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Synchronous Generators

Series DGG, DWG and WG


Size BG 132 and BG 160

Operating and Installation Instructions

English 08/2002
Synchronous Generators BG 132 / BG 160
Copyright, general information, manufacturer's address

Copyright
No part of this Operation Manual may be reproduced, published or transmitted in
any form or by any means without the express permission of Generator-Technik
Schwäbisch Gmünd GmbH &Co. KG.
© 2002 Generator-Technik Schwäbisch Gmünd GmbH & Co. KG. All rights
reserved.

General information
Technical modifications after date of printing are not considered. Subject to
change without notice.
Issue date: August 2002

Validity of the manual


This manual applies to all synchronous generators of the types DGG (three-phase
DC generators), DWG (three-phase AC generators) and WG (single-phase AC
generators). However, for reasons of clarity only three-phase AC generators are
represented and mentioned in the manual. In their general sense the given
explanations are however also applicable for single-phase AC generators of the
series WG and appropriate generators with special voltages and frequencies.
Further information about the designation system for the various generator types
can be found in chapter 1 on page 11.

Manufacturer's address
For any information and support concerning technical problems, services and
orders please contact us.
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG
Ziegelfeldstraße 18
D-73563 Mögglingen, Germany
Phone +49 7174 89 80 0 0
Fax +49 7174 89 80 0 25

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Synchronous Generators BG 132 / BG 160
Table of contents

Table of contents
Some important and valuable information .................................................. 5

Warranty ............................................................................................... 5

Proper use ............................................................................................ 6

Preconditions and requirements to be met by the place of installation ........... 6

Safety precautions ................................................................................. 7

1 Designation system for generator types .............................................. 11


1.1 Type codes .............................................................................. 11
1.2 Examples for designations .......................................................... 12

2 Description .................................................................................... 13
2.1 Use of different sizes (BG 132 and BG 160) .................................. 13
2.2 Overview of features and options for different sizes and designs ...... 13
2.3 General functionality ................................................................ 15
2.4 Generator governor ................................................................... 17
2.5 Mechanical designs ................................................................... 19
2.6 Drive types .............................................................................. 21
2.7 Terminal box (standard version) .................................................. 22
2.8 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 23

3 Technical data ................................................................................ 25


3.1 Generators ............................................................................... 25
3.2 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 25
3.3 Generator governor ................................................................... 25

4 Installation .................................................................................... 27
4.1 Safety precautions for installation ............................................... 27
4.2 Requirements to be met by the place of installation and use ........... 29
4.3 General regulations for installation ............................................. 29
4.4 Permissible mounting positions and drain holes for cond. water ....... 31
4.5 Installation for single-bearing generators ..................................... 35

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Synchronous Generators BG 132 / BG 160
Table of contents

4.6 Installation of two-bearing generators (BG 132) ........................... 49


4.7 Installation of two-bearing generators (BG 160) ........................... 62
4.8 Electrical connection of the generators ........................................ 70

5 Operation ...................................................................................... 73
5.1 Safety information for operation ................................................. 73
5.2 Permissible operating conditions ................................................ 75
5.3 Electric protection equipment, protective measures and grounding ... 75
5.4 Connection to an existing power distribution network
(e.g. house wiring) ................................................................... 77
5.5 Operating information for safe working with electric devices ........... 78
5.6 Operation of the generator ......................................................... 80

6 Maintenance .................................................................................. 85
6.1 Maintenance overview ............................................................... 86
6.2 Safety precautions .................................................................... 87
6.3 Visual inspections and cleaning to be performed by the user ........... 88
6.4 Maintenance to be performed by authorized qualified personnel ...... 89

7 Reconditioning ............................................................................... 92

8 Removal ........................................................................................ 93
8.1 Safety precautions .................................................................... 93
8.2 Removal of two-bearing generators (BG132 and BG160) ................. 93
8.3 Removal of single-bearing generators .......................................... 93

9 Transport and storage .....................................................................103

10 Putting out of operation, storage after dismantling, disposal ................104


10.1 Waste disposal information .......................................................104

11 Spare parts ...................................................................................105

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Synchronous Generators BG 132 / BG 160
Some important and valuable information

Some important and valuable information


Dear customer,
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG is a technically leading
manufacturer of power generators in the best tradition and manufactures
generators with ratings of 4 to 30 kVA as well as its own design of electronic
control units for those generators. What makes GTS generators stand out is their
excellent fitness for practical use and superior quality. They are maintenance-
free, durable, precise and robust.
Choosing a synchronous generator of this series was a decision for a technically
superior product. This product has been manufactured using only high-quality
components which meet the requirements of VDE testing and comply with
appropriate German (DIN) and European (EN) standards.
All information contained in these operating instructions has been carefully
compiled and checked by us to the best of our knowledge and belief. Please be
sure to read and understand the operating instructions before installing,
commissioning and using the generator.
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG does not assume any
liability for any applications which are contrary to the descriptions given in
these operating instructions, and for any loss or damage which has been caused
by incorrect operation and handling, faulty installation, improper use, abuse,
non-approved technical modifications or by any repairs performed by
unauthorized personnel.
If you have any questions, please contact Generator-Technik Schwäbisch Gmünd
GmbH & Co. KG.

Yours sincerely,
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG

Warranty
For the generators of the series described in this manual, we issue warranty
according to the latest version of the "Allgemeine Lieferbedingungen für
Erzeugnisse und Leistungen der Elektroindustrie (general conditions for the
supply of products and services of the electrical industry)" of the ZVEI.

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Synchronous Generators BG 132 / BG 160
Proper use

Proper use
The generators described in this manual are intended for the generation of
electrical energy within the context of emergency standby operation for feeding
in mobile distribution systems. The generators must only be used according to
the voltage and power specifications listed on the type plate. Reverse feeding
operation (e.g. connection of four-quadrant converters) is not planned and only
conditionally possible after consulting the manufacturer.
The generators have to be driven with the specified rated speed. The generator
outputs have to be protected against overcurrent and short-circuit by adequate
fuse equipment according to the specifications on the type plate.
The generators must not be connected to other power distribution or electricity
generation systems (such as other generators or the public electricity supply
network, for example).
The use of the generators is only allowed for applications described here and in
conformity with the specifications given in this manual. Any other application is
considered to be improper use and is not permitted.
In case of improper use, misuse or abuse of the generators or of parts of them,
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG will not assume any
liability.

Preconditions and requirements to be met by the place of


installation
Single-bearing generators are mounted directly to the engine. These generators
may only be mounted to engines which comply with the applicable regulations,
rules and requirements.
Two-bearing generators are usually installed right next to the engine. The
generator has to be firmly and securely mounted on an absolutely flat base with
a bearing capacity adequate to the weight class of the generator. When using a
belt drive, it is advisable to mount the generator adjustable. For that purpose
e.g. mounting rails can be used, providing the possibility of adjusting the belt
tension.
All generators are splash-proof according to IP54 specifications and can thus
also be mounted and used outdoor. The generators are not explosion-protected
and thus must no be used in explosive atmospheres. Further regulations on this
have to be observed!

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Synchronous Generators BG 132 / BG 160
Safety precautions

When selecting the place of installation and use, the required minimum
clearances have to be observed, adequate ventilation has to be ensured at any
time, and the temperature of the cooling air must not exceed 40 °C. Further
information can be found in chapter 4 on page 27.
The generators and the parts mounted to them must not be sprayed with high-
pressure cleaners. Therefore, the generators should preferably be installed in a
way and place which makes it impossible to even inadvertently spray the
generator with high-pressure cleaners.

Safety precautions
This section summarizes the safety precautions of relevance. Read and
understand the safety precautions before installing, commissioning and
operating the generator and observe the precautions. You will find the safety
precautions in the relevant passages through the manual as well.


Work on electrical installations and equipment may only be
performed by adequately trained qualified personnel and in
conformity with the applicable national rules and regulations
(in Germany: VDE regulations, among others).
DANGER
Risk of Work on electrical installations and equipment may only be
personal injury
or death
performed in the off and de-energized state. Mortal danger by
and electric shock! Engines that have been turned off must be
destruction
hazard
secured against accidental restarting (e.g. by removing the
ignition key and keeping it safe)!
Installation and commissioning of the generator as well as any
maintenance, service and replacement work may only be
performed by authorized and qualified personnel.
Do not operate the generator in explosive environments.
Further regulations on this have to be observed!
Do not perform any visual inspections for maintenance
purposes and cleaning work on the generator during operation.
Always turn off the engine first and make sure that it cannot be
restarted accidentally (e.g. by removing the ignition key and
keeping it safe). Mortal danger by electric shock!

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Synchronous Generators BG 132 / BG 160
Safety precautions


Never connect the generator to the public electricity supply
network or to any other systems for power generation. Risk of
death, fire and destruction hazard!
DANGER Never connect several generators to each other. Risk of death,
Risk of fire and destruction hazard!
personal injury
or death If the generator shall be connected to an existing power
and
destruction distribution network (e.g. a house wiring), it has to be
hazard ensured, that the system is completely and reliably
disconnected from the public electricity supply network of the
energy supply company. Reverse feeding into the public
electricity supply network or network interconnection is not
allowed. Reverse feeding involves mortal danger by electric
shock for persons possibly working at the de-energized public
electricity supply network. Due to network interconnection
with the public electricity supply network, the generator can be
damaged, burn or cause fire in electrical cables of the system.
Grounding the neutral conductor of the generator (N, midpoint
conductor) supersedes the protective measure "protection
separation" and should therefore be avoided. If the neutral
conductor N shall be grounded anyway, this may only be
performed by an electrically qualified person. In this case, a
current-operated earth-leakage circuit breaker has to be
connected on the load side of the generator output. The
efficiency of the electrical protective measure has to be
confirmed by an appropriate measurement.
The generator supplies highly dangerous voltages during
operation! Never touch the generator or the devices connected
to the generator with wet hands during operation. Mortal
danger by electric shock!
Generator components may be very hot, not just during but also
after operation. Burning hazard!
The generator may only be operated with the protective covers
for the drive mounted as specified. Risk of personal injury!

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Synchronous Generators BG 132 / BG 160
Safety precautions


Be sure to read and understand the operating instructions
completely before using the generator. The generator may only
be used for applications described in section "Proper use"
above and in conformity with the specifications in this manual.
DANGER
Risk of Before connecting devices to the generator, ensure that the
personal injury
or death
devices are switched off. Accident hazard! Unsupervised
and starting devices can endanger or injure persons as well as cause
destruction
hazard
damages or damage themselves.
Infants and animals must never have admittance to the
generator, not just during but also after operation. Make
appropriate precautions. Mortal danger by electric shock, injury
and burning hazard!
The generator or its components must never be
exposed to the jet of high-pressure cleaners.
Mortal danger by electric shock and
destruction hazard!

Be sure to observe the permissible operating conditions given in


section 5.2 on page 75. The generator may only be operated in
conformity with the operating conditions and data specified there.
This particularly applies to the ambient and cooling conditions and
CAUTION the permissible current load.
Destruction
hazard
For installation and repair only genuine components or external
or components expressly approved by the manufacturer may be used.
damage
It is not permitted to perform any modifications on the generator
or on individual components or the control box. Any modification,
improper repair or use of unsuitable external components will
terminate all and any claims under a warranty as well as the type
approval according to the German Equipment Safety Law and the
certification to EU / EEC directives. In this case the manufacturer
will not assume any liability.

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Synchronous Generators BG 132 / BG 160
Safety precautions

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Synchronous Generators BG 132 / BG 160
Chapter 1, Designation system for generator types

1 Designation system for generator types


This chapter provides information about the designation system for the
individual generator types as well as examples of generator designations.

