö Fig. 32, Disassembly of single-bearing brush generators (1), page 105 Ö Fig. 33, Disassembly of single-bearing brush generators (2), page 106 > Remove the fan wheel cover [4] and fan wheel [3] from the generator.

  • Page 106: Fig. 33 Disassembly Of Single-Bearing Brush Generators (2)

    Disassembly Disassembly of single-bearing generators > Remove the special hexagon nut [1] from the generator shaft. > Assemble the carbon brush holders [4] again in the generator and connect the connection lines. > Insert the special wooden wedge for the transportation lock of the rotor. >...

  • Page 107: Fig. 34 Disassembly Of Single-Bearing Brush Generators With Tension Bolt

    Disassembly Disassembly of single-bearing generators Disassembly of shaft attachment via tension bolt Ö Fig. 34, Disassembly of single-bearing brush generators with tension bolt, page 107 > Remove the cover lid [2] from the fan wheel cover. > Restrain the motor shaft with the special tool from the motor manufacturer.

  • Page 108: Disassembly Of Brushless Single-Bearing Generators

    Disassembly Disassembly of single-bearing generators 10.4.2 Disassembly of brushless single-bearing generators Preparatory work > Disconnect electrical connection lines of the generator. Ö Electrical generator connection, page 73 > Continue with the disassembly with the following descriptions: > For shaft attachment via grub screw, continue with the next section. >...

  • Page 109: Fig. 35 Disassembly Of Brushless Single-Bearing Generators (1)

    Disassembly Disassembly of single-bearing generators > Remove the generator front bearing plate that is still attached to drive motor. To do so, unscrew the four screws [3] (Figure 36) and remove the bearing plate [4]. > Attach the front bearing plate [4] to the generator. >...

  • Page 110: Fig. 36 Disassembly Of Brushless Single-Bearing Generators (2)

    Disassembly Disassembly of single-bearing generators Fig. 36 Disassembly of brushless single-bearing generators (2) Fig. 37 Disassembly of brushless single-bearing generators (3) Page 110 Issue 05/2013...

  • Page 111: Fig. 38 Disassembly Of Brushless Single-Bearing Generators With Tension Bolts (1)

    Disassembly Disassembly of single-bearing generators Disassembly of shaft attachment via tension bolt Ö Fig. 38, Disassembly of brushless single-bearing generators with tension bolts (1), page 111, Ö Fig. 39, Disassembly of brushless single-bearing generators with tension bolts (2), page 112 > Remove the cover lid [2] (Figure 38) from the fan wheel cover.

  • Page 112: Fig. 39 Disassembly Of Brushless Single-Bearing Generators With Tension Bolts (2)

    Disassembly Disassembly of single-bearing generators Fig. 39 Disassembly of brushless single-bearing generators with tension bolts (2) Page 112 Issue 05/2013...

  • Page 113: Transport And Storage

    Transport and storage Generator Transport and storage Note ► Transport and store the generators and the switch cabinets in a dry space and protect against water. ► Only transport or store the generator in the as-delivered condition with packaging and safety devices attached. 11.1 Generator Generators in the factory are bolted down for transport on a pallet and are...

  • Page 114: Decommissioning, Storage After Disassembly Of, Disposal

    Decommissioning, storage after disassembly of, disposal Disposal instructions Decommissioning, storage after disassembly of, disposal Carry out removal and decommissioning of generators according to the descriptions in the Disassembly of chapter. Ö Disassembly, page 102 After removal, package and store generators that are still functional in accordance with descriptions.

  • Page 115: Designation System For Generator Types

    Designation system for generator types Type code Designation system for generator types This chapter contains information about the design coding system for the individual generator types as well as examples for generator descriptions. 13.1 Type code DWG (BL) 17/ 7,0 -2 Z ...

  • Page 116: Examples Of Designations

    Designation system for generator types Examples of designations 13.2 Examples of designations Type designation Features or properties DWG 8,0/5,0-2EE Three phase AC generator, brush machine, 8 kVA three-phase AC voltage output, 5 kVA AC generator output, 2-pole machine, construction type single-bearing, electronically regulated, model BG 132 (as 2-pole <...

  • Page 117: Spare Parts

    Spare parts Generator Spare parts Companies authorised for repair and replacement work, must refer directly to the manufacturer for the service manual. 14.1 Generator Obtain the generator ID and serial number from the rating plate. Item designation Item code Housing / stator 1010 Footer 1030...
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  • Page 122: Index Of Figures

    Index of figures Index of figures Fig. 1 Mains configuration of generator, principle circuit diagram, electrical separation ......18 Fig. 2 Block circuit diagram, DWG-brushless generator with generator controller LCAR4BASIC ....19 Fig. 3 Block circuit diagram, DWG generator with brushes and generator controller LCAR4STD (with connected electronic idling mechanism) ......................20 Fig.
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  • Page 124: Index

    Index Index Disposal instructions .......... 113 Domestic installations .........82 Drive shaft ..............25 Drive types ..............25 Dual-bearing generators ......30, 34 Assembly of brush generators ......41 Assembly of brushless generators ....45 Assembly of flange mount ....60, 70, 72 Assembly to engine ..........40 Earthing ..............80 Electrical connection ..........73 Electrical protection ..........80...
  • Page 125 Index Instructions on the installation position for generator ..........30 Safety devices ...........32, 80 Insulation monitor ..........24, 85 Safety instructions, installation ....10, 28 Insulation monitor with disconnect ....18 Safety instructions legend ........2 Intended use ..............6 Safety instructions, operation ......76 Safety measures .............80 Seal ................40 Loads on the shaft ..........53...
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  • Page 128 Ziegelfeldstraße 62 + 65 // D-73563 Mögglingen// T. +49 (0) 71 74 8 98 00-0 // F. +49 (0) 71 74 8 98 00-25 // E. info@gts-generator.com // W. www.gts-generator.com...

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