Bender VG12 User manual

EN
Manual
VG12
Safety distributor for mobile power generators
ready for connection
VG12_D00032_03_M_XXEN/01.2019

Photos: Bender archive and bendersystembau archive.
Bender GmbH & Co. KG
P.O. Box 1161 • 35301 Grünberg • Germany
Londorfer Straße 65 • 35305 Grünberg • Germany
Tel.: [phone] • Fax: [phone]
E-mail: [email protected] • www.bender.de
© Bender GmbH & Co.KG
All rights reserved.
Reprinting only with permission
of the publisher!
Subject to change!

3
Table of Contents
VG12_D00032_03_M_XXEN/01.2019
1. Making effective use of this document ............................................... 5
1.1 How to use this manual ......................................................................................... 5
1.2 Explanation of symbols and notes .................................................................... 5
2. Safety instructions .................................................................................. 6
2.1 Intended use ............................................................................................................. 6
2.2 Work activities on electrical installations ........................................................ 6
2.3 Device-specific safety instructions .................................................................... 7
2.4 General safety instructions .................................................................................. 7
3. System description ................................................................................. 8
3.1 Protective measures for mobile generators .................................................. 8
3.2 Prerequisites for use ............................................................................................... 8
3.3 Functional description ........................................................................................... 9
3.3.1 Display and operating elements ...................................................................... 10
4. Installation and connection ............................................................... 12
4.1 Installation ............................................................................................................... 12
4.1.1 Dimension diagrams ............................................................................................ 12
4.2 Connection .............................................................................................................. 14
5. Commissioning and continous operation ....................................... 16
5.1 Specific factory settings ...................................................................................... 16
5.2 Functional test before first use ......................................................................... 16
5.3 Test before daily use ............................................................................................. 17
5.4 Regular tests ............................................................................................................ 18
5.5 Troubleshooting .................................................................................................... 18

Table of Contents
4VG12_D00032_03_M_XXEN/01.2019
6. Technical data ........................................................................................ 19
6.1 Standards and certifications .............................................................................. 21
6.2 Ordering details ..................................................................................................... 22
6.3 Other safety distributors ..................................................................................... 22
INDEX ............................................................................................................ 23

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VG12_D00032_03_M_XXEN/01.2019
1. Making effective use of this document
1.1 How to use this manual
This manual describes the operation of the safety distributor VG12. It informs about the
essential safety instructions to be considered and the underlying regulations of the
concept.
This manual is intended for qualified personnel working in electrical engineering and
electronics.
Please read this manual and the instructions of the power generator prior to using the
devices. Keep the two manuals within easy reach near the power generator.
If you have any questions, please do not hesitate to contact us. In this case, please refer
to our service:
www.bender.de/en/service-support/downloads
1.2 Explanation of symbols and notes
The following symbols to indicate hazards and to indicate optimum use of the product
are used in this manual
DANGER
This signal word indicates that there is a high risk of danger that will result
in death or serious injury if not avoided.
WARNING
This signal word indicates a medium risk of danger that can lead to
death or serious injury if not avoided.
CAUTION
This signal word indicates a low level risk that can result in minor or
moderate injury or damage to property if not avoided.
This symbol denotes information intended to assist the user in making
optimum use of the product.

6VG12_D00032_03_M_XXEN/01.2019
2. Safety instructions
2.1 Intended use
The VG12 safety distributor is intended for guaranteeing the protective measure "Pro-
tective separation with insulation monitoring and disconnection" according to
DIN VDE 0100-410, DIN VDE 0100-551 and GW 308 of the DVGW (German Association of
Gas and Water Line e.V.) and thus for the safe operation of mobile power generators.
The VG12 safety distributor is suitable for the direct connection to single-phase power
generators. The total load current must not exceed 16 A with respect to the plug of the
input cable.
The chapter "System description" lists the requirements to be fulfilled in order to be
able to apply the protective measure.
2.2 Work activities on electrical installations
 Only electrically skilled persons are permitted to carry out the work necessary to
install, commission and run a device or system.
 Compliance with applicable regulations governing work on electrical installations
and with the regulations derived from and associated with them, is mandatory.
EN 50110 is of particular importance in this regard.
 If the device is being used in a location outside the Federal Republic of Germany,
the applicable local standards and regulations must be complied with. The Euro-
pean standard EN 50110 can be used as a guide.
WARNING
Danger as a result of unprofessional work!
Any work on electrical installations which is not carried out properly can
lead to death and injury! Therefore, observe the following safety
instructions!

