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
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
Table of contents
Some important and valuable information .................................................. 5
Warranty ............................................................................................... 5
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
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
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
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.
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.
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!
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!
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!
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.
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"
L1
L2
L3
N
PE
Generator
Load
• 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
Generator governor
Terminal box
Suppression filter (optional)
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.
Sockets 230 V
Socket 400 V
Figure 6 Control box with installed options hour meter and insulation
monitoring
CAUTION
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
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.
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!
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.
4.4 Permissible mounting positions and drain holes for cond. water
no
no
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.
CAUTION
Yanmar L90 / L100 Fluid sealing Apply liquid sealant into the
corresponding clearance in the
end shield.
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).
1 2
Flange represented
turned by 45°
Installation
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).
4x
2
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.
11. Remount the sleeve (Figure 9/3) and fasten it by tightening the two screws
(2).
Flange represented
turned by 45°
1
4 2
2. Unscrew the four fastening screws (3) at the generator and detach the front
end shield (2).
2
1
Installation
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).
1
Apply appropriate sealing
depending on the engine
3 4x
2 4x
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.
2 4x
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.
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.
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.
1
4x
2
2 4x
CAUTION
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
2. Unscrew the four screws M12 x 12 (3) and detach them together with the
washers.
1
2
3 4x
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.
4x
6 4a
5 4b
4x
3b
3a
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.
4x
2a
4 2b
3
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.
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.
2x
1
9 8x
8 7a
7b 2
2x
6
4x
5
4a
4b
3b 4x
3a
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.
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.
2x
7
8x
1
6 5a
5b 4x
4 2a
3 2b
CAUTION
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
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.
4x
2a
4 2b
3
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.
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.
2x
7
8x
1
6 5a
5b 4x
4 2a
3 2b
Figure 24 Installation of the flange mounting for hydraulic drive (BG 160)
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.
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.
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.
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.
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.
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.
Figure 26 Circuit breaker in control box (only applicable for 8 kVA and
13 kVA generators)
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.
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.
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.
Hour meter
(optional)
Socket 400 V
3 sockets 230 V
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.
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.
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:
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.
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).
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.
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.
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
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!
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.
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.
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
6 mm min.
red
gray
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).
1
2
red 3
gray
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.
8 Removal
To remove the generator, proceed according to the descriptions given in this
chapter.
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!
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).
1 2
3
4
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.
8. Detach the special hexagon nut (Figure 33/1) from the generator shaft.
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.
1
6
2
5 3
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.
7. Remove the pushing screw and the pushing rod from the generator shaft.
Remount the cap onto the fan impeller shroud.
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
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).
9. Unscrew the grub-screw (Figure 37/1) from the engine shaft using an Allen
wrench.
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
1
4
1 2
3
4
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.
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.
1 4
2
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.
11 Spare parts
Companies authorized for repair and replacement work are asked to contact the
manufacturer for the service manual.