1.1 Type codes


DWG (BL) 17 / 7,0 - 2ZE

E: Electronic generator governor


Z: Two-bearing design
E: Single-bearing design
Number of poles:
2 poles (rated speed 3000 rpm)
or
4 poles (rated speed 1500 rpm)
Single-phase output power in kVA, e.g. 7 kVA
Three-phase output power in kVA, e.g. 17 kVA.
Power determines size:
• 2-pole generator: up to 17 kVA = BG 132,
20 kVA and higher = BG 160
• 4-pole generator: 10 kVA and higher = BG 160
With specification (BL): Brushless generator
Without specification (BL): Brush-type generator
DWG: Three-phase AC generator
WG: Single-phase AC generator
DGG: Three-phase DC generator

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Synchronous Generators BG 132 / BG 160
Chapter 1, Designation system for generator types

1.2 Examples for designations


Type Features
DWG 8,0/5,0-2EE Three-phase AC generator, brush-type machine, 8 kVA
three-phase power, 5 kVA single-phase power, 2-pole
machine, single-bearing design, electronic governor, size
BG 132 (2-pole generator < 17 kVA).
DWG (BL) 10/6-4ZE Three-phase AC generator, brushless, 10 kVA three-phase
power, 6 kVA single-phase power, 4-pole machine, two-
bearing design, electronic governor, size BG 160 (10 kVA,
4-pole generator).

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2 Description
2.1 Use of different sizes (BG 132 and BG 160)
Depending on the rated output power and the number of poles the generators
are produced in two different sizes: BG 132 or BG 160.
BG 132
Size BG 132 is used for
• 2-pole generators (driving speed 3000 rpm) with rated power outputs smaller
than 17 kVA.

BG 160
Size BG 160 is used for
• 2-pole generators (driving speed 3000 rpm) with rated power outputs greater
than and including 20 kVA or
• 4-pole generators (driving speed 1500 rpm) with rated power outputs greater
than and including 10 kVA.

2.2 Overview of features and options for different sizes and


designs

The following table shows an overview of features and possible options for the
different generator sizes and types.
Key for the table:
x = possible or "yes"
- = not possible or "no"

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

Version / Option BG 132 BG 160


2-pole up to 2-pole ≥ 20 kVA
17 kVA 4-pole ≥ 10 kVA
1-bear. 2-bear. 2-bearing
Generator directly mounted to x - -
engine
Engine-/manufacturer-depending x - -
sealing betw. engine and generator
Direct coupling via flange - x x
Belt or hydraulic drive - x x
Brushless Generator x x x
Brush-type generator x x -
Supply without terminal box, x x x
cable directly lead out in a hose
Terminal box mounted, x x x
no governor/filter functions
Terminal box mounted, x x x
governor/filter functions partly
implemented
Terminal box mounted, x x x
governor/filter functions completely
implemented
Option "Expanded generator x x x
governor with no-load automatic"
Control box mounted, x1 x1 -
aluminum cast or sheet metal
Option hour meter in control box x1 x1 -

Option insulation monitoring in x1 x1 -


control box
1. Only available for versions with rated power output of 8 kVA or 13 kVA.

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.3 General functionality


All generators of these series are self-excited synchronous inner-pole generators.
The generator consists of the functional groups main machine, exciter and
rotating rectifier mounted in a common housing. The electronic generator
governor can be placed in a terminal box mounted on the generator, an external
control box or in the optional control box mounted on the generator instead of
the terminal box.
Due to various constructional measures, an amortisseur and a balancing control
the generators have an extreme asymmetric load capability.
Cooling of the generators is performed by a rotating direction-independent self-
ventilation. For this purpose, the cooling air is sucked on the rear side by a fan
impeller and then blown to the front outside along the generator.
The supplied generator voltage is regulated by the electronic generator governor,
so that the output voltage fulfills the requirements of IEC 38 for the entire range
between no-load and rated load condition. This corresponds to the quality
standard of the public electricity supply network. The output frequency
constancy depends on the speed constancy of the engine.
In case of short generator overload conditions (below the reaction time of the
circuit breakers) or if devices with a too high power consumption or a too high
starting power are connected to the generator, the generator governor
automatically limits the output power (by limiting the exciter field current) and
reduces the output voltage.
Optionally an expanded generator governor with no-load automatic is available.
Further information about the generator governor can be found in section 2.4 on
page 17.
If the generator is not equipped with the option "Insulation monitoring with
switching-off", it fulfills the protective measure "Protection separation with
equipotential bonding" according to VDE 0100 part 728. The used power system
is the IT system with neutral conductor N and equipotential bonding conductor
PE (see Figure 1).
If the generator is equipped with the option "Insulation monitoring with
switching-off", it fulfills the better protective measure "Protection separation
with insulation monitoring" according to VDE 0100, part 728.
The generators of this series comply with the EMC regulations EN ISO 14982, ISO
TC 127 / ISO FDIS 13766 / DIN EN 13909 and further EMC regulations referenced
in these regulations.

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

L1
L2
L3
N
PE
Generator

Load

Figure 1 Power system of the generator: Principle diagram for protection


separation

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.4 Generator governor

Figure 2 Generator governor LCAR3LIM for brush-type generators


(simplified schematic representation)

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

Figure 3 Generator governor LCAR3LIM for brushless generators


(simplified schematic representation)

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.5 Mechanical designs


Depending on the rated power output and the number of poles the generators
are produced in two different sizes: BG 132 or BG 160.
Size BG 132 is used for 2-pole generators with rated power outputs up to 17
kVA. These generators are available as brushless type or with carbon brushes.
Depending on the kind of use, generators of the size BG 132 can either be built
as single-bearing generators or as two-bearing generators. Single-bearing
generators are directly mounted to the engine. In this case the engine bearing is
used as second bearing.
Size BG 160 is used for
• 2-pole generators with rated power outputs starting from 20 kVA or for
• 4-pole generators with rated power outputs starting from 10 kVA.
Generators of the size BG 160 are exclusively available as brushless generators
and are only produced as two-bearing generators.
Two-bearing generators are usually installed right next to the engine. Regarding
the generator drive, there are various options to choose from (refer to section
2.6 on page 21).
To cover a wide range of applications, the generators can be delivered in
different versions regarding the electrical connection.
• Generator with terminal box mounted (standard type):
The terminal box mounted on the generator contains a connection terminal
plate for the connecting cables as well as the generator governor.
Furthermore, a suppression filter can be installed in the terminal box.
However, the suppression filter can also be located in an external control
cabinet, if desired. Further information about the terminal box can be found
in section 2.7 on page 22.
• Cable directly lead out of the generator in a hose without a terminal box
mounted:
For this version, all connecting cables of the generator as well as the cables
for the generator governor are led out of the generator housing using a hose.
This version offers the special advantage, that the generator can also be used
in relatively hot environments. In this case, the generator governor as well as
the complete current distribution and the electrical fuse protection has to be
installed in an external control cabinet.

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

• Generator with a control box mounted (only applicable for 8 kVA and 13 kVA
versions):
In the standard version the control box optionally mounted on the generator
contains the generator governor, a suppression filter, the sockets for
connecting the loads as well as an all-pole circuit breaker for protecting the
installed sockets against overcurrent and short-circuit. As additional options
an hour meter and an insulation monitoring can be installed. Further
information about the optional control box can be found in section 2.8 on
page 23.

Terminal box

Drive shaft

Mounting profile
(all around with 45°
spacing)
Drain hole for Cooling air intake
condensation water
(if available)
Fan impeller shroud
Angle brackets Cooling
(fitted on both sides) profiles

Drain hole for condensation water


(if available)

Figure 4 Two-bearing generator, size BG 132 with terminal box

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.6 Drive types

2.6.1 Single-bearing generators (only BG 132)


Single-bearing generators are exclusively intended for direct mounting to the
engine. The shafts of the generator and the engine are directly connected to
each other and the bearing of the engine is used as second bearing for the
generator. Therefore, the generator always runs at the same speed as the engine.
With this type of drive, it has to be ensured that the engine has an appropriate
speed rating. Otherwise the generator is operated at underspeed or overspeed
which can restrict the functionality of the generator.
For information regarding the installation of the generator please refer to
chapter 4 on page 27.

2.6.2 Two-bearing generators


Two-bearing generators can be driven in different ways as described below. For
information regarding the installation of components necessary for the
corresponding type of driving, please refer to chapter 4 on page 27.
Belt pulley drive
The generator is mechanically connected to the engine via a belt pulley and a
belt. The belt drive is a particularly simple and inexpensive type of drive.
Moreover it offers the advantage that the speeds of the engine and the generator
can be optimally balanced by selecting the transmission ratio.
Direct coupling of the generator via flange
Using direct flange mounting, the shafts of the generator and the engine are
connected by a flange. Therefore, the generator always runs at the same speed as
the engine. With this type of drive, it has to be ensured that the engine has an
appropriate speed rating. Otherwise the generator is operated at underspeed or
overspeed which can restrict the functionality of the generator.
Hydraulic motor drive
In this case, the generator is driven by a hydraulic motor supplied from a
hydraulic system. When using this type of drive, attention must be particularly
drawn to the fact that the generator is not operated at overspeed. This may have
adverse effects on the functionality of the generator as well.

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.7 Terminal box (standard version)


The terminal box mounted to the generator contains a connection terminal plate
for the connecting cables. Inside the terminal box cover the completely sealed-
in generator governor is installed. The terminal box can furthermore contain a
suppression filter which, however, can also be placed in an external control
cabinet, if desired.
The generator governor in the terminal box cover can also be replaced by an
optionally available expanded generator governor with a no-load automatic
function. Further information about this can be found in section 2.4 on page 17.

Generator governor

Connection terminal plate

Terminal box
Suppression filter (optional)

Figure 5 Terminal box with connection terminal plate, generator governor


and suppression filter

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.8 Control box (optional, only for 8 kVA and 13 kVA generators)

2.8.1 General
The control box mounted on the generator is only available for generators with
rated power outputs of 8 kVA and 13 kVA. In the standard version it contains the
generator governor, a suppression filter, the sockets for connecting the loads as
well as an all-pole circuit breaker for protecting the installed sockets against
overcurrent and short-circuit. As additional options an hour meter and an
insulation monitoring with switching-off can be installed.
The generator governor in the control box can also be replaced by an optional
expanded generator governor with no-load automatic function. Further
information about this can be found in section 2.4 on page 17.

Hour meter Insulation monitoring unit Circuit breaker


(optional) (optional) (4-pole)

Sockets 230 V
Socket 400 V

Figure 6 Control box with installed options hour meter and insulation
monitoring

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Synchronous Generators BG 132 / BG 160
Chapter 2, Description

2.8.2 Option insulation monitoring with switching-off


If the generator is equipped with the option "Insulation monitoring with
switching-off", it fulfills the protective measure "Protection separation with
insulation monitoring" according to VDE 0100, part 728.
The insulation monitoring unit (see Figure 6) monitors the insulation of the
devices connected to the sockets. If it detects a defective insulation of a
connected device or extension cord, the insulation monitoring unit immediately
switches off all sockets and the red signal lamp "FAULTY INSULATION" lights up
to indicate the fault. In this case the defective device has to be disconnected
and taken out of operation and the insulation monitoring unit has to be reset.
Generators which are equipped with an insulation monitoring unit
must not be connected to further insulation monitoring units,
since the insulation monitoring units can mutually interact.

CAUTION

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Synchronous Generators BG 132 / BG 160
Chapter 3, Technical data

3 Technical data
3.1 Generators
The technical data of the generator can be found on the type plate mounted on
the generator.

