GTS DGG Series Bedienungsanleitung

Issue 05/2013

Synchronous generators of series

DGG, DWG and WG

Models BG132and BG160

Installation and operating manual

English 05/2013

Synchronous generators of series DGG, DWG and WG

Issue 05/2013Page 2

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. Depending on the hazard class, the

warning information is shown as follows in descending order.

Danger

Means that death or serious bodily injury will occur if the

appropriate precautionary measures are not met.

Warning

Means that death or serious bodily injury can occur if the

appropriate precautionary measures are not met.

Caution

Means that minor bodily injury can occur if the appropriate

precautionary measures are not met.

Important

Means that property damage can occur if the appropriate

precautionary measures are not met.

Note

Means that an unexpected event or condition can arise if the

appropriate information is not followed.

If more than one hazard class arises, the warning level with the highest level

is always the one used. If awarning of injury to personnel in awarning notice

with warning triangle appears, an additional warning about material or

property damage can be attached to the same warning notice.

Page 3Issue 05/2013

Legend, safety instructions

Contents

Legend, safety instructions 2

1 Important information and notes 6

1.1 Qualied personnel 6

1.2 Intended use 6

1.3 Validity of the manual 7

1.4 Copyright 8

1.5 General safety instruction 8

1.6 Manufacturer's address 8

1.7 Warranty 8

2 Safety instructions 10

3 References to norms and directives 14

4 Description 15

4.1 Models (BG132and BG160) 15

4.1.1 Features and options of the models 16

4.2 General functions 17

4.3 Generator 17

4.3.1 Function 17

4.3.2 Generator controller 19

4.3.3 Mechanical versions 21

4.4 Variants for the electrical connection 21

4.4.1 Generator with attached terminal box (standard version) 21

4.4.2 Generator with attached corrugated pipe,

controller electronics installed externally 23

4.4.3 Generator with attached switch box 23

4.5 Drive types 25

4.5.1 Single-bearing generators (only BG132) 25

4.5.2 Dual-bearing generators 25

4.5.3 Direct connection via acoupling 25

4.5.4 Drive via hydraulic motor 25

4.5.5 Drive via belt pulley 26

5 Technical data 27

5.1 Generators 27

5.2 Switch box 27

5.3 Generator controller 27

6 Installation of generator 28

6.1 General safety instructions, installation 28

6.2 Requirements on the installation position 30

6.3 General provisions for installation 31

6.4 Permissible installation positions 33

6.4.1 Single-bearing generators 33

6.4.2 Dual-bearing generators (BG132an BG160) 34

Contents

Synchronous generators of series DGG, DWG and WG

Issue 05/2013Page 4

Legend, safety instructions

6.5 Holes for condensation water discharge 35

6.6 Installation of single-bearing generators 37

6.6.1 Delivery scope 37

6.6.2 Installation dimensions 38

6.6.3 Minimum clearances and cooling provisions 38

6.6.4 Assembly to engine 40

6.6.5 Additional assembly instructions for shaft attachment withtension bolt 48

6.7 Installation of dual-bearing generators (BG132) 52

6.7.1 Installation dimensions and assembly 52

6.7.2 Minimum clearances and cooling provisions 53

6.7.3 Assembly instructions for belt drive 55

6.7.4 Assembly instructions for ange mount 57

6.7.5 Assembly instructions for hydraulic drive 61

6.8 Installation of dual-bearing generators (BG160) 64

6.8.1 Installation dimensions and assembly 65

6.8.2 Minimum clearances and cooling provisions 66

6.8.3 Assembly instructions belt drive 67

6.8.4 Assembly instructions for ange mount 69

6.8.5 Assembly instructions hydraulic drive 71

6.9 Electrical generator connection 73

6.9.1 General 74

6.9.2 Version with terminal box 74

6.9.3 Version without terminal box, cable is routed in the tube 75

7 Operation 76

7.1 General safety instructions, operation 76

7.2 Operating conditions 80

7.3 Electrical safety devices, safety measures and earthing 81

7.3.1 Electrical protection and earth/potential equalization 81

7.3.2 Protection against overcurrent 82

7.4 Connection to an existing distribution network (e.g.company installation) 83

7.5 Working safely with electrical devices 84

7.6 Generator operation 86

7.6.1 Control elements in the optional switch box 86

7.6.2 Electricity distribution and the connection of devices 87

7.6.3 Check insulation monitor 91

8 Maintenance and care 92

8.1 General safety instructions, maintenance and care 93

8.2 Maintenance overview 95

8.3 Visual checks/cleaning work, users 96

8.4 Maintenance work, authorised technicians 97

8.4.1 Check/replace carbon brushes (only for brush generators) 98

8.4.2 Check carbon brush holder 99

8.4.3 Install the carbon brush holder 99

8.4.4 Replacement of the ball bearing 100

Contents

Page 5Issue 05/2013

Legend, safety instructions

9 Repairs 101

10 Disassembly 102

10.1 Safety instructions 102

10.2 Disassembly 102

10.3 Disassembly of dual-bearing generators

(BG132and BG160models) 103

10.4 Disassembly of single-bearing generators 103

