GTS BG 132 Installation And Operating Manual Download Page 1

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Issue 05/2013

Synchronous generators of series

DGG, DWG and WG

Models BG 132 and BG 160

Installation and operating manual

English 05/2013

Summary of Contents for BG 132

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

Page 2: ...y 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 Mean...

Page 3: ...ion 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...

Page 4: ...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 7...

Page 5: ...e 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 11...

Page 6: ...on the rating plate y y The 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...

Page 7: ...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: ...uction 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...

Page 9: ...mation in this operating manual has been composed and verified carefully to the best of our knowledge Before installation commissioning and use of the current generator please read the operating manua...

Page 10: ...e information in the operating manuals Danger Danger to life through electric shock y y During operation the power generation system generates voltages that are potentially fatal Never touch the gener...

Page 11: ...ch other Do not connect any other insulation monitors downstream of the power generation system Warning Risk of injury and risk of damage y y Inadequately qualified persons are at risk when working on...

Page 12: ...is possible Do not operate the generator in environments where there is a risk of explosion Warning Risk of accident y y Devices which start up in an uncontrolled fashion can put persons at risk or i...

Page 13: ...e not suitable for supplies to fixed distribution networks y y These generators are designed for a certain performance and speed They can be destroyed by voltage peaks and overloads Do not use the gen...

Page 14: ...nal voltages of up to 1 000 V y y DIN VDE 0100 430 VDE 0100 Part 430 installing high voltage machines with nominal voltages of up to 1 000 V protective measures protecting cables and lines in the even...

Page 15: ...hen operates as a second bearing y y 4 pole generators drive speed 1500 1 min with rated output of 5 kVA up to 15 kVA These generators are only constructed as a brushless version Depending on the type...

Page 16: ...nly Delivery without terminal box cable guided directly in tube X X X Terminal box attached without controller filter function X X X Terminal box attached controller filter functions included in part...

Page 17: ...the output voltage between idle speed and the nominal load meets the requirements of DIN EN 60038 This equates to a quality standard which is comparable with the public electricity supply network The...

Page 18: ...mains configuration is the IT network with neutral conductor N and protective earth conductor PE Fig 1 Mains configuration of generator principle circuit diagram electrical separation page 18 L1 L2 L...

Page 19: ...Ref 1V6 Ref 5V Ref U_GEN U_P f_GEN I_K_Feld J GND 1 2 3 4 J3 Serial COM GND 5V Ref R_Shunt GND LED1 7V5 14V 28V 280V I_F_n 2 2A T1 DF B6U CS P18F252 RC0 RA4 RA0 RA3 RA1 RA2 IO RC2 RX TX 6 1 2 3 4 5 6...

Page 20: ...J GND 1 2 3 4 J3 Serial COM GND 5V Ref S2M S1M 1R 2W K1A V23092 A1012 A302 B LLA AUS Si max 1A MT 1 2 3 4 R_Shunt GND LED1 LED2 7V5 14V 28V 280V I_F_n 2 2A T1 DF B6U CS P18F252 RC0 RC3 RA4 RA0 RA3 RB7...

Page 21: ...witch box page 23 4 4 1 Generator with attached terminal box standard version The terminal box attached to the generator contains a terminal board for the connection lines as well as the generator con...

Page 22: ...Noise filter option 4 Terminal board Fig 5 Terminal box with terminal board generator controller and noise filter Foot mount motors Flange motors Motors without bearing plate IM B3 IM 1001 IM B5 IM 3...

Page 23: ...ntroller a noise filter the power sockets for connecting the consumers and an all pole protective circuit breaker for protecting the installed power sockets against overcurrent and short circuit An op...

Page 24: ...ion monitor An insulation fault exists when the insulation on a 400 230 V generator falls below 23 kOhm The insulation fault is reset by means of the green RESET button or by switching off the drive D...

Page 25: ...ators can be powered in various ways Installation and required components depend on the drive type Installation of dual bearing generators BG 132 page 52 Installation of dual bearing generators BG 160...

Page 26: ...lley 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 selecti...