3.2 Control box (optional, only for 8 kVA and 13 kVA generators)
Type of enclosure IP54 (all covers closed and locked)
Connectors 1 CEE socket 5 x 16 A (3P + N + PE)
3 protective contact sockets 16 A (1P + N + PE)
Features 4-pole circuit breaker B 16 A
Governor, filter and noise suppression installed
Optional features Hour meter
Insulation monitoring unit with signal lamp
Fulfills protective measure "Protection separation
with insulation monitoring" according to DVGW 308
Permissible length of Total length of all connected cables:
connected cables 250 m max. at conductor cross section 2.5 mm2
100 m max. at conductor cross section 1.5 mm2

3.3 Generator governor


Governor type LCAR3
Pin assignment Pin Color Function
1 red F1
2 gray F2
3 yellow 1/2 U
4 yellow 1/2 V
5 yellow 1/2 W
6

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Chapter 3, Technical data

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Synchronous Generators BG 132 / BG 160
Chapter 4: 4.1 Safety precautions for installation

4 Installation
The installation procedures may differ depending on the generator version and
type. Where applicable, such differences are mentioned in the concerning texts.
Prior to installation of the generator, read and understand the safety precautions
in section 4.1 as well as all other applicable sections of this chapter and observe
the instructions and information given therein.
The installation work described in this chapter
may only be performed by authorized and
qualified personnel.
Do not open or disassemble the generator and/or
CAUTION
the control box mounted on the generator
(depending on the version)! The generator may
only be opened by the manufacturer or an agency
authorized by the manufacturer. It is not allowed
to perform any work or operations not described
in this manual.

4.1 Safety precautions for installation


Work on electrical installations and equipment may only be
performed by adequately trained qualified personnel and in
conformity with the applicable national rules and regulations
(in Germany: VDE regulations, among others).
DANGER
Work on electrical installations and equipment may only be
performed in the off and de-energized state. Mortal danger by
electric shock!
Engines that have been turned off have to be secured against
accidental restarting (e.g. by removing the ignition key and
keeping it safe)!
Installation of the generator as well as any maintenance,
service and replacement work may only be performed by
authorized and qualified personnel.
Never connect the generator to the public electricity supply
network or to any other systems for power generation. Risk of
death, fire and destruction hazard!

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Synchronous Generators BG 132 / BG 160
Chapter 4: 4.1 Safety precautions for installation


Never connect several generators to each other. Risk of death,
fire and destruction hazard!
Grounding the neutral conductor of the generator (N, midpoint
DANGER conductor) supersedes the protective measure "protection
separation" and should therefore be avoided. If the neutral
conductor N shall be grounded anyway, this may only be
performed by an electrically qualified person. In this case, a
current-operated earth-leakage circuit breaker has to be
connected on the load side of the generator output. The
efficiency of the electrical protective measure has to be
confirmed by an appropriate measurement.
The generator may only be operated with the protective covers
for the drive mounted as specified. Risk of personal injury!
Be sure to completely read and understand the operating
instructions before installing and using the generator. The
generator may only be used for applications described in
section "Proper use" and in conformity with the specifications
given in this manual.
For installation only genuine components or external components
expressly approved by the manufacturer may be used.
It is not permitted to perform any modifications on the generator
or on individual components or the control box. Any modification,
CAUTION
improper repair or use of unsuitable external components will
terminate all and any claims under a warranty as well as the type
approval according to the German Equipment Safety Law and the
certification to EU / EEC directives. In this case the manufacturer
will not assume any liability.

28 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.2 Requirements to be met by the place of installation and use

4.2 Requirements to be met by the place of installation and use


Single-bearing generators are mounted directly to the engine. These generators
may only be mounted to engines which comply with the applicable regulations,
rules and requirements.
Two-bearing generators are usually installed right next to the engine. The
generator has to be firmly and securely mounted on an absolutely flat base with
a bearing capacity adequate to the weight class of the generator. When using a
belt drive, it is advisable to mount the generator adjustable. For that purpose
e.g. mounting rails can be used, providing the possibility of adjusting the belt
tension.
All generators are splash-proof according to IP54 specifications and can thus
also be mounted and used outdoor. The generators are not explosion-protected
and thus must no be used in explosive atmospheres. Further regulations on this
have to be observed!
When selecting the place of installation and use, the required minimum
clearances have to be observed, adequate ventilation has to be ensured at any
time, and the temperature of the cooling air must not exceed 40 °C.
The generators and the parts mounted to them must not be sprayed with high-
pressure cleaners. Therefore, the generators should preferably be installed in a
way and place which makes it impossible to even inadvertently spray the
generator with high-pressure cleaners.

4.3 General regulations for installation


A correct and proper installation of the generator is a prerequisite for a safe,
reliable and error-free operation as well as the electrical and mechanical safety.
Usually the generators are operated with a counterclockwise direction of
rotation. In this case the output voltage has a "clockwise rotating field".
However, the generators can also be operated with a clockwise direction of
rotation. Then the output voltage has a "counterclockwise rotating field".
Due to the dynamic processes during the switching of electric loads, the engine
must have adequate power reserves and its governor system must be able to deal
with such processes.
The constructional form and design of the generator must not be changed.
Mounting surfaces must be precisely flat. Misalignments during installation have
to be avoided.

Issue date: August 2002 29


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.3 General regulations for installation

After installation, a test finger according to EN 60034, part 5, or a foreign part


with a diameter greater than 12 mm (e.g. a sphere) must not come in contact
with rotating parts, if a risk could result from this. Especially the protective
covers of the power transmission have to be constructed stable and mounted
firmly. It must not be possible to remove protective covers without using tools.
The cooling air must be supplied and eliminated in a way, that the accumulating
dissipation heat is eliminated definitively. Only harmless amounts of dust and
water may be sucked with the cooling air. Short-circuits of the air have to be
avoided.
Generators with a second shaft end must not be operated without a machine or
protective cover correctly installed to this end.
If the generator is not already equipped ex works with a control box containing
electric protection equipment and sockets, adequate fuse equipment has to be
installed in an external control cabinet to protect the circuits (sockets) against
overcurrent and short-circuit. Observe that the neutral conductor N has to be
fused as well. Consult the generator manufacturer GTS for the correct types and
nominal currents of the circuit breakers to be used. Further information about
this can be found in section 4.8 on page 70.
If the generator is not already equipped ex works with a control box containing
electric protection equipment and sockets, the generator, the control cabinet
and the complete electric installation have to be checked by visual inspection,
testing and measurement according to DIN VDE 0100, part 610, before bringing
the generator into operation for the first time.
Observe the specific installation rules and instructions for the individual
generator types listed in the following sections of this manual. There you
can also find particular installation notes for the different drive types of the
generators.
• Refer to section 4.5 on page 35 for single-bearing generators of the size
BG 132.
• Refer to section 4.6 on page 49 for two-bearing generators of the size
BG 132.
• Refer to section 4.7 on page 62 for two-bearing generators of the size
BG 160.
• Refer to section 4.8 on page 70 for notes and instructions concerning the
electrical connection of the generators.

30 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water

4.4 Permissible mounting positions and drain holes for cond. water

4.4.1 Permissible mounting positions for single-bearing


generators
Single-bearing generators are mounted directly to the ok
engine. Thus, a horizontal mounting position is
predetermined by the engine.
When ordering the generator, the position of the
terminal box has to be specified (or the position of
the cable lead-out or the control box, depending on ok
the version).
The following mounting positions are possible:
• Terminal box on top
ok
• Terminal box turned by 45° or 90° to the left or
to the right
No other mounting positions are permitted!

Issue date: August 2002 31


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water

4.4.2 Permissible mounting positions for two-bearing generators


(BG 132 and BG 160)
The generator has to be mounted on a horizontal flat ok
base standing on its angle brackets, as shown in
the accompanying figure.
When mounted in normal position, the terminal box
is positioned on the top of the generator (or the
cable lead-out or the control box, depending on the
version). ok

It is also possible to install the generator turned by


45° or 90° to the left or to the right, as shown in the
accompanying figure. For this purpose, the angle
brackets have to be removed and mounted again to
the corresponding mounting profiles. ok

No other mounting position is permitted! no

no

no

32 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water

4.4.3 Drain holes for condensation water (BG 132 and BG 160)

NOTE This section is only applicable, if drain holes are available in the
generator housing.
The drain holes for condensation water are not available at all
generators. Depending on the intended field of application of the
generator, these holes can also be missing. In case of doubt, please
check the generator.

Under unfortunate circumstances, possibly


condensation water can occur inside the
generator. To provide an outlet for this
condensation water, the generator housing
possibly has several drain holes (4 holes
each on the front and on the rear, 90°
spacing).
If these drain holes are available in the
housing, the holes at the lowest point in
mounting position has always to be
opened.
All other holes (on both sides and on the
top) have to be closed by screws.
NOTE: The holes on the rear side are
covered by the fan impeller shroud. The
holes are only accessible after removing Max. thread length 8 mm!
the shroud.

Make sure that the two drain holes located


on the bottom are opened. If necessary,
remove the screws to open the
condensation water drain holes.

Issue date: August 2002 33


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water

Make sure that the holes on both sides and


on the top are closed with screws.

If you are installing the generator turned


from the mid position, remove the screws
from the holes located at the bottom side
in order to open the condensation water
drain holes and then use these screws to
close the open holes which are now
located on the side.

34 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4.5 Installation for single-bearing generators


For installing the generator proceed according to the descriptions in this section
4.5. Prior to installation, read and understand the safety precautions in section
4.1 as well as the sections 4.2 to 4.4 and observe the instructions and
information given there.
Optionally, lifting eye bolts are provided on the top or on both sides of the
generator (45° from the vertical) for attaching lifting equipment. Lifting
equipment may only be attached to the generator using these lifting eye bolts.
Only appropriate lifting equipment may be used.

4.5.1 Scope of delivery (single-bearing generators)


The scope of delivery may differ depending on the generator version and the
engine type. The type of sealing against the engine depends on the engine/
manufacturer. For this reason, the appropriate sealings have to be ordered
together with the generator.

4.5.2 Dimensions (single-bearing generators)


The dimensions of the generator can be found in the drawing sheet included in
the annex.
No other parts may be mounted to the mounting
profiles of the generator housing.

CAUTION

4.5.3 Minimum clearances and regulations for cooling (single-


bearing generators)
In order to provide sufficient cooling the generator needs adequate ventilation.
The cooling air is sucked on the rear side by the fan impeller and then blown to
the front side through the cooling profiles along the housing. If necessary,
adequate openings for cooling air inlet and outlet have to be provided.
It is absolutely important to observe the following regulations for minimum
clearances and cooling.

Issue date: August 2002 35


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

Minimum clearances (single-bearing)


The following minimum clearances towards
a
parts or walls have to be observed for
installation (see also the accompanying a a
figures on the right): b

• All sides: a = 100 mm


• Rear side: b = 170 mm
Cooling (single-bearing)
It is absolutely important to observe the
following regulations for cooling. Danger b
of overheating! Pmax = 4 Pa
The temperature of the supplied cooling air
must not exceed 40 °C.
In the cooling air intake area on the rear
side of the generator a maximum partial
vacuum of Pmax = 4 Pa may arise. Pmax = 7 Pa
Otherwise the fan impeller cannot suck
enough cooling air.
In the cooling air blow out area on the
front side of the generator a maximum
overpressure of Pmax = 7 Pa may arise.
Otherwise the circulation of the cooling air
is not sufficient.
Cooling air circulation must not be
impaired by other air flows (e.g.
directed from the side or from the front
to the generator).

36 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4.5.4 Installation to the engine (single-bearing generators)


The minimum clearances and regulations for cooling given in the section above
have to be met for installation.