Safety instructions
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VG12_D00032_03_M_XXEN/01.2019
2.3 Device-specific safety instructions
2.4 General safety instructions
Bender devices are designed and built in accordance with the state of the art and ac-
cepted rules in respect of technical safety. However, the use of such devices may intro-
duce risks to the life and limb of the user or third parties and/or result in damage to
Bender devices or other property.
 Use Bender devices only:
– as intended
– in perfect working order
– in compliance with the accident prevention regulations and guidelines appli-
cable at the location of use
 Eliminate all faults immediately which may endanger safety.
 Do not make any unauthorised changes and only use replacement parts and opti-
onal accessories purchased from or recommended by the manufacturer of the
devices. Failure to observe this requirement can result in fire, electric shock and
injury.
 Reference signs must always be clearly legible.
CAUTION
Danger due to inappropriate power generators!
The VG12 safety distributor is only suitable for single-phase power
generators with AC 230 V. VG12 can conduct a maximum of 16 A.
CAUTION
Danger during insulation and voltage tests!
The VG12 safety distributor must be disconnected from the mains for the
duration of the test. Check the correct connection of the VG12 safety
distributor when recommissioning it. Perform a functional test according to
the instructions in the chapter
"Chapter 5. Commissioning and continous operation“.

8VG12_D00032_03_M_XXEN/01.2019
3. System description
3.1 Protective measures for mobile generators
The VG12 safety distributor is intended for the practical implementation of the protec-
tive measure "Protective separation with insulation monitoring and disconnection"
specified in section 551.4.4.2 of the standard DIN VDE 0100-551.
The voltage supply is designed in a way that protective separation is realised with more
than one load. The continuously measuring ISOMETER® switches off the mains voltage
if the value falls below the response value. This results in the following characteristics:
 No earth spike
 High-resistance insulation faults are detected immediately. When reaching the
response value, the socket-outlets of the VG12 are switched off.
(DIN VDE 0100-410, Annex C3)
 Suitable only for operation and monitoring by electrically skilled or instructed
persons.
 The exposed conductive parts of the whole generator circuit must be connected
by insulated, unearthed protective equipotential-bonding conductors PA (see
schematic wiring diagram on Page 15).
Such conductors must not be connected to the protective conductors or exposed
conductive parts of other circuits or to any other conductive parts.
An ISOMETER® measures the sum of all insulation faults in the system, i.e. the absolute
insulation value.
Page 21 provides a list of all relevant standards.
3.2 Prerequisites for use
The protective measure "Protective separation with insulation monitoring and discon-
nection" avoids hazards from indirect contact with parts carrying voltage due to faults
in the basic insulation of the circuit.
 The power generator must supply a single-phase AC voltage of 230 V. Tolerances
according to IEC 38 are permissible. Higher voltages may destroy components of
the safety distributor. Hence, the protective function may be disabled.
 The maximum load current must not exceed 16 A. Higher load currents may
destroy the contacts of the connection plug of the VG12 safety distributor and
thus disable the protective function.