Page 27: ...ts according to the version CEE Euro style earthed Nema Equipment All pole shut down using miniature circuit breaker Controller filter and interference suppression built in Optional equipment Operatin...

Page 28: ...safety instructions installation Danger Danger to life through electric shock y y Insulation monitors can mutually influence each other Do not connect any other insulation monitors downstream of the p...

Page 29: ...tallation of the generator can lead to malfunctioning damage or danger Before the installation of the generator read this operating manual completely and carefully The assembly disassembly of generato...

Page 30: ...bearing generators are usually installed near the drive unit y y Install the generator safely and securely on a 100 level surface with a load bearing capacity adequate for the weight class of the gene...

Page 31: ...he generator Generally the generators run clockwise In this case the output voltage has a clockwise field of rotation Dual bearing generators can also be operated in anticlockwise rotation the rotary...

Page 32: ...ons and regulations for the individual generator types y y Do not operate generators with a second shaft end without a properly assembled working machine or protective covering y y Install suitable sa...

Page 33: ...ment 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 whe...

Page 34: ...the cable outlet or switch box is positioned on the top side of the generator y y The generator can be installed rotated by 45 or 90 to the left or right as shown in the accompanying image Remove the...

Page 35: ...he generator housing as a drain for condensation water front and rear each has 4 holes arranged at an angle of 90 y y Do not use the holes on both sides and on the top side Seal them with M4x8 screws...

Page 36: ...rator Holes for condensation water discharge y 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...

Page 37: ...regulations given therein Intended use page 6 Safety instructions page 10 General safety instructions installation page 28 Important y y Single bearing generators are damaged if operated in an anticl...

Page 38: ...oling provisions y y 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 hous...

Page 39: ...ssure of Pmax 4 Pa is allowed in the suction path of the cooling air otherwise a sufficient quantity of cooling air cannot be drawn in y y In the blow out area of the cooling air on the front side a m...

Page 40: ...Generator seal to the drive motor Use a seal between generator and drive motor during assembly The type of the seal depends on the drive motor used The following table lists the specified seals for th...

Page 41: ...0 mm 2 Remove the sleeve 1 Remove both connection lines from the connecting lugs of the carbon brush holder 4 The connection lines are coded by the size of the connecting lugs thus protecting them aga...

Page 42: ...spacer below the generator as appropriate Move the generator against the flange of the drive motor Align the threaded hole of the generator shaft onto the grub screw inserted in the motor shaft Rotat...

Page 43: ...sh onto the slip rings on the shaft so that the carbon brushes are pressed into the carbon brush holder and the carbon brush holder is resting against its mounting base Press the carbon brush holder f...

Page 44: ...sue 05 2013 Page 44 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 4 3 2 1 Flange shown rotate...

Page 45: ...ry disassembly 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...

Page 46: ...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 Slide the gener...

Page 47: ...plate to the generator with the four mounting screws 2 Figure 12 Attach the fan wheel cover 1 Figure 12 1 4x 3 2 Install a appropriate seal for the drive motor Fig 11 Assembly of brushless single bea...

Page 48: ...crew page 42 Install a appropriate seal on the front bearing plate of the generator Generator seal to the drive motor page 40 Align the generator in front of the drive motor so that the generator shaf...

Page 49: ...Fig 15 Assembly of brushless single bearing generators with tension bolts 2 page 51 Perform preparatory disassembly Remove the carbon brush holder s Preparatory disassembly page 45 The steps describe...

Page 50: ...the tension bolt yet After screwing in the tension bolt the shaft of the generator is pressed onto the shaft of the drive motor NOTE When screwing in the tension bolt align the generator according to...

Page 51: ...Page 51 Issue 05 2013 Installation of generator Installation of single bearing generators 1 2 4x Fig 15 Assembly of brushless single bearing generators with tension bolts 2...

Page 52: ...attached lifting equipment can lead to accidents Secure the lifting equipment to the generator exclusively using the ring screws provided Only use suitable lifting equipment 6 7 1 Installation dimens...

Page 53: ...using 6 7 2 Minimum clearances and cooling provisions y y The generator needs sufficient ventilation for cooling The cooling air is drawn through the cooling profiles by the fan wheel on the rear side...