4.5.4.1 Sealing of the generator against the engine


During installation a sealing has to be attached between the generator and the
engine. The type of sealing depends on the used engine. The sealings prescribed
for the different engines are listed in the following table.

Engine Type of sealing Installation instructions


B&S 12.5 HP / 14 HP VE1/877 or VE1/977 Press the sealing into the
shaft opening in the end
shield.

Honda GX 390 K1V VE1/871 Bond the sealing into the


corresponding clearance in the
Yamaha MZ 360 K
end shield.

Yanmar L90 / L100 Fluid sealing Apply liquid sealant into the
corresponding clearance in the
end shield.

Hatz 1D 60C No sealing required.

Issue date: August 2002 37


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4.5.4.2 Installation of brush-type generators

Removal prior to installation and removal of the carbon brushes holder


1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 7/2) and
detach the sleeve (1).

2. Remove both connection cables from the connection lugs of the carbon
brushes holder (4). The connection cables are coded by the width of the
connection lugs and therefore secured against interchanging.

3. Unscrew the fastening screw of the carbon brushes holder and detach the
carbon brushes holder (4).

4. Pull out the transport locking (wooden chock).

5. Remove the fan impeller shroud (3) from the generator.

1 2

Flange represented
turned by 45°

Figure 7 Removal prior to installation of single-bearing brush-type


generators

38 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

Installation

NOTE For differing installation instructions for shaft fastening by tension


bolt (instead of the grub-screw described here), please refer to
section 4.5.4.4 on page 45.

1. Screw the supplied grub-screw (Figure 8/1) into the engine shaft as far as it
will go using an Allen wrench.

2. Apply the sealing to the front end shield of the generator as described in
section 4.5.4.1 on page 37.

3. Align the generator in front of the engine in a way, that the generator shaft
lies in one line with the engine shaft. If necessary, support the generator
accordingly.

4. Push the generator against the engine flange and align the threaded hole of
the generator shaft with the grub-screw screwed into the engine shaft.

5. Screw the generator shaft by turning the fan impeller onto the grub-screw in
the engine shaft as far as it will go. This pulls the generator against the
engine flange.

NOTE While screwing the generator shaft onto the grub-screw, align
the mounting holes in the end shield with the drillings in the
engine flange.
It is not necessary to tighten the generator shaft on the grub-
screw. It is sufficient, if the shaft is screwed onto the grub-
screw as far as it will go, since the screw-connection tightens
itself when the generator is loaded.
For installation instructions for shaft fastening by tension bolt,
please refer to section 4.5.4.4 on page 45.

6. Fasten the generator's end shield to the engine flange using four fastening
screws (Figure 8/2).

Issue date: August 2002 39


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

1 Apply appropriate sealing


depending on the engine

4x
2

Figure 8 Installation of single-bearing brush-type generators to the


engine

7. Insert the carbon brushes holder (Figure 9/4) correctly positioned into the
generator and press it on to the collector rings on the shaft, so that the
carbon brushes are pressed into the carbon brushes holder and the carbon
brushes holder lies on its mounting base.

8. Continue to press on the carbon brushes holder and screw in the fastening
screw, but do not tighten it completely. While screwing in the fastening
screw, the carbon brushes holder is automatically positioned on the
mounting base.

9. Check the proper seating of the carbon brushes holder and then tighten the
fastening screw.

10. Plug both connection cables onto the connection lugs of the carbon brushes
holder according to the width of the connectors.

40 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

11. Remount the sleeve (Figure 9/3) and fasten it by tightening the two screws
(2).

12. Remount the fan impeller shroud (Figure 9/1).

Flange represented
turned by 45°
1

4 2

Figure 9 Installing the carbon brushes holder

Issue date: August 2002 41


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4.5.4.3 Installation of brushless generators

Removal prior to installation


1. Remove the fan impeller shroud (Figure 10/1) from the generator.

2. Unscrew the four fastening screws (3) at the generator and detach the front
end shield (2).

2
1

Figure 10 Removal prior to installation of brushless single-bearing


generators

42 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

Installation

NOTE For additional installation instructions for shaft fastening by


tension bolt (instead of the grub-screw described here), please
refer to section 4.5.4.4 on page 45.

1. Screw the supplied grub-screw (Figure 11/1) into the engine shaft as far as it
will go using an Allen wrench.

2. Apply the sealing to the removed front end shield of the generator as
described in section 4.5.4.1 on page 37.

3. Set the removed front end shield (Figure 11/2) with the sealing applied onto
the engine flange and fasten it using the four screws (Figure 11/3).

4. Align the generator in front of the engine in a way, that the generator shaft
lies in one line with the engine shaft. If necessary, support the generator
accordingly.

5. Push the generator against the engine and align the threaded hole of the
generator shaft to the grub-screw screwed into the engine shaft.

6. Screw the generator shaft by turning the fan impeller onto the grub-screw in
the engine shaft as far as it will go. This pulls the generator housing against
the front end shield already mounted on the engine.

NOTE While screwing the generator shaft onto the grub-screw, align
the generator with the front end shield mounted on the engine.
It is not necessary to tighten the generator shaft on the grub-
screw. It is sufficient, if the shaft is screwed onto the grub-
screw as far as it will go, since the screw-connection tightens
itself when the generator is loaded.
For installation instructions for shaft fastening by tension bolt,
please refer to section 4.5.4.4 on page 45.

7. Fasten the end shield to the generator using four fastening screws (Figure
12/2).

8. Remount the fan impeller shroud (Figure 12/1).

Issue date: August 2002 43


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

1
Apply appropriate sealing
depending on the engine

3 4x

Figure 11 Installation of brushless single-bearing generators to the


engine (1)

2 4x

Figure 12 Installation of brushless single-bearing generators to the


engine (2)

44 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4.5.4.4 Additional installation instructions for shaft fastening by


tension bolt
Instead of the grub-screw described in the sections 4.5.4.2 and 4.5.4.3,
optionally a tension bolt can be used to connect the shafts. In this case the
generator shaft is drilled hollow.
In this case proceed as follows instead of using the particular installation
instructions.

When installing single-bearing brush-type generators


The following descriptions assume that you have already performed the removal
prior to installation and the removal of the carbon brushes holder according to
section 4.5.4.2 on page 38.
The steps listed here replace the steps 1. to 6. on page 39.
1. Apply the sealing to the front end shield of the generator as described in
section 4.5.4.1 on page 37 (see also Figure 13).

2. As shown in Figure 13, align the generator in front of the engine in a way,
that the generator shaft lies in one line with the engine shaft. If necessary,
support the generator accordingly.

3. Push the generator against the engine flange, so that the shafts hit each
other.

4. Insert the tension bolt (Figure 13/1) from the rear side through the generator
shaft and screw it into the engine shaft, but do not yet tighten it.

NOTE While screwing in the tension bolt, align the mounting holes in
the end shield of the generator according to the drillings in the
engine flange.

5. Fasten the end shield of the generator to the engine flange using four
fastening screws (Figure 13/2).

6. Secure the engine shaft against twisting and tighten the tension bolt.

7. Continue with the further steps described in section 4.5.4.2: Start with step
7. on page 40.

Issue date: August 2002 45


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

Apply appropriate sealing


depending on the engine

2 4x

Figure 13 Installation of single-bearing brush-type generators fastened


with tension bolt

When installing brushless single-bearing generators


The following descriptions assume that you have already performed the removal
prior to installation according to section 4.5.4.3 on page 42.
The steps listed here replace the steps 1. to 8. on page 43.
1. Apply the sealing to the removed front end shield of the generator as
described in section 4.5.4.1 on page 37 (see also Figure 14).

2. Set the removed front end shield with the sealing applied onto the engine
flange and fasten it using the four screws (Figure 14/2).

3. As shown in Figure 14, align the generator in front of the engine in a way,
that the generator shaft lies in one line with the engine shaft. If necessary,
support the generator accordingly.

46 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

4. Push the generator against the engine, so that the shafts hit each other.

5. Insert the tension bolt (Figure 14/1) from the rear side through the generator
shaft and screw it into the engine shaft, but do not yet tighten it. By
screwing in the tension bolt, the generator shaft is pushed onto the engine
shaft.

NOTE While screwing in the tension bolt, align the generator


according to the front end shield mounted at the engine.

6. Fasten the end shield to the generator using four fastening screws (Figure
15/2).

7. Secure the engine shaft against twisting and tighten the tension bolt. Be
sure to use the correct torque! Please contact the manufacturer, if you do not
know the correct torque for the tension bolt.

8. Remount the fan impeller shroud (Figure 15/1).

Apply appropriate sealing


depending on the engine

1
4x
2

Figure 14 Installation of brushless single-bearing generators with tension


bolt (1)

Issue date: August 2002 47


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.5 Installation for single-bearing generators

2 4x

Figure 15 Installation of brushless single-bearing generators with tension


bolt (2)

48 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6 Installation of two-bearing generators (BG 132)


For installing two-bearing generators of the size BG 132 proceed according to
the descriptions in this section 4.6. Prior to installation, read and understand
the safety precautions in section 4.1 as well as the sections 4.2 to 4.4 and
observe the instructions and information given there.
On both sides of the generator, a lifting eye bolt is provided for
attaching lifting equipment. Lifting equipment may only be
attached to the generator using these lifting eye bolts. Only
appropriate lifting equipment may be used.
CAUTION

4.6.1 Dimensions and mounting (two-bearing type, BG 132)


The minimum clearances and regulations for cooling given in the following
section 4.6.2 have to be met for installation.
The dimensions of the generator can be found in the drawing sheet included in
the annex.
The generator has to be fastened using four
screws (min. requirements: M8 or
comparable, quality 8.8). The fastening must
be durable as well as shock and vibration
resistant. The screws must be secured
against self-acting unscrewing by suitable
measures, e.g. a clamp collar according to 4 fastening screws
DIN 128.
Tightening torque for fastening screws:
M = 25 Nm

Issue date: August 2002 49


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

Permissible load on the shaft: Frmax


• Standard end shield (shaft ø 28 mm):
Frmax = 2000 N (measured at an axial Famax

distance of 50 mm from the shaft outlet


in the end shield)
Famax = 200 N
• Reinforced end shield (shaft ø 32 mm):
Frmax = 3800 N (measured at an axial
distance of 50 mm from the shaft outlet
in the end shield)
Famax = 380 N

No other parts may be mounted to the mounting


profiles of the generator housing.

CAUTION

4.6.2 Minimum clearances and regulations for cooling (two-


bearing types, BG 132)
In order to provide sufficient cooling the generator needs adequate ventilation.
The cooling air is sucked on the rear side by the fan impeller and then blown to
the front side through the cooling profiles along the housing. If necessary,
adequate openings for cooling air inlet and outlet have to be provided.
It is absolutely important to observe the following regulations for minimum
clearances and cooling.

50 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

Minimum clearances (BG 132, two-


bearing types)
a
The following minimum clearances towards
parts or walls have to be observed for a a
installation (see also the accompanying b
figures on the right):
• Both sides and top: a = 100 mm
• Front side: b = 200 mm
• Rear side: c = 170 mm
Cooling (BG 132, two-bearing types) b

It is absolutely important to observe the Pmax = 4 Pa


following regulations for cooling. Danger
of overheating!
The temperature of the supplied cooling air
must not exceed 40 °C.
Pmax = 7 Pa
In the cooling air intake area on the rear
side of the generator a maximum partial c
vacuum of Pmax = 4 Pa may arise.
Otherwise the fan impeller cannot suck
enough cooling air.
In the cooling air blow out area on the
front side of the generator a maximum
overpressure of Pmax = 7 Pa may arise.
Otherwise the circulation of the cooling air
is not sufficient.
Cooling air circulation must not be
impaired by other air flows (e.g.
directed from the side or from the front
to the generator).

