GTS DWG (BL) 13/7-2 ZE Installation And Operating Manual Download Page 25

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Page 25

Issue 07/2011

Technical data

Generator controller

2.2

Generator controller

Controller type

LCAR4

Pin assignment (applies for all of the

generator types described)

Color

Function

red

gray

violet

1/2 U

violet

1/2 V

violet

1/2 W

2.3

Switch cabinet

All switch cabinets meet the protection class IP43 at least.

Equipment and dimensions of switch cabinet

section “Switch cabinet”,

page 21 or loose sheet in the Appendix.

Summary of Contents for DWG (BL) 13/7-2 ZE

Page 1: ...Built in generators with switch cabinet for permanently installed power generation systems 12 kVA in fire engines DWG BL 13 7 2 ZE to DWG BL 40 14 4 ZE A A A V k Hz Installation and operating manual E...

Page 2: ...ath 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...

Page 3: ...enerator 18 1 3 1 Connection via drive shaft 18 1 3 2 Drive via hydraulic motor 18 1 3 3 Drive via belt pulley 18 1 4 Generator 19 1 4 1 Function 19 1 4 2 Mechanical versions 19 2 pole generators 20 4...

Page 4: ...4 Assembly instructions coupling via drive shaft 45 3 6 5 Assembly instructions for hydraulic drive 45 3 6 6 Assembly instructions for belt drive 47 4 Installation of switch cabinet and electrical con...

Page 5: ...Maintenance work carried out by authorised personnel 78 6 4 1 Replacing the ball bearings 79 7 Repairs 79 8 Disassembly 80 8 1 Safety instructions 80 8 2 Disassembly 80 9 Transport and storage 81 9 1...

Page 6: ...These power generation systems are designed exclusively for use as permanently installed power generation systems in fire engines y y Only use the generators for mains backup operations or for providi...

Page 7: ...nently installed power generation systems in fire engines In this manual the different generator types are distinguished by their type designation and their model Two pole execution nominal speed 3 00...

Page 8: ...f the type and the means by which this occurs 2003 2011 Generator Technik Systeme GmbH Co KG All rights reserved General note Technical changes after going to press are not taken into account We reser...

Page 9: ...n system All information in this operating manual has been composed and verified carefully to the best of our knowledge Before installation commissioning and use of the current power generation system...

Page 10: ...enerator and the switch cabinet 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 y...

Page 11: ...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 Danger Danger to life through electric shock...

Page 12: ...ccording to applicable national regulations in Germany these include VDE specifications Warning Risk of injury y y When protective coverings are not in use there is a risk of injury through electric s...

Page 13: ...eration Allow the generator or parts of the generator to cool down before you touch them Important y y These generators are not suitable for supplies to fixed distribution networks y y These generator...

Page 14: ...ts y y DIN 49442 Two pole watertight power sockets with earthing contact 10 A 250 V and 10 A 250 V 16 A 250 V principal dimensions y y DIN EN 50014 VDE 0170 0171 Part 1 Electrical equipment for use in...

Page 15: ...t Chapter 55 other equipment main section 551 low voltage power supply systems y y DIN VDE 0105 100 operating electrical installations y y DIN VDE 0470 1 VDE 0470 Part 1 protection class provided by e...

Page 16: ...em 1 1 Components The power generation system comprises the following units y y Generator section 1 4 page 19 y y Switch cabinet section 1 5 page 21 1 2 Circuit diagram The circuit diagram shown below...

Page 17: ...ment as per DIN 14686 Switch cabinet form AA Switch cabinet form BB and CC Power contactor Main circuit breaker Switch cabinet lighting supplied from on board vehicle power supply Ammeter CEE Power so...

Page 18: ...nd constantly regulated speed in order to avoid operating the generator at an under or overspeed which can impair the function of the generator or may even damage it 1 3 2 Drive via hydraulic motor Th...