System description
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VG12_D00032_03_M_XXEN/01.2019
3.3 Functional description
The VG12 safety distributor provides a protective measure which
 meets the legal provisions
 is practice-oriented
 does not hinder the work with the power generator
 can be mounted quickly, simply and cost-effectively (plug connection)
 can be connected to the interior of the power generator without any intervention
 does not require maintenance.
The VG12 safety distributor has a compact plastic enclosure made of impact-resistant
material. The Schuko socket-outlets are integrated in this enclosure. The loads are sup-
plied exclusively via this socket-outlet after mounting and commissioning. A cable con-
nects the VG12 safety distributor to the power generator.
The VG12 safety distributor contains an insulation monitoring device in accordance
with EN 61557-8. It is an actively measuring ISOMETER® type IR423 which superimposes
a measuring voltage onto the system.
When the power generator is running, this device constantly monitors the insulation
condition of the power generator system against the equipotential bonding. If the in-
sulation resistance falls below 23 kΩ, the ISOMETER® triggers and disconnects the so-
cket-outlets from the main voltage via a relay within one second. At the same time, the
LEDs "AL1", "AL2" on the insulation monitoring device indicate the change in the insu-
lation resistance.
The disconnection and the indication via the LEDs "AL1", "AL2" can be reset via the com-
bined test/reset button "T/R" if the insulation fault is at least 25 % above the response
value of 23 kΩ.

System description
10 VG12_D00032_03_M_XXEN/01.2019
3.3.1 Display and operating elements
Fig. 3.1: Connecting cable and front view of the VG12
1Input: 0.7 m connecting cable H07RN-F3G 2.5 with Schuko plug for max. 16 A
2Output: 2 Schuko socket-outlets for max. 16 A output current
CAUTION
Danger due to excessive nominal current at the socket-outlets!
If both sockets are used, the total nominal current of both sockets
must not exceed 16 A.
3Insulation monitoring device IR423
4Instruction for daily test
5Combined test/reset button "T/R"
Achtung!
Tägliche Prüfung
Kombinierte Test/Reset-Taste:
- lang drücken (> 2 s) = TEST
"AL1" und "AL2" leuchten
- kurz drücken (< 1,5 s) = RESET
"AL1" und "AL2" erlöschen
Bedienungsanleitung beachten!
Attention!
Daily test
Combined test/reset button:
- long pressing (> 2 s) = TEST
"AL1" and "AL2" light
- short pressing (< 1.5 s) = RESET
"AL1" and "AL2" go out
Refer to operating manual!
123
4
"T/R"
5

System description
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VG12_D00032_03_M_XXEN/01.2019
In general, an operation of the IR423 is not required. Thus, the description of the opera-
ting elements is only informative.
Fig. 3.2: Front view of the IR423
1POWER ON LED
2The alarm LED "AL1" lights up if the value falls below the response value
Ran1 (Alarm 1) (prewarning).
3The alarm LED "AL2" lights up if the value falls below the response value
Ran2 (Alarm 2) (prewarning).
4The test button "T" is intended for the daily test of the safety distributor.
After pressing it, "AL1" and "AL2" light up.
5The insulation monitoring device is reset by pressing the reset button "R".
The alarm LEDs "AL1" and "AL2" go out.
6The menu/enter button is intended for accessing the menu operation,
choosing functions and changing values. The button is not required for
normal operation!
7Display for indicating the insulation value and for navigating in the menu
123
456
MENU
7

12 VG12_D00032_03_M_XXEN/01.2019
4. Installation and connection
4.1 Installation
The cover of the VG12 must be unscrewed prior to installation. Mount the VG12 safety
distributor with four M4 screws to the power generator. Make sure that the mounting
parts have the required stability so that they are not destroyed by the typical vibrations
of the power generator. Avoid sharp edges and corners. Secure the mounting screws
via lock washers, spring washers or the like.
4.1.1 Dimension diagrams
Fig. 4.1: Drilling template
DANGER
Risk of an electric shock!
Do not carry out installation work while the power generator is
running. Make sure that the power generator is not activated during
installation work. Work activities on the running power generator
may cause severe injuries!
163 mm
113

Installation and connection
13
VG12_D00032_03_M_XXEN/01.2019
Fig. 4.2: Dimensions of the VG12
130
180 mm
96
ca. 40 mm
163 mm
113