Issue date: August 2002 51


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6.3 Installation instructions for belt drive (two-bearing


types, BG 132)


Belt pulleys and belts must be covered by a
protective cover. Never operate the generator
without the protective covers correctly
mounted. Risk of personal injury!
DANGER
Never touch a running belt. Risk of personal
injury!
Do not knock the belt pulley onto the shaft.
Taper bushes must be preferred for fastening.

CAUTION

To prevent the belt pulley against twisting,


it is protected on the shaft by a feathered
key. The belt pulley is fastened by a screw to
the front end of the shaft. This screw has to
be protected against accidental loosening
using a suitable lock washer.
• Threaded hole in the shaft:
M10 x 22 mm
• Tightening torque: M = 50 Nm

The axis of the driving shaft must be


absolutely parallel to the shaft of the
generator.
The belt pulleys on both shafts must be
flush to each other so that the belt runs
absolutely straight.

52 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

The belt must not sag loosely.


When using slim SPA-type V-belts, the
distance between the shafts must not
exceed 600 mm. Permissible shaft distances
for other belts can be obtained from the
manufacturer.
Fmax
Maximum tractive force (tension) of the
drive belt on the shaft:
• Fmax = 2000 N for standard end shield
(shaft ø 28 mm)
• Fmax = 3800 N for reinforced end shield lmax
(shaft ø 32 mm)
The specified maximum tractive force is
applicable at an axial distance of max. 50
mm from the shaft outlet in the end shield.
If the belt is to be mounted with a greater
distance to the end shield, the belt tension
must be reduced in order to compensate the
higher leverage to the shaft.
Type and number of used belts
The type and number of used belts have to
be adapted to the power of the generator.
The maximum belt tension force has to be
observed!

Issue date: August 2002 53


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6.4 Installation instructions for flange mounting (two-bearing


types, BG 132)

4.6.4.1 Flange mounting for BG 132 with standard end shield

Removal prior to installation


1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 16/2) and
detach the sleeve (1).

2. Unscrew the four screws M12 x 12 (3) and detach them together with the
washers.

1
2

3 4x

Figure 16 Removal prior to installation for flange mounting (two-bearing


types, BG 132 with standard end shield)

54 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

Installation
1. Set the flange (Figure 17/1) onto the generator and fasten it using the four
screws (4a) with nuts (3a). Underlay the screw head with a blocking disk
(4b) and apply threadlocking adhesive to the thread of the screw. Underlay
the nuts with toothed disks (3b).

2. Remount the sleeve (Figure 17/2) and fasten it by tightening the two screws.

3. Plug the clutch-plate (5) onto the generator shaft and protect it against
twisting on the shaft by means of a feathered key.

4. Fasten the driving side of the clutch (6) to the engine and insert it into the
clutch-plate. When inserting, twist the clutch a little bit until the gearing
locks, if necessary.

5. Fasten the flange (1) to the engine.

4x

6 4a
5 4b

4x
3b
3a

Figure 17 Installation for flange mounting (two-bearing types, BG 132


with standard end shield)

Issue date: August 2002 55


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6.4.2 Flange mounting for BG 132 with reinforced end shield

Removal prior to installation


Unscrew the four headless setscrews M12 x 25 (Figure 18/1).

Figure 18 Removal prior to installation for flange mounting (two-bearing


types, BG 132 with reinforced end shield)

56 Issue date: August 2002


Synchronous Generators BG 132 / BG 160
Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

Installation
1. Set the flange (Figure 19/1) onto the generator and fasten it using the four
screws (2a). Underlay the screw head with a toothed disk (2b) and apply
threadlocking adhesive to the thread of the screw.

2. Plug the clutch-plate (3) onto the generator shaft and protect it against
twisting on the shaft by means of a feathered key.

3. Fasten the driving side of the clutch (4) to the engine and insert it into the
clutch-plate. When inserting, twist the clutch a little bit until the gearing
locks, if necessary.

4. Fasten the flange (1) to the engine.

4x

2a
4 2b
3

Figure 19 Installation for flange mounting (two-bearing types, BG 132


with reinforced end shield)

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Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6.5 Installation instructions for hydraulic drive (two-bearing


types, BG 132)

4.6.5.1 Hydraulic drive for BG 132 with standard end shield

Removal prior to installation


At the generator perform the removal prior to installation as described on page
54 (see Figure 16).

Installation
1. Set the flange (Figure 20/2) onto the generator and fasten it using the four
screws (4a) with nuts (3a). Underlay the screws with a blocking disk (4b) and
apply threadlocking adhesive to the thread of the screws. Underlay the nuts
with a toothed disk (3b).

2. Remount the sleeve (1) and fasten it by tightening the two screws.

3. Plug the first part of the clutch (5) onto the generator shaft and protect it
against twisting on the shaft by means of a feathered key.

4. Mount the disc (6) to the hydraulic motor (8).

5. Set the second part of the clutch (5) onto the hydraulic motor.

6. Set the hydraulic motor (8) together with the disc (6) and the second part of
the clutch onto the generator. When inserting, twist the clutch a little bit
until the gearing locks, if necessary.

7. Underlay the eight screws (7a) with a blocking disc (7b) and use them to
fasten the disc (6) to the flange (2).

8. Place the sleeve (9) to the clutch assembly and fasten it by tightening the
two screws.

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2x

1
9 8x

8 7a
7b 2
2x
6
4x
5
4a
4b

3b 4x
3a

Figure 20 Installation of the flange mounting for hydraulic drive (two-


bearing types, BG 132 with standard end shield)

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Chapter 4: 4.6 Installation of two-bearing generators (BG 132)

4.6.5.2 Hydraulic drive for BG 132 with reinforced end shield

Removal prior to installation


At the generator perform the removal prior to installation as described on page
56 (see Figure 18).

Installation
1. Set the flange (Figure 21/1) onto the generator and fasten it using the four
screws (2a). Underlay the screws with a blocking disk (2b) and apply
threadlocking adhesive to the thread of the screws.

2. Plug the first part of the clutch (3) onto the generator shaft and protect it
against twisting on the shaft by means of a feathered key.

3. Mount the disc (4) to the hydraulic motor (6).

4. Set the second part of the clutch (3) onto the hydraulic motor.

5. Set the hydraulic motor (6) together with the disc (4) and the second part of
the clutch onto the generator. When inserting, twist the clutch a little bit
until the gearing locks, if necessary.

6. Underlay the eight screws (5a) with a blocking disc (5b) and use them to
fasten the disc (4) to the flange (1).

7. Place the sleeve (7) to the clutch assembly and fasten it by tightening the
two screws.

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2x

7
8x
1
6 5a
5b 4x

4 2a
3 2b

Figure 21 Installation of the flange mounting for hydraulic drive (two-


bearing types, BG 132 with reinforced end shield)

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Chapter 4: 4.7 Installation of two-bearing generators (BG 160)

4.7 Installation of two-bearing generators (BG 160)


For installing generators of the size BG 160 proceed according to the
descriptions in this section 4.7. Prior to installation, read and understand the
safety precautions in section 4.1 as well as the sections 4.2 to 4.4 and observe
the instructions and information given there.
On both sides of the generator, a lifting eye bolt is provided for
attaching lifting equipment. Lifting equipment may only be
attached to the generator using these lifting eye bolts. Only
appropriate lifting equipment may be used.
CAUTION

4.7.1 Dimensions and mounting (BG 160)


The minimum clearances and regulations for cooling given in section 4.7.2 must
be met for installation. The dimensions of the generator can be found in the
drawing sheet included in the annex.
The generator has to be fastened using
four screws (min. requirements: M12 or
comparable, quality 8.8). The fastening
must be durable as well as shock and
vibration resistant. The screws must be
secured against self-acting unscrewing by
suitable measures, e.g. a clamp collar 4 fastening screws
according to DIN 128.
• Tightening torque for fastening screws: Frmax
M = 87 Nm
• Permissible load on the shaft: Famax
Frmax = 5000 N (measured at an axial
distance of 60 mm from the shaft
outlet in the end shield)
Famax = 500 N

No other parts may be mounted to the mounting


profiles of the generator housing.

CAUTION

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4.7.2 Minimum clearances and regulations for cooling (BG 160)


In order to provide sufficient cooling the generator needs adequate ventilation.
The cooling air is sucked on the rear side by the fan impeller and then blown to
the front side through the cooling profiles along the housing. If necessary,
adequate openings for cooling air inlet and outlet have to be provided.
It is absolutely important to observe the following regulations for minimum
clearances and cooling.
Minimum clearances (BG 160)
The following minimum clearances towards
parts or walls have to be observed for a
installation (see also the accompanying a a
figures on the right): b
• Both sides and top: a = 100 mm
• Front side: b = 300 mm
• Rear side: c = 200 mm
Cooling (BG 160)
It is absolutely important to observe the b
following regulations for cooling. Danger
of overheating! Pmax = 4 Pa

The temperature of the supplied cooling air


must not exceed 40 °C.
In the cooling air intake area on the rear Pmax = 7 Pa
side of the generator a maximum partial
vacuum of Pmax = 4 Pa may arise. c
Otherwise the fan impeller cannot suck
enough cooling air.
In the cooling air blow out area on the
front side of the generator a maximum
overpressure of Pmax = 7 Pa may arise.
Otherwise the circulation of the cooling air
is not sufficient.
Cooling air circulation must not be
impaired by other air flows (e.g.
directed from the side or from the front
to the generator).

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Chapter 4: 4.7 Installation of two-bearing generators (BG 160)

4.7.3 Installation instructions for belt drive (BG 160)


Belt pulleys and belts must be covered by a
protective cover. Never operate the generator
without the protective covers correctly
mounted. Risk of personal injury!
DANGER
Never touch a running belt. Risk of personal
injury!
Do not knock the belt pulley onto the shaft.
Taper bushes must be preferred for fastening.

CAUTION

To prevent the belt pulley against twisting,


it is protected on the shaft by a feathered
key. The belt pulley is fastened by a screw to
the front end of the shaft. This screw has to
be protected against accidental loosening
using a suitable lock washer.
• Threaded hole in the shaft:
M16 x 36 mm
• Tightening torque: M = 200 Nm

The axis of the driving shaft must be


absolutely parallel to the shaft of the
generator.
The belt pulleys on both shafts must be
flush to each other so that the belt runs
absolutely straight.

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The belt must not sag loosely.


When using slim SPA-type V-belts, the
distance between the shafts must not
exceed 800 mm. Permissible shaft distances
for other belts can be obtained from the
manufacturer.
Fmax
Maximum tractive force (tension) of the
drive belt on the shaft:
Fmax. = 5000 N at an axial distance of max.
60 mm from the shaft outlet in the end
shield. If the belt is to be mounted with a
greater distance to the end shield, the belt lmax
tension must be reduced in order to
compensate the higher leverage to the
shaft.

Type and number of used belts


The type and number of used belts have to
be adapted to the power of the generator.
The maximum belt tension force has to be
observed!

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Chapter 4: 4.7 Installation of two-bearing generators (BG 160)

4.7.4 Installation instructions for flange mounting (BG 160)

Removal prior to installation


Unscrew the four headless setscrews M12 x 25 (Figure 22/1).

Figure 22 Removal prior to installation for flange mounting (BG 160)

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Chapter 4: 4.7 Installation of two-bearing generators (BG 160)

Installation
1. Set the flange (Figure 23/1) onto the generator and fasten it using the four
screws (2a). Underlay the screw head with a toothed disk (2b) and apply
threadlocking adhesive to the thread of the screw.

2. Plug the clutch-plate (3) onto the generator shaft and protect it against
twisting on the shaft by means of a feathered key.