Page 54: ...4 Pa is allowed in the suction path of the cooling air otherwise a sufficient quantity of cooling air cannot be drawn in In the blow out area of the cooling air on the front side a maximum overpressu...

Page 55: ...shaft Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Secure the belt pulley with a screw threaded into the face of the shaft Prevent this screw from bein...

Page 56: ...tension force tension of drive belt on the shaft y y Fmax 2 000 N for standard bearing plate shaft 28 mm y y Fmax 3 000 N for reinforced bearing plate shaft 32 mm The maximum tension force indicated...

Page 57: ...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 alon...

Page 58: ...ft at the generator and prevent it from twisting on the shaft with a key Follow the manufacturer s instructions when assembling the coupling plate Secure the drive side of the coupling 6 to the drive...

Page 59: ...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 1 Fig 18 Preparatory disassembly of flang...

Page 60: ...rew Place the flange 1 onto the generator and secure with four screws 2a to a tightening torque of 75 Nm Mount the coupling plate 3 on the shaft at the generator and prevent it from twisting on the sh...

Page 61: ...erneath the nuts Place the collar 1 and clamp securely with two screws Mount the first half of the coupling 5 on the shaft at the generator and prevent it from twisting on the shaft using with a key W...

Page 62: ...Installation of dual bearing generators BG 132 1 4x 3b 3a 4x 8x 7a 7b 2 5 6 8 9 2x 2x 4a 4b 3a M8 DIN 985 3b A8 DIN 125 4a M8 x 45 DIN 912 4b VH 8 DIN 128 7a M8 x 20 DIN 912 7b VH 8 DIN 128 Fig 20 Ass...

Page 63: ...unt the first half of the coupling 3 on the shaft at the generator and prevent it from twisting on the shaft using with a key When carrying out the attachment follow the instructions of the coupling m...

Page 64: ...dual bearing generators with BG 160 model proceed according to the descriptions in this section y y Before installation read the chapter on intended use the general safety instructions and the safety...

Page 65: ...least four mounting screws minimum M12 or comparable bolt grade min 8 8 The attachment must be permanent and resistant to shock and vibrations Use suitable means to prevent the screws from coming und...

Page 66: ...res In individual cases the clearances may vary from these figures Get in touch with Generator Technik Systeme GmbH Co KG y y Both sides and above a 100 mm y y Front b 300 mm y y Rear c 200 mm Cooling...

Page 67: ...e pulley on the shaft Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Secure the belt pulley with a screw threaded into the face of the shaft Prevent this...

Page 68: ...missible axis clearances for other belts ask the manufacturer Maximum tension force tension of the drive belt on the shaft Fmax 5 000 N at a max 60 mm axial clearance from the point where the shaft ex...

Page 69: ...n 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 1 Fig 22 Preparatory disassem...

Page 70: ...ctite to the screw thread on the four screws 2a and place a toothed washer 2b underneath the screw Mount the coupling plate 3 on the shaft at the generator and prevent it from twisting on the shaft wi...

Page 71: ...at the generator and prevent it from twisting on the shaft using with a key When carrying out the attachment follow the instructions of the coupling manufacturer Mount the washer 4 onto the hydraulic...

Page 72: ...05 2013 Page 72 Installation of generator Installation of dual bearing generators BG 160 1 4x 8x 5a 5b 3 4 6 7 2x 2a 2b 2a M12 x 35 DIN 912 2b VH 12 DIN 128 5a M8 x 30 DIN 912 5b VH 8 DIN 128 Fig 24...

Page 73: ...replacement work may only be carried out by authorised and qualified technicians Only use the generator according to the information in the operating manual and the purposes indicated in the section o...

Page 74: ...enerators with an attached terminal box y y When opening the terminal box make sure that the connecting wires of the generator controller built into the cover are not torn off or damaged y y After ope...

Page 75: ...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 generato...

Page 76: ...y instructions operation Danger Danger to life through electric shock y y During operation the power generation system generates voltages that are potentially fatal Never touch the generator the switc...