10.4.1 Disassembly of single-bearing brush generators 104

10.4.2 Disassembly of brushless single-bearing generators 108

11 Transport and storage 113

11.1 Generator 113

12 Decommissioning, storage after disassembly of, disposal 114

12.1 Disposal instructions 114

13 Designation system for generator types 115

13.1 Type code 115

13.2 Examples of designations 116

14 Spare parts 117

14.1 Generator 117

14.2 Explosion drawing BG132 118

14.3 Explosion drawing BG160 120

16 Index of gures 122

17 Index 124

Contents

Synchronous generators of series DGG, DWG and WG

Issue 05/2013Page 6

Important information and notes

1 Important information and notes

1.1 Qualied 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 qualied personnel.

Qualied 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.

1.2 Intended use

yOnly use the generator for mains backup operations or for providing

current to mobile distribution systems. Only use the generator in

accordance with the performance data on the rating plate.

yThe system is not designed for feedback mode (e.g.connection of

4-quadrant converters), so this mode is only available to alimited extent

after consultation with the manufacturer.

ySecure the generator outputs against overcurrent and short circuit using

suitable safety devices, according to the information on the rating plate.

yDo not connect the generator to supply other energy distribution or

generator systems (e.g.domestic installations, distribution boards on

building sites, other generators, or the public electricity supply network).

yOnly operate the generator at the nominal speed indicated on the rating

plate.

yOnly use the generator for the uses indicated here and only in accordance

with the information in this manual.

All other uses are not as intended and are not allowed.

In the event of improper use or misuse of the current generator or individual

components thereof, the Generator. Technik. Systeme. GmbH&Co. KG

cannot take any responsibility.

Page 7Issue 05/2013

Important information and notes

1.3 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. The specied descriptions apply

analogously for WG series AC generators and for generators with special

voltages and special frequencies.

Synchronous generators of series DGG, DWG and WG

Issue 05/2013Page 8

Important information and notes

1.4 Copyright

Without the express approval of

Generator. Technik. Systeme. GmbH&Co. KG, no part of this operating

manual may be distributed, published or transmitted, irrespective of the type

and the means by which this occurs.

1.5 General safety instruction

Technical changes after going to press are not taken into account.

We reserve the right to make changes.

Version: May 2013

1.6 Manufacturer's address

We are more than happy to provide information, assistance, service and

ordering assistance.

Generator. Technik. Systeme. GmbH&Co. KG

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

1.7 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” of the ZVEI.

Page 9Issue 05/2013

Important information and notes

Dear customer,

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.

All information in this operating manual has been composed and veried

carefully to the best of our knowledge. Before installation, commissioning

and use of the current generator please read the operating manual closely.

Generator. Technik. Systeme. GmbH&Co. KG cannot take any responsibility

for any application contrary to the descriptions in this operating manual nor

for damage arising from incorrect operation and management, incorrect

installation, failing to use the unit as intended, prohibited technical

modications or due to repairs by unauthorised personnel.

If you have questions, please get in touch with

Generator. Technik. Systeme. GmbH&Co. KG.

Best regards

Generator. Technik. Systeme. GmbH&Co. KG

Synchronous generators of series DGG, DWG and WG

Issue 05/2013Page 10

Safety instructions

2 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

►Before installing and using the generator, please read the

operating manual fully and carefully.

►Only use the generator for the uses listed in the sections on

“intended use” and only in accordance with the information in

the operating manuals.

Danger

Danger to life through electric shock

yDuring operation, the power generation system generates

voltages that are potentially fatal.

►Never touch the generator, the switch cabinet or the

devices attached to the power generation system with wet

hands during operation.

Danger

Danger to life through electric shock

yWorking on the generator or switch cabinet, visual inspections

for maintenance purposes or cleaning work on the power

generation system during operation can lead to potentially

fatal injuries through electric shock.

►Switch o the drive unit before performing any inspection

or maintenance work on the generator or switch cabinet.

Prevent the drive unit from being switched back on

by accident (e.g.remove the ignition key and keep

somewheresafe).

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