3. Fasten the driving side of the clutch (4) to the engine and insert it into the
clutch-plate. When inserting, twist the clutch a little bit until the gearing
locks, if necessary.

4. Fasten the flange (1) to the engine.

4x

2a
4 2b
3

Figure 23 Installation of the flange mounting (BG 160)

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Synchronous Generators BG 132 / BG 160
Chapter 4: 4.7 Installation of two-bearing generators (BG 160)

4.7.5 Installation instructions for hydraulic drive (BG 160)

Removal prior to installation


At the generator perform the removal prior to installation as described on page
66 (see Figure 22).

Installation
1. Set the flange (Figure 24/1) onto the generator and fasten it using the four
screws (2a). Underlay the screws with a blocking disk (2b) and apply
threadlocking adhesive to the thread of the screws.

2. Plug the first part of the clutch (3) onto the generator shaft and protect it
against twisting on the shaft by means of a feathered key.

3. Mount the disc (4) to the hydraulic motor (6).

4. Set the second part of the clutch (3) onto the hydraulic motor.

5. Set the hydraulic motor (6) together with the disc (4) and the second part of
the clutch onto the generator. When inserting, twist the clutch a little bit
until the gearing locks, if necessary.

6. Underlay the eight screws (5a) with a blocking disc (5b) and use them to
fasten the disc (4) to the flange (1).

7. Place the sleeve (7) to the clutch assembly and fasten it by tightening the
two screws.

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2x

7
8x
1
6 5a
5b 4x

4 2a
3 2b

Figure 24 Installation of the flange mounting for hydraulic drive (BG 160)

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Synchronous Generators BG 132 / BG 160
Chapter 4: 4.8 Electrical connection of the generators

4.8 Electrical connection of the generators


Prior to installation, read and understand the safety precautions in section 4.1
as well as the connection notes in this section 4.8 and observe the instructions
and information given there.
This section is only applicable for generators which are not equipped with a
control box ex works.


Work on electrical installations and equipment may only be
performed by adequately trained qualified personnel and in
conformity with the applicable national rules and regulations
(in Germany: VDE regulations, among others).
DANGER
Work on electrical installations and equipment may only be
performed in the off and de-energized state. Mortal danger by
electric shock!
Engines that have been turned off must be secured against
accidental restarting (e.g. by removing the ignition key and
keeping it safe)!
Grounding the neutral conductor of the generator (N, midpoint
conductor) supersedes the protective measure "protection
separation" and should therefore be avoided. If the neutral
conductor N shall be grounded anyway, this may only be
performed by an electrically qualified person. In this case, a
current-operated earth-leakage circuit breaker has to be
connected on the load side of the generator output. The
efficiency of the electrical protective measure has to be
confirmed by an appropriate measurement.

4.8.1 General
If the generator is not equipped with a control box ex works, adequate fuse
equipment has to be installed in an external control cabinet to protect the
connected circuits (sockets):
• Short-circuit tripping: characteristic "B"
• Protection against overcurrent: according to nominal current
• The neutral conductor has also to be fused.

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Chapter 4: 4.8 Electrical connection of the generators

4.8.2 Version with terminal box


Observe the following connection notes when connecting generators equipped
with a terminal box:
• When opening the terminal box, be careful not to tear-off or damage the
connecting wires of the generator governor installed in the cover.
• After opening the terminal box, remove the plug-and-socket connector to the
generator governor installed in the terminal box cover. The plug-and-socket
connector is mechanically coded and thus can not be plugged-in twisted.
Plug-in the connector only immediately before closing the cover.
• For leading cables into the terminal box only use appropriate waterproof
IP54 cable glands.
• Lay the connecting wires inside the terminal box with utmost care.
• When closing the cover, be careful not to catch or squeeze any connecting
wires.

Figure 25 Pin assignment of the connection terminal plate in the terminal


box

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Chapter 4: 4.8 Electrical connection of the generators

4.8.3 Version without terminal box, cables are lead out in a hose
Optionally the generator can also be delivered without a terminal box equipped.
In this case, the connecting cables are lead out of the generator in a hose.
This is a customized version. For this reason, the connection of the cables has to
be discussed with the generator manufacturer.

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Chapter 5, Operation

5 Operation
This chapter provides information about operating the generator. The operation
can differ depending on the generator version and equipment. Where applicable,
such differences are mentioned in the concerning texts.
Prior to operating the generator, read and understand the safety precautions
listed in section 5.1 as well as the sections 5.2 through 5.6 below and observe
the instructions and information given there.

5.1 Safety information for operation


This section summarizes all relevant safety precautions for operating the
generator.


Do not operate the generator in explosive environments.
Further regulations on this have to be observed!
Never connect the generator to the public electricity supply
DANGER network or to any other systems for power generation. Risk of
death, fire and destruction hazard!
Never connect several generators to each other. Risk of death,
fire and destruction hazard!
The generator supplies highly dangerous voltages during
operation! Never touch the generator or the devices connected
to the generator with wet hands during operation. Mortal
danger by electric shock!
Generator components may be very hot, not just during but also
after operation. Burning hazard!
The generator may only be operated with the protective covers
for the drive mounted as specified. Risk of personal injury!
Grounding the neutral conductor of the generator (N, midpoint
conductor) supersedes the protective measure "protection
separation" and should therefore be avoided. If the neutral
conductor N shall be grounded anyway, this may only be
performed by an electrically qualified person. In this case, a
current-operated earth-leakage circuit breaker has to be
connected on the load side of the generator output. The
efficiency of the electrical protective measure has to be
confirmed by an appropriate measurement.

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Chapter 5, Operation


If the generator shall be connected to an existing power
distribution network (e.g. a house wiring), it has to be
ensured, that the system is completely and reliably
disconnected from the public electricity supply network of the
DANGER
energy supply company. Reverse feeding into the public
electricity supply network or network interconnection is not
allowed. Reverse feeding involves mortal danger by electric
shock for persons possibly working at the de-energized public
electricity supply network. Due to network interconnection
with the public electricity supply network, the generator can be
damaged, burn or cause fire in electrical cables of the system.
Be sure to completely read and understand these operating
instructions before using the generator. The generator may only
be used for applications described in section "Proper use" and
in conformity with the specifications given in this manual.
Before connecting devices to the generator, ensure that the
devices are switched off. Accident hazard! Unsupervised
starting devices can endanger or injure persons as well as cause
damages or damage themselves.
Infants and animals must have no admittance to the generator,
not just during but also after operation. Make appropriate
precautions. Mortal danger by electric shock, injury and
burning hazard!
The generator or its components must never be
exposed to the jet of high-pressure cleaners.
Mortal danger by electric shock and
destruction hazard!
Be sure to observe the operating conditions given in section 5.2.
The generator may only be operated in conformity with the
operating conditions and data specified there. This especially
applies to the ambient and cooling conditions and the permissible
CAUTION current load.

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5.2 Permissible operating conditions


The generator may only be used, if the operation conditions listed below are
kept.
Only those devices may be connected, the voltage and frequency specifications
of which meet the specifications given on the type plate of the generator. The
generator may not be overloaded. The total power consumption of all connected
devices must not exceed the output power specified for the generator.
The generator must have a free cooling air supply as well as an unimpeded
cooling air dissipation. The cooling air temperature must not exceed 40 °C. If
the cooling conditions can not be met, the generator must not be loaded with
its full rated output power.
In case of inadequate cooling of the generator or under conditions other than
permissible operation conditions, the generator output voltage is automatically
reduced. In this case, the load connected to the generator has to be reduced to
avoid damage of the connected devices.

5.3 Electric protection equipment, protective measures and


grounding

5.3.1 Electric protection and grounding/equipotential bonding


If the generator is not equipped with the option "Insulation monitoring with
switching-off", it fulfills the protective measure "Protection separation with
equipotential bonding" according to VDE 0100, part 728.
If the generator is equipped with the option "Insulation monitoring with
switching-off", it fulfills the better protective measure "Protection separation
with insulation monitoring" according to VDE 0100, part 728.
For a proper function of the mentioned electrical protective measures, it is not
required to ground the generator (e.g. using a grounding rod). If this is desired
anyway or required for some special cases, a defined grounding of the generator
housing can be performed or the generator housing can be included into an
equipotential bonding with other devices. For this purpose, only the

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Chapter 5, Operation

corresponding earth connection points marked with the earth symbol may
be used.


Grounding the neutral conductor of the generator (N, midpoint
conductor) supersedes the protective measure "protection
separation" and should therefore be avoided. If the neutral
conductor N shall be grounded anyway, this may only be
DANGER
performed by an electrically qualified person. In this case, a
current-operated earth-leakage circuit breaker has to be
connected on the load side of the generator output. The
efficiency of the electrical protective measure has to be
confirmed by an appropriate measurement.

5.3.2 Protection against overcurrent


If the generator is equipped with a control box ex works, the sockets of the
control box mounted on the generator are protected against overcurrent and
short-circuit conditions using automatic circuit breakers. See Figure 26.
Circuit breaker block
(protection: 3P + N)

Figure 26 Circuit breaker in control box (only applicable for 8 kVA and
13 kVA generators)

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If the generator is not equipped with a control box ex works, adequate fuse
equipment has to be installed in an external control cabinet to protect the
connected circuits (sockets):
• Short-circuit tripping: characteristic "B"
• Protection against overcurrent: according to nominal current
• The neutral conductor has also to be fused.

5.4 Connection to an existing power distribution network (e.g.


house wiring)
The connection of generators to an existing power distribution network (e.g.
house wiring) may only be performed by a qualified electrically skilled person
and only after permission of the energy supply company. Observe all relevant
DIN and VDE regulations, especially DIN VDE 0100, part 728.6, as well as
possibly existing additional technical connection regulations of the energy
supply company.
For this purpose, considerable changes at the generator can be necessary which
may only be performed by a qualified electrically skilled person and after
consultation of the generator system manufacturer.


If the generator shall be connected to an existing power
distribution network (e.g. a house wiring), it has to be
ensured, that the system is completely and reliably
disconnected from the public electricity supply network of the
DANGER
energy supply company. Reverse feeding into the public
electricity supply network or network interconnection is not
allowed. Reverse feeding involves mortal danger by electric
shock for persons possibly working at the de-energized public
electricity supply network. Due to network interconnection
with the public electricity supply network, the generator can be
damaged, burn or cause fire in electrical cables of the system.

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Chapter 5, Operation

5.5 Operating information for safe working with electric devices


Observe the following operating information for a safe
operation and handling of electric devices.
Please also observe the safety precautions for operation given
DANGER in section 5.1 on page 73.

• Devices that caused the insulation monitoring unit to switch-off and to


indicate a "FAULTY INSULATION" must also not be operated at other
generators without insulation monitoring or in the public electricity supply
network. Devices with defective insulation have to be immediately taken out
of operation and replaced or repaired by the device manufacturer or an
authorized electric company.
• Only connect devices that are in a faultless and safe condition. The devices
and connectors have to be clean and dry.
• Before connecting devices to the generator, ensure that the devices are
switched off. Accident hazard! Unsupervised starting devices can endanger or
injure persons as well as cause damages or damage themselves.
• Depending on the field of operating and application, regulations,
prescriptions, requirements or recommendations of the professional
associations and trade associations have to be observed when working with
generators. Additionally, the Gerätesicherheitsgesetz (GSG, German
Equipmant Safety Law), the relevant regulations for preventing accidents as
well as the mine regulations of the countries have also to be considered.
When using generators outside the scope of requirements of the Federal
Republic of Germany, the suitability of the generator has to be proofed under
consideration of the individual national requirements. If you have any
questions, please contact the system manufacturer.
• The generator may only be operated under the permissible operating
conditions given in section 5.2 on page 75.
• Many portable electric tools comply with protection class II (protective
insulation, identification ). It is recommended to use such devices as far
as possible. If devices of protection class I are used (i.e. with metal housing
parts which are not insulation protected), these must be equipped with a
connection cable and a connector with PE conductor.
• When working in "conductive areas with limited freedom of movement", i.e.
in areas within the scope of DIN VDE 0100 part 706 (e.g. in metal tanks),
only one single device may be connected to the generator if it is a "hand-

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Chapter 5, Operation

held electric tool or a mobile measuring instrument". Otherwise for each


device a separate isolating transformer or an isolating transformer with
several separate secondary windings must be used. Hand-held luminaires in
conductive areas with limited freedom of movement may only be operated via
an isolated transformer with protection low voltage (SELV).
• Cables for distribution (e.g. extension cords and cord sets) must be
extensively selected, laid and maintained. Electric cables have to be checked
in regular intervals. Defective cables and cords have to be exchanged. When
connecting extension cords, observe the following section 5.6.2 on page 81.