Page 19: ...nerator with excessive power draw or excessive start up power draw the generator controller will automatically restrict the power output by reducing the exciter field current and reduce the output vol...

Page 20: ...00 1 min 3000 1 min 3000 1 min 3000 1 min 4 pole generators DWG BL 13 7 4 ZE DWG BL 17 7 4 ZE DWG BL 23 12 4 ZE DWG BL 30 15 4 ZE DWG BL 40 14 4 ZE Output 13 kVA 17 kVA 23 Kva 30 kVA 40 kVA Model BG 1...

Page 21: ...e following figures show examples of front panels and components for the possible switch cabinet variants according to DIN 14686 For the actual execution of your switch cabinet Appendix A separate ope...

Page 22: ...ic indication acknowledgment and check button 8 Four pole 16 A circuit breaker optional 32 A built in power socket with thermal and magnetic tripping for CEE power sockets No 12 9 Four pole main circu...

Page 23: ...7 14 6 4 5 13 9 10 8 11 1 11 2 12 Max cabinet dimensions H x W x D max 600 x 380 x 210 mm Figure 4 Switch cabinet form BB Legend page 22 Hz A A A V 1 2 2 2 3 7 14 6 4 5 13 9 10 8 11 1 11 2 12 Max cab...

Page 24: ...minal speed 3 000 min 1 Rated frequency 50 Hz Distortion factor 5 Efficiency at cos Phi 0 8 0 80 Efficiency at cos Phi 1 0 0 82 Protection class IP54 Weight approx 65 kg 84 kg 121 kg 153 kg 184 kg 4 p...

Page 25: ...applies for all of the generator types described Pin Color Function 1 red F1 2 gray F2 3 violet 1 2 U 4 violet 1 2 V 5 violet 1 2 W 6 2 3 Switch cabinet All switch cabinets meet the protection class...

Page 26: ...ger 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 dismantle the generator The generator may...

Page 27: ...y in such a case Never make modifications to the generator or individual components Only use third party parts expressly approved by the manufacturer for the installation Warning Risk of injury y y Wh...

Page 28: ...he required minimum clearances when adequate ventilation is maintained at all times and where possible the temperature of the cooling air does not exceed 40 C y y Do not spray the generator with high...

Page 29: ...h the cooling air Avoid short circuits in the airflow Observe the specific installation instructions and regulations for the individual generator types Do not operate generators with a second shaft en...

Page 30: ...installation position the terminal box is positioned on the top side of the generator The generator can be installed rotated by 45 or 90 to the left or right as shown in the accompanying image Remove...

Page 31: ...ovided Only use suitable lifting equipment 3 5 1 Installation dimensions and assembly During assembly observe the minimum clearances and specifications for cooling in the following section Dimensions...

Page 32: ...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 housing towards the fro...

Page 33: ...ir should not exceed 40 C y y A maximum underpressure 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 o...

Page 34: ...rforming any inspection or maintenance work on the drive shafts Prevent the drive unit from being switched back on by accident e g remove the ignition key and keep somewhere safe Important Do not use...

Page 35: ...the generator shaft Assembly instructions for belt drive Generators of model 132 Section 3 5 1 page 31 Generators of model 160 section 3 6 1 page 42 The permissible lateral offset is dependent on the...

Page 36: ...flange mounting screws 1 with a torque key to the specified moment With divided hubs Mod ZAE Figure at right respect the clearance C from the shaft end face to the shaft end face of the shafts to be...

Page 37: ...ified torque Specified moment Manufacturer s description drive shaft manufacturer The clamping procedure is now complete Important Do not tighten the mounting screws any further Doing so could damage...

Page 38: ...ve 1 Unscrew and remove four screws M12 x 12 3 along with the washers 1 2 4x 3 Figure 6 Preparatory disassembly for flange mounting in case of hydraulic drive generator model 132 Assembly Place the fl...