Page 77: ...onditions for fault free operation Only operate the power generation system according to the indicated operating conditions and data In particular this applies to the environment and cooling condition...

Page 78: ...injury and risk of damage y y Inadequately qualified persons are at risk when working on the generator or switch cabinet and may damage the generator Assembly connection and commissioning of the gene...

Page 79: ...ors 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 boards or other fixed distributi...

Page 80: ...tor output can supply sufficiently Do not overload the generator y y A cooling air feed above 40 C can lead to power restrictions in extreme cases it can cause damage to the generator The temperature...

Page 81: ...thing rod However if this is still required or if it should become required in special cases a pre defined earthing of the generator housing must be done or the generator housing must be added to a po...

Page 82: ...ed switch box using line circuit breakers Line circuit breaker block protection 3P N Fig 26 Miniature circuit breakers in the switch box only for generators 8kVA and 13 kVA Generators without factory...

Page 83: ...rk or parallel operation with the mains is not permitted Make sure that the installation is completely and reliably disconnected from the public power network of the power utility company The connecti...

Page 84: ...owing operating instructions and follow them y y Devices which caused a shutdown by the insulation monitor and the INSULATION FAULT error indication must not be operated from other power generation sy...

Page 85: ...on class I i e with metal housing parts without protective insulation are used these must be fitted with a connection cable and a plug with PE connector With such devices the protective earth must be...

Page 86: ...ral safety instructions operation page 76 Check the correct function of the insulation monitor every day before starting work Only put the generator into service when the check has showed that the ins...

Page 87: ...generator is the ideal scenario Wherever possible distribute the current drawn by the consumers evenly on the three phase conductors of the generator to ensure safe operation Warning Risk of injury a...

Page 88: ...y y Devices with deviating voltage and frequency may be damaged upon connection Only connect devices which have voltage and frequency data on their rating plate matching that for the power generation...

Page 89: ...ust always be closed correctly to ensure protection class IP54 tighten the lock screws by hand NOTE Fault current RCD protective circuit breakers are in principal not fully functional in unearthed net...

Page 90: ...ker depending on the model in the attached switch box or in the switch box position ON or 1 Switch box Fig 6 Switch box with installed options operating hours counter and insulation monitor page 24 Sw...

Page 91: ...hen the generator is running Open the cover to the switch box Switch on the switch of the insulation monitor position ON or I Press the red check button The check button also acts as a signal lamp at...

Page 92: ...ements and regulations of the drive system manufacturer This also includes installed protective coverings Observe the maintenance instructions of the drive or system manufacturer Danger Risk of injury...

Page 93: ...e g remove the ignition key and keep somewhere safe Warning Risk of injury and risk of damage y y Inadequately qualified persons are at risk when working on the generator or switch cabinet and may da...

Page 94: ...nce and care General safety instructions maintenance and care Warning Risk of injury and risk of damage y y The use of unauthorised third party parts can lead to malfunctions damage or danger Only use...

Page 95: ...contamination or damage Clean where necessary Check the cover and power socket cover to ensure they are sealed tight Visual checks cleaning work users page 96 user every 1 000 operating hours For bru...

Page 96: ...g 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 electri...

Page 97: ...loth Generator with attached switch box Check the housing of the switch box and the integrated power sockets for outwardly visible damage and contamination Where necessary clean the switch box with a...

Page 98: ...half replace the entire carbon brush holder The carbon brushes cannot be replaced individually Remove the carbon brush holder s Unscrew the two M8 x 45 screws wrench size 10 mm 2 Remove the sleeve 1 R...

Page 99: ...enerator and push it onto the slip rings on the shaft so that the carbon brushes are pressed into the carbon brush holder and the carbon brush holder is resting against its mounting base Press the car...

Page 100: ...ng 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 Danger Risk of injury and risk of...

Page 101: ...carried out by the manufacturer only Danger Risk of injury and risk of damage y y Opening or disassembling the generator puts the system at risk and compromises the safety of the user Never open or di...

Page 102: ...move the ignition key and keep somewhere safe Warning Risk of injury and risk of damage y y Inadequately qualified persons are at risk when working on the generator or switch cabinet and may damage th...