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Chapter 5, Operation

5.6 Operation of the generator


Only take the generator into operation after you have completely
read and understood all sections of this chapter 5, particularly the
safety precautions given in section 5.1 on page 73.
If your generator is equipped with the option "Insulation
CAUTION
monitoring with switching-off", the correct function of the
insulation monitoring unit has to be checked every working day.
The generator may only be taken into operation, if the correct
function of the insulation monitoring unit has been confirmed.

5.6.1 Control elements in the control box (if available)


Figure 27 shows all possible control elements and indicators in the control box
optionally mounted on the generator (insulation monitoring unit and hour meter
are also optional).
Insulation monitoring unit Circuit breaker block
with switch and signal lamp (protection: 3P + N)
(optional)

Hour meter
(optional)

Socket 400 V

3 sockets 230 V

Figure 27 Control elements and indicators in the control box (optional)

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Chapter 5, Operation

5.6.2 Current distribution and connection of devices


The generator must not be used for the supply of assemblies
for construction sites.
Generators which are equipped with an insulation monitoring
DANGER unit must not be connected to further insulation monitoring
units since the insulation monitoring units can mutually
interact.
The generator may not be overloaded. The total power consumption
of all connected devices must not exceed the output power
specified for the generator.
Only those devices may be connected the voltage and frequency
CAUTION
specifications of which meet the specifications listed on the type
plate of the generator.
If your generator is equipped with a control box:
• Do not use the circuit breakers in the control box for switching
the connected devices on and off. When using several devices
connected to the single-phase AC voltage sockets at the same
time (especially when using devices with different power
consumptions), short-term over- or undervoltages may arise due
to a turn-on delay of the neutral conductor.
• The cover of the control box and the hinged lids of unused
sockets have always to be kept correctly closed in order to
guarantee IP54 protection (tighten the locking screws by
hand).
NOTE Current-operated earth-leakage circuit breakers are not functional
in ungrounded networks (IT systems, as supplied by the generator),
because there is no grounding. However, since the generator
supplies the protective measure "protection separation", additional
protection by means of current-operated earth-leakage circuit
breakers is not necessary.

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Proceed as follows to take the generator into operation and to connect the
loads:
1. If necessary, perform the daily check of the insulation monitoring unit. See
section 5.6.3 on page 84.

2. Make sure that no devices are connected to the generator.

3. Switch off all devices which are to be connected later (switch in position
"OFF" or "0"). Accident hazard by unsupervised starting devices!

4. Start the engine. Wait until the engine has reached its rated speed.

5. If necessary, switch on the circuit breakers in the control box (if equipped,
see Figure 27) or in the control cabinet (position "ON" or "I").

6. Connect (or switch on) the devices one after the other. First switch on the
powerful devices with high current consumptions or high starting currents
and then the less powerful devices.

NOTE The total length of all connected extension cables may not
exceed the following values:

• 250 m max. at a conductor cross section of 2.5 mm2

• 100 m max. at a conductor cross section of 1.5 mm2


Devices driven by electric motors possibly require starting
currents that are many times higher than the specified
operating currents. In case of doubt, please contact the
manufacturer.
To ensure a safe operation of three-phase generators, the load
currents should be distributed to all three phases as equal as
possible.
Take care that the maximum currents specified for each socket
are not exceeded.

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7. When switching off the connected devices, switch off the devices one after
the other and unplug their mains plugs. If possible, first switch off the less
powerful devices and finally the powerful devices with high current
consumptions.

NOTE Ensure that the hinged lids of the sockets are correctly closed
again after unplugging the mains plugs.

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Chapter 5, Operation

5.6.3 Checking the insulation monitoring unit (if available)

If your generator is equipped with the option "Insulation


monitoring with switching-off", the correct function of the
insulation monitoring unit has to be checked every working day.
The generator may only be taken into operation, if the correct
CAUTION
function of the insulation monitoring unit has been confirmed.

Proceed as follows to check the insulation monitoring unit (refer to Figure 27 for
the location of the control elements and indicators):
1. Unplug all devices and cables connected to the generator.

2. Start the engine. The check must be performed while the generator is
running.

3. Open the cover of the control box and switch on the insulation monitoring
unit (position "ON" or "I").

4. Push the red test push-button which is at the same time used as an indicator.
Now the insulation monitoring unit must trip.

5. Check whether the insulation monitoring unit has tripped and the red
indicator "FAULTY INSULATION" is on.

NOTE If the insulation monitoring unit does not trip or if the "FAULTY
INSULATION" indicator does not light, the generator must not
be used any longer. In this case, mark the generator as
defective and have it repaired (refer to section 7 on page 92).

6. Stop the engine to reset the insulation monitoring unit.

7. Switch on the insulation monitoring unit again (position "ON" or "I") and
correctly close the cover of the control box (tighten the locking screws by
hand).

8. If the check was successful the generator is now ready for operation.

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Chapter 6, Maintenance

6 Maintenance
All components of the generator are maintenance-free in principle (exception:
changing the carbon brushes holder for brush-type generators, see section 6.4.1
on page 89). Nevertheless, the maintenance operations listed in section 6.1
have to be performed regularly and on time to ensure reliable operation of the
generator.

In addition to the work described in this chapter, the driving


system/engine possibly has to be checked according to the
guidelines and regulations of the driving system/engine
manufacturer. This also includes the correct attachment of
CAUTION protective covers. Be sure to observe the maintenance instructions
of the driving system/engine manufacturer.
Do not open or disassemble the housing of the
generator or the control box! The generator may
only be opened by the manufacturer or an agency
authorized by the manufacturer. It does not
contain any components which can be replaced or
repaired by the user. It is not allowed to perform
any work or operations not described in this
manual.

Any damages and defects found on the generator have to be repaired


immediately by authorized and qualified personnel independent of the
maintenance intervals. The generator must not be taken into operation until any
defects have been removed. Any repair work must only be carried out by
adequately trained qualified personnel.

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Chapter 6, Maintenance

6.1 Maintenance overview


Interval Maintenance operation To be performed by
Every Check the correct function of the insulation User
working day monitoring unit (if available).
See section 5.6.3 on page 84.
Monthly At the generator: User
• Visual inspection for contamination or
damages. Cleaning if necessary.
• If necessary, clean the plates and labels
or replace them.
• Check the cooling air openings for
contamination or blocking and clean
them, if necessary.
See section 6.3 on page 88.
At the control box (if mounted): User
• Visual inspection for contamination or
damages. Cleaning if necessary.
• Check the cover and the socket lids for
waterproof locking.
See section 6.3 on page 88.
Every 1.000 Only for brush-type generators: Qualified
hours of Check the carbon brushes electrically skilled
operation person
See section 6.4.1 on page 89.
Every 5.000 Check the ball bearings by "listening". Qualified
hours of Replace, if necessary (rough noises at the skilled person
operation bearings).
Every 20.000 Replace the ball bearings Manufacturer
hours of
The standard maintenance interval for
operation
replacing the ball bearings is 20.000 hours.
If necessary (see check every 5.000 hours),
the ball bearings have to be replaced earlier.
See section 6.4.2 on page 91.

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Chapter 6, Maintenance

6.2 Safety precautions


This section summarizes the safety precautions relevant for maintenance
operations.


Work on electrical installations and equipment may only be
performed by adequately trained qualified personnel and in
conformity with the applicable national rules and regulations
(in Germany: e.g. VDE regulations).
DANGER
Work on electrical installations and equipment may only be
performed in the off and de-energized state. Mortal danger by
electric shock!
Engines that have been turned off must be secured against
accidental restarting (e.g. by removing the ignition key and
keeping it safe)!
Any maintenance, service and replacement operations on the
generator may only be performed by authorized and qualified
personnel.
Generator components may be very hot, not just during but also
after operation. Burning hazard!
Do not perform any visual inspections for maintenance
purposes and cleaning work on the generator during operation.
Always turn off the engine first and make sure that it cannot be
restarted accidentally (e.g. by removing the ignition key and
keeping it safe). Mortal danger by electric shock!
The generator or its components must never be
exposed to the jet of high-pressure cleaners.
Mortal danger by electric shock and
destruction hazard!
For repair and replacement operations, only genuine components or
external components expressly approved by the manufacturer may
be used.

CAUTION

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Chapter 6, Maintenance

6.3 Visual inspections and cleaning to be performed by the user


In addition to the safety precautions provided below, read and observe the
safety precautions listed in section 6.2 above.


Do not perform any visual inspections for maintenance
purposes and cleaning work on the generator during operation.
Always turn off the engine first and make sure that it cannot be
restarted accidentally (e.g. by removing the ignition key and
DANGER
keeping it safe). Mortal danger by electric shock!
Generator components may be very hot, not just during but also
after operation. Burning hazard!

The following operations have to be performed by the user in monthly intervals.


1. Check the generator housing for damages visible on the outside as well as for
excessive contamination which could impair cooling. If necessary, use a wet
cloth to clean the generator.

2. If the generator is equipped with a control box, check the housing of the
control box and the installed sockets for damages and contamination visible
on the outside. If necessary, use a wet cloth to clean the control box. Check
the transparent cover of the control box and the hinged lids of the sockets
for damages and waterproof locking.

3. Check whether the safety and warning label and the type plate attached to
the generator are readable. If necessary, clean the plates and labels or
replace them.

4. Check the cooling air openings on the rear side of the generator for
contamination which could obstruct the cooling air flow and use a wet cloth
to clean the openings, if necessary.

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Chapter 6, Maintenance

6.4 Maintenance to be performed by authorized qualified


personnel


Any maintenance, service and replacement operations on the
generator may only be performed by authorized and qualified
personnel.
DANGER

In addition to the safety precautions listed below, read and observe the safety
precautions given in section 6.2.

6.4.1 Checking and/or replacing the carbon brushes (only brush-


type generators)
The carbon brushes of brush-type generators have to be removed and checked
every 1.000 hours of operation by qualified personnel as described below. If the
carbon brushes are used up more than half, the complete carbon holder must be
replaced. It is not possible to replace only one single carbon brush.
Removing the carbon brushes holder
1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 28/2) and
detach the sleeve (1).

2. Remove both connection cables from the connection lugs of the carbon
brushes holder (Figure 28/3). The connection cables are coded by the width
of the connection lugs and therefore protected against interchanging (see
Figure 29).

3. Unscrew the fastening screw of the carbon brushes holder and detach the
carbon brushes holder (Figure 28/3).

1
2

Figure 28 Removing the carbon brushes holder

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Chapter 6, Maintenance

Checking the carbon brushes


The carbon brushes holder has to be replaced, if the carbon brushes are used up
more than half, i.e. if they jut out of the carbon brushes holder less than 6 mm
(see Figure 29).