Page 39: ...coupling on the generator Where necessary turn the coupling slightly to ensure the gearing locks Place toothed washers 7b to eight screws 7a and secure disk 6 to the flange 2 Place the collar 9 onto...

Page 40: ...nning Important Do not strike the pulley on the shaft Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Thread in a screw into the end face of the shaft to s...

Page 41: ...t a max 50 mm axial clearance from the point where the shaft exits the bearing plate The belt tension must not exceed a radial force of 2 000 N at a max axial clearance of 60 mm from the point where t...

Page 42: ...the generator exclusively using the ring screws provided Only use suitable lifting equipment 3 6 1 Installation dimensions and assembly During assembly observe the minimum clearances and specificatio...

Page 43: ...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 y y Ensure adequate air feed and exhaust openings...

Page 44: ...e to the generator The temperature of the supplied cooling air should not exceed 40 C y y A maximum underpressure of Pmax 4 Pa is allowed in the suction path of the cooling air otherwise a sufficient...

Page 45: ...s an alternative to the bearing plate shown here the generators can also be fitted with a gray cast iron bearing shield When using a gray cast iron bearing plate assembly of a hydraulic drive is not p...

Page 46: ...rom twisting on the shaft using with a key Mount the washer 4 onto the hydraulic motor 6 Place the second half of the coupling 3 to the hydraulic motor Place the hydraulic motor 6 with washer 4 and th...

Page 47: ...Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Thread in a screw into the end face of the shaft to secure the belt pulley Prevent this screw from being un...

Page 48: ...ce 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 exits the bearing plate The belt tension must not exceed a radial force of 2 000 N...

Page 49: ...by the manufacturer or an authority authorised by the manufacturer Only carry out the work described in this manual Danger Danger to life through electric shock y y A grounding of the neutral conduct...

Page 50: ...nnel 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 third party parts expressly approved by the manufacturer...

Page 51: ...the uses listed in the sections on intended use and only in accordance with the information in the operating manuals Do not make any modifications to the switch cabinet Any modification incorrect rep...

Page 52: ...and gears according to DIN 14555 3 Do not spray the switch cabinet with high pressure cleaners 4 3 General provisions for installation The basic requirement for safe reliable and fault free operation...

Page 53: ...the instructions and information therein Also note the instructions and requirements of the switch cabinet 4 5 1 Instructions laying of cables When laying lines and cables follow these instructions y...

Page 54: ...amaged y y After opening the terminal box remove the plug connector to the generator controller in the terminal box cover The plug connector is mechanically coded and cannot be reversed inadvertently...

Page 55: ...erators run clockwise In this case the output voltage has a clockwise field of rotation Generators can also be operated in anticlockwise rotation the rotary field of the output voltage then switches t...

Page 56: ...ion 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 Dang...

Page 57: ...accident y y Devices which start up in an uncontrolled fashion can put persons at risk or injury them or cause damage or themselves be damaged Switch off all devices before you connect them to the pow...

Page 58: ...according to applicable national regulations in Germany these include VDE specifications Caution Burn hazard y y Parts of the generator can become very hot during and after the operation Allow the ge...

Page 59: ...n the type plate of the power generation system y y Do not overload the power generation system The total power draw of all connected units must not exceed the output indicated for the current power g...

Page 60: ...uctions in section 5 1 page 56 and follow them Read the following operating instructions and follow them y y Devices which caused a shutdown by the insulation monitor and the INSULATION FAULT error in...

Page 61: ...f you have any questions please get in touch with the system manufacturer directly y y Only operate the power generation system under permissible operating conditions section 1 1 page 16 y y Many port...

Page 62: ...ely assigned to the relevant power sockets Figure 1 page 17 There is no need to earth the power generation system e g through an earthing rod for the electrical safety measures mentioned above to work...

Page 63: ...Section 5 1 page 56 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 insulation monitor was in...