Page 103: ...s are necessary for the disassembly of single bearing generators y y Special tool provided by the motor manufacturer for locking the motor shaft y y For shaft attachment via grub screw special hexagon...

Page 104: ...onnection lines from the connecting lugs of the carbon brush holder 5 The connection lines are coded by the size of the connecting lugs thus protecting them against being swapped Unscrew the mounting...

Page 105: ...he generator shaft Use the key 1 to secure against twisting Restrain the motor shaft with the special tool from the motor manufacturer Apply a screw spanner to the special hexagon nut and undo the gru...

Page 106: ...brush holders 4 again in the generator and connect the connection lines Insert the special wooden wedge for the transportation lock of the rotor Place the collar 6 and clamp securely with two screws 5...

Page 107: ...the drive motor Instead of the tension bolt thread the rod 4 into the generator shaft and insert the set screw 5 into the generator shaft Screwing in the set screw undoes the generator shaft from the...

Page 108: ...le bearing generators 2 page 110 Fig 37 Disassembly of brushless single bearing generators 3 page 110 Remove the fan wheel cover 3 Figure 35 and fan wheel 2 from the generator The fan wheel is secured...

Page 109: ...nd remove the bearing plate 4 Attach the front bearing plate 4 to the generator Unscrew the grub screw 1 Figure 37 from the shaft of the drive motor with a hexagon socket wrench Remove the special hex...

Page 110: ...es DGG DWG and WG Issue 05 2013 Page 110 Disassembly Disassembly of single bearing generators 1 2 3 4 Fig 36 Disassembly of brushless single bearing generators 2 1 2 3 4 Fig 37 Disassembly of brushles...

Page 111: ...special tool from the motor manufacturer Undo the tension bolt 1 and remove from the generator shaft Instead of the tension bolt thread the rod 3 into the generator shaft and insert the set screw 4 in...

Page 112: ...chronous generators of series DGG DWG and WG Issue 05 2013 Page 112 Disassembly Disassembly of single bearing generators 1 2 Fig 39 Disassembly of brushless single bearing generators with tension bolt...

Page 113: ...rator Generators in the factory are bolted down for transport on a pallet and are packaged to protect them from damage and moisture ingress If ring screws are not attached to the generator in the fact...

Page 114: ...enerators that are still functional in accordance with descriptions Transport and storage page 113 Label generators that are no longer operable as such and dispose of them or send to a recycling cente...

Page 115: ...l Z Dual bearing construction type E Single bearing construction type Number of generator poles 2 pole nominal speed 3000 1 min or 4 pole nominal speed 1500 1 min AC generator output in kVA e g 7 kVA...

Page 116: ...ree 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 17 kV...

Page 117: ...bearing B side 2110 Ball bearing A side 2111 B bearing plate 3010 A bearing plate 4010 Blades 5110 Cover 5130 Controller LCAR4 5400 Terminal box 5150 Terminal board 1020 When ordering spare parts alwa...

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Page 122: ...ange mount dual bearing BG 132 model with standard bearing plate 58 Fig 18 Preparatory disassembly of flange mount dual bearing BG 132 model with reinforced bearing plate 59 Fig 19 Assembly of flange...

Page 123: ...Page 123 Issue 05 2013...

Page 124: ...nge mount 57 Disassembly of power generation system 101 Display elements 85 Disposal 113 Disposal instructions 113 Domestic installations 82 Drive shaft 25 Drive types 25 Dual bearing generators 30 34...

Page 125: ...6 R Reinforced bearing plate 59 63 Repairs 100 Replace ball bearing 99 Rotated generator installation 36 S Safety devices 32 80 Safety instructions installation 10 28 Safety instructions legend 2 Saf...

Page 126: ...Synchronous generators of series DGG DWG and WG Issue 05 2013 Page 126...

Page 127: ...Page 127 Issue 05 2013...

Page 128: ...Ziegelfeldstra e 62 65 D 73563 M gglingen T 49 0 71 74 8 98 00 0 F 49 0 7174 89800 25 E info gts generator com W www gts generator com...

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GTS BG 132, Installation And Operating Manual

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