6 mm min.
red
gray

Figure 29 Checking/Replacing the carbon brushes

Installing the carbon brushes holder


1. Insert the carbon brushes holder (Figure 30/3) correctly positioned into the
generator and press it onto the collector rings on the shaft, so that the
carbon brushes are pressed into the carbon brushes holder and the carbon
brushes holder lies on its mounting base.

2. Continue to press on the carbon brushes holder and screw in the fastening
screw, but do not tighten it completely. While screwing in the fastening
screw, the carbon brushes holder is automatically positioned on the
mounting base.

3. Check the proper seating of the carbon brushes holder and then tighten the
fastening screw.

4. Plug both connection cables onto the connection lugs of the carbon brushes
holder according to the width of the connectors (see Figure 30).

5. Remount the sleeve (Figure 30/1) and fasten it by tightening the two screws
(2).

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Chapter 6, Maintenance

1
2

red 3
gray

Figure 30 Installing the carbon brushes holder

6.4.2 Replacing the ball bearings


The ball bearings of the generator have to be replaced at least every 20.000
hours of operation. However, if rough noises are detected at the ball bearings
during the check prescribed every 5.000 hours of operation, the ball bearings
have to be replaced earlier.
We strongly recommend for these operations to remove the generator and to
send it to the manufacturer or to an agency authorized by the manufacturer.
Removing the generator is described in chapter 8 on page 93.

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Chapter 7, Reconditioning

7 Reconditioning
Aside from the work described for maintenance in chapter 6, no other
reconditioning operations can be carried out for the generators outside the
manufacturer plant.
If repair work is necessary, we recommend to remove the generator and to send
it to the manufacturer or to an agency authorized by the manufacturer.
Removing the generator is described in chapter 8 on page 93.

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Chapter 8, Removal

8 Removal
To remove the generator, proceed according to the descriptions given in this
chapter.

8.1 Safety precautions


Removing of the generator may only be performed by
authorized and qualified personnel.
Generator components may be very hot, not just during but also
DANGER after operation. Burning hazard!
For removing the generator make sure that the switched-off
engine cannot be restarted accidentally (e.g. by removing the
ignition key and keeping it safe). Mortal danger by electric
shock, risk of personal injury!

8.2 Removal of two-bearing generators (BG132 and BG160)


The removal of two-bearing generators has to be performed in accordance with
the descriptions in chapter 4.

8.3 Removal of single-bearing generators


NOTE For the removal of single-bearing generators the following special
tools are required:
• Special tool of the engine manufacturer to hold the engine
shaft.
• For shaft fastening by grub-screw:
Special hexagon nut for turning the generator shaft using a
spanner as well as special sawing ring pliers for removing and
mounting the sawing ring which secures the fan impeller on the
shaft.
• For shaft fastening by tension bolt:
Pushing rod and pushing screw.
• Additionally for brush-type generators:
Special wooden chock serving as transport locking for the rotor.

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Chapter 8, Removal

8.3.1 Removal of single-bearing brush-type generators

Work prior to removal and removal of the carbon brushes holder


1. Disconnect the electric connection cables of the generator as described in
section 4.8 on page 70.

2. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 31/2) and
detach the sleeve (1).

3. Remove both connection cables from the connection lugs of the carbon
brushes holder (Figure 31/5). The connection cables are coded by the width
of the connection lugs and therefore secured against interchanging.

4. Unscrew the fastening screw of the carbon brushes holder and detach the
carbon brushes holder (Figure 31/5).

5. Refer to the following descriptions to continue the removal:


- For shaft fastening by grub-screw continue on page 95.
- For shaft fastening by tension bolt continue on page 97.

1 2
3
4

Figure 31 Work prior to removal of single-bearing brush-type generators

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Chapter 8, Removal

Removal for shaft fastening by grub-screw


1. Remove the fan impeller shroud (Figure 31/4) and the fan impeller (Figure
31/3) from the generator. The fan impeller is secured against twisting on the
shaft by means of a feathered key and a sawing ring.

2. Attach the special hexagon nut (Figure 32/2) onto the generator shaft
instead of the fan impeller and secure it against twisting by means of the
feathered key (1).

3. Hold the engine shaft using the special tool of the engine manufacturer.

4. Attach the spanner to the special hexagon nut and undo the grub-screw
connection between engine and generator shaft.

5. Support the generator if necessary and unscrew the four end shield fastening
screws (Figure 32/3) at the engine flange.

6. Unscrew the generator shaft from the grub-screw screwed into the engine
shaft and detach the generator.

7. Unscrew the grub-screw (Figure 32/4) from the engine shaft using an Allen
wrench.

Figure 32 Removal of single-bearing brush-type generators (1)

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Chapter 8, Removal

8. Detach the special hexagon nut (Figure 33/1) from the generator shaft.

9. Remount the carbon brushes holder (Figure 33/4) according to the


descriptions on page 90 (section 6.4.1) into the generator and reconnect the
connection cables.

10. Insert the special wooden chock serving as transport locking for the rotor.

11. Remount the sleeve (Figure 33/6) and fasten it by tightening the two
screws (5).

12. Remount the fan impeller (Figure 33/2) and secure it on the generator shaft
by means of the feathered key (against twisting) and the sawing ring.

13. Remount the fan impeller shroud (Figure 33/4).

1
6
2
5 3

Figure 33 Removal of single-bearing brush-type generators (2)

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Chapter 8, Removal

Removal for shaft fastening by tension bolt


1. Detach the cap (Figure 34/2) at the fan impeller shroud.

2. Hold the engine shaft using the special tool of the engine manufacturer.

3. Undo the tension bolt (Figure 34/1) and pull it out of the generator shaft.

4. Support the generator if necessary and unscrew the four end shield fastening
screws (Figure 34/3) at the engine flange.

5. Insert the pushing rod (Figure 34/4) into the generator shaft instead of the
tension bolt and screw the pushing screw (5) into the generator shaft. By
screwing in the pushing screw, the generator shaft is detached from the
engine shaft.

6. Detach the generator from the engine.

7. Remove the pushing screw and the pushing rod from the generator shaft.
Remount the cap onto the fan impeller shroud.

8. Remount the carbon brushes holder (Figure 33/5) according to the


descriptions on page 90 (section 6.4.1) into the generator and reconnect the
connection cables.

9. Insert the special wooden chock serving as transport locking for the rotor.

10. Remount the sleeve (Figure 33/7) and fasten it by tightening the two
screws (6).

1 4

2 5

Figure 34 Removal of single-bearing brush-type generators with tension


bolt

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Chapter 8, Removal

8.3.2 Removal of brushless single-bearing generators

Work prior to removal


1. Disconnect the electric connection cables of the generator as described in
section 4.8 on page 70.

2. Refer to the following descriptions to continue the removal:


- For shaft fastening by grub-screw continue with the following section on
this side.
- For shaft fastening by tension bolt continue on page 101.

Removal for shaft fastening by grub-screw


1. Remove the fan impeller shroud (Figure 35/3) and the fan impeller (Figure
35/2) from the generator. The fan impeller is secured against twisting on the
shaft by means of a feathered key and a sawing ring.

2. Support the generator if necessary and unscrew the four end shield fastening
screws (Figure 35/4) at the generator.

3. Attach the special hexagon nut (Figure 36/2) onto the generator shaft
instead of the fan impeller and secure it against twisting by means of the
feathered key (Figure 36/1).

4. Hold the engine shaft using the special tool of the engine manufacturer.

5. Attach the spanner to the special hexagon nut and undo the grub-screw
connection between engine and generator shaft.

6. Unscrew the generator shaft from the grub-screw screwed into the engine
shaft and detach the generator.

7. Remove the front end shield of the generator which is still mounted on the
engine. For this purpose, unscrew the four screws (Figure 36/3) and detach
the end shield (Figure 36/4).

8. Remount the front end shield (Figure 36/4) to the generator.

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Chapter 8, Removal

9. Unscrew the grub-screw (Figure 37/1) from the engine shaft using an Allen
wrench.

10. Detach the special hexagon nut (Figure 37/2).

11. Remount the fan impeller (Figure 37/3) and the fan impeller shroud (Figure
37/4). Secure the fan impeller on the generator shaft by means of the
feathered key (against twisting) and the sawing ring.

4 2

Figure 35 Removal of brushless single-bearing generators (1)

1
4

Figure 36 Removal of brushless single-bearing generators (2)

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Chapter 8, Removal

1 2
3
4

Figure 37 Removal of brushless single-bearing generators (3)

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Chapter 8, Removal

Removal for shaft fastening by tension bolt


1. Detach the cap (Figure 38/2) from the fan impeller shroud.

2. Detach the front end shield from the generator. For this purpose, unscrew the
four fastening screws (Figure 38/5) of the front end shield at the generator.

3. Hold the engine shaft using the special tool of the engine manufacturer.

4. Undo the tension bolt (Figure 38/1) and pull it out of the generator shaft.

5. Insert the pushing rod (Figure 38/3) into the generator shaft instead of the
tension bolt and then screw the pushing screw (Figure 38/4) into the
generator shaft. By screwing in the pushing screw, the generator shaft is
detached from the engine shaft.

6. Detach the generator from the engine.

7. Remove the pushing rod (Figure 38/3) and the pushing screw (Figure 38/4)
from the generator shaft. Remount the cap (Figure 38/2) onto the fan
impeller shroud.

8. Remove the front end shield (Figure 39/1) of the generator which is still
mounted to the engine. For this purpose, unscrew the four screws (Figure 39/
2) and detach the end shield.

9. Remount the front end shield to the generator.

1 4
2

Figure 38 Removal of brushless single-bearing generators with tension bolt


(1)

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Chapter 8, Removal

Figure 39 Removal of brushless single-bearing generators with tension bolt


(2)

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Chapter 9, Transport and storage

9 Transport and storage


The generators are bolted onto a transport pallet and packed accordingly for
protection against damages and penetrating humidity when leaving the factory.
Single-bearing generators achieve IP54 protection only when they are mounted
to the engine.

The generators have to be transported and stored dry and protected


against water. Transport and storage may only be performed in
delivery state with the packaging and protective devices mounted.

CAUTION

On both sides of the generator, a lifting eye bolt is provided for attaching lifting
equipment. Lifting equipment may only be attached to the generator using these
lifting eye bolts. Only appropriate lifting equipment may be used.
If no lifting eye bolts are provided at the generator ex works, these must be
mounted later for lifting the generator.

Generators BG 132 Generators BG 160


Weight (mass) approx. 40 - 80 kg approx. 140 -180 kg
Permissible temperatures:
transport -25 °C to +60 °C
storage -20 °C to +50 °C
Permissible rel. humidity:
transport 95%, non-condensing
storage 95%, non-condensing

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Chapter 10, Putting out of operation, storage after dismantling, disposal

10 Putting out of operation, storage after dismantling,


disposal
Dismantling the generators and putting the generators out of operation have to
be performed according to the descriptions in chapter 8.
Generators which are still functional have to be packed and stored as described
in chapter 9.
Generators which are no longer functional have to be labeled accordingly and
disposed or supplied for recycling in accordance with the legal requirements. For
more detailed information refer to the relevant environmental protection
authority or to the manufacturer.

10.1 Waste disposal information


Generator housing Aluminum
Fan impeller shroud Iron/steel
Fan impeller Polypropylene
Rotor and shaft Iron/steel
Windings Copper, impregnated by modified Ester-
Imide (THEIC)
Electronic components Electronics scrap

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Chapter 11, Spare parts

11 Spare parts
Companies authorized for repair and replacement work are asked to contact the
manufacturer for the service manual.

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Chapter 11, Spare parts

106 Issue date: August 2002

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