Page 64: ...onductor Insulation monitor Check button signal lamp Acknowledgment button and switch for switch cabinet lighting Switch cabinet lighting Frequency display Line circuit breaker for power sockets Voltm...

Page 65: ...you must switch the optional pole reversing switch to position 0 Leave the pole reversing switch in position 0 until all connected motors have come to a stop Important Risk of damage y y The total pow...

Page 66: ...eakers in the switch cabinet for switching the connected equipment on or off Important y y The power generation system is not suitable for supplying fixed distribution networks Do not use the power ge...

Page 67: ...switch them on in sequence Switch on the powerful units with high current consumption or high starting current first followed by the less powerful units Danger Danger to life through electric shock y...

Page 68: ...ower sockets have load limits Do not exceed the maximum indicated amperage for power sockets Important After disconnecting the consumers from the switch cabinet the hinged covers of the power sockets...

Page 69: ...to be operated with all of the connected devices though the faulty devices and or cables should be located and disconnected as soon as possible to remedy the fault y y To localize a faulty device or f...

Page 70: ...sulation monitor was in correct working order Check the insulation monitor as follows Position of operating and control elements Figure 11 page 64 Remove all devices and cables connected to the power...

Page 71: ...rth was in correct working order Check the protective earth as follows Position of the test device Figure 11 page 64 Start the drive unit Only perform the check when the generator is running Switch on...

Page 72: ...y out the work described in this manual 5 6 1 Description Where possible check all resistance values according to the data sheet Carry out a visual check If anomalies are found e g faulty electronic p...

Page 73: ...Check phase voltage Is it nominal Measured output voltage above 40 V AC Check resistance of main windings and excitation windings Do values match data sheet Measured output voltage is 40 V and below...

Page 74: ...ns 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 and risk of damage...

Page 75: ...g air openings for contaminants and blockages clean where necessary Section 6 3 page 77 user front panel of switch cabinet y y Visual check for contamination or damage Clean where necessary y y Check...

Page 76: ...cabinet Prevent the drive unit from being switched back on by accident e g remove the ignition key and keep somewhere safe Warning Risk of injury and risk of damage y y Inadequately qualified persons...

Page 77: ...rk on the power generation system during operation can lead to potentially fatal injuries through electric shock Switch off the drive unit before performing any inspection or maintenance work on the g...

Page 78: ...ck that the hinged covers of the power sockets box are free of damage and seal tightly y y Check whether the sign attached to the generator for the safety and warning information and the rating plate...

Page 79: ...rator The generator may only be opened by the manufacturer or an authority authorised by the manufacturer Only carry out the work described in this manual Carry out disassembly of generator as shown i...

Page 80: ...from being switched back on by accident 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 th...

Page 81: ...Lifting eye screws have been attached to the generator to secure the lifting equipment Secure the lifting equipment to the generator exclusively using this ring screws Only use suitable lifting equip...

Page 82: ...5 non condensing 9 2 Switch cabinet Screw switch cabinets for transport onto a pallet or pack into suitable transport cases and protect them against damage and moisture ingress Where necessary fix the...

Page 83: ...ose of them or send to a recycling center according to the applicable legal requirements More information is available from the relevant environmental authorities or manufacturers 10 1 Disposal instru...

Page 84: ...ooter 1030 Pole wheel 2010 Ball 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 102...

Page 85: ...Decommissioning 83 Disassembly for flange mount 38 45 Disassembly of power generation system 80 Displays 63 Disposal 83 Disposal instructions 83 Drive shaft 18 36 37 45 Drive shaft assembly 34 Drive...

Page 86: ...ter 22 Operation 56 P Pole wheel 84 Power sockets 63 Protective earth test device 22 Q Qualified personnel 6 R Repairs 79 Replace ball bearing 79 S Safety devices 62 Safety instructions installation 1...

Page 87: ...Page 87 Issue 07 2011...

Page 88: ...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 Original operating manual...

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