Installation and connection
14 VG12_D00032_03_M_XXEN/01.2019
4.2 Connection
The VG12 is connected via a plug connection:
 Connect the Schuko plug connecting cable of the VG12 safety distributor to a
Schuko socket-outlet of the power generator.
DANGER
Risk of an electric shock!
Work activities on electrical parts of the power generator and on the
electrical equipment must only be carried out by electrically skilled
persons.
WARNING
Danger due to freely accessible generator socket-outlets!
Use the socket-outlets of the VG12 safety distributor only.
Any other socket-outlets of the power generator must be shut down.
When the socket-outlets have been shut down and closed by means of
a protective cap, secure the socket-outlets with a locking wire against
unauthorised use.
CAUTION
Danger due to excessive nominal system voltage!
VG12 is only suitable for power generators with AC 230 V. Higher
voltages may destroy components of the safety distributor. Hence, the
protective function may be disabled.

Installation and connection
15
VG12_D00032_03_M_XXEN/01.2019
Schematic wiring diagram
The following wiring diagram informs you about the interaction of the components ge-
nerator, VG12 safety distributor and loads. The details are purely informative and not re-
quired for the connection of the VG12 to the power generator.
Fig. 4.3: Schematic wiring diagram
PA
Test/
Reset
„T/R“
IR423
< R
PA
VG12
Generator
AC 230 V Verbraucher/
Load
Verbraucher/
Load

16 VG12_D00032_03_M_XXEN/01.2019
5. Commissioning and continous operation
5.1 Specific factory settings
5.2 Functional test before first use
1. Check the correct mechanical mounting of the VG12 to the power generator.
2. Make sure that the connecting cable of the VG12 is connected to the generator secu-
rely.
3. Ensure that other socket-outlets of the generator are sealed.
4. Start the power generator.
5. Plug a load (e.g. an AC 230 V hand lamp) into a socket-outlet of the VG12 safety distri-
butor. The lamp should light up.
6. Press the combined test/reset button "T/R" of the VG12. A short time later, "tES"
appears on the display for a few seconds.
In the following, the alarm LEDs "AL1" and "AL2" light up and the VG12 disconnects all
poles of the safety socket-outlets (The hand lamp goes out).
The specific factory settings of the ISOMETER® IR123 in the VG12 differ
from the standard factory settings of an IR123!
Response value 1/2 (Alarm 1/2):
Operating mode K1/K2:
Fault memory:
Start-up delay:
Response delay:
Password:
46 kΩ/23 kΩ
N/C operation (n.c.)
activated (on)
t = 0 s
ton = 0 s
0, deactivated
CAUTION
Risk of malfunction!
If the power generator is not switched off after pressing the combined
test/reset button "T/R", a fault exists. Protect the power generator
against accidental switch-on. Please contact Bender.

Commissioning and continous operation
17
VG12_D00032_03_M_XXEN/01.2019
If the shutdown was carried out as intended:
1. Press the combined test/reset button "T/R“ for 1 s
– VG12 reconnects the socket-outlets (The hand lamp lights up).
– The alarm LEDs "AL1"and "AL2"go out.
2. Ensure that this manual as well as the instructions of the power generator are kept
within easy reach near the device.
5.3 Test before daily use
Check the safe function of the VG12 daily before each use of the power generator:
1. Start the power generator.
2. Plug a load (e.g. a hand lamp) into a socket-outlet of the VG12 safety distributor.
3. Press the combined test/reset button "T/R" of the VG12 for 3 s. A short time later, "tES"
appears on the display for a few seconds.
In the following, the alarm LEDs "AL1" and "AL2" light up and the VG12 disconnects all
poles of the safety socket-outlets. (The hand lamp goes out).
If the shutdown was carried out as intended:
1. Press the combined test/reset button "T/R“ for 1 s
– VG12 reconnects the socket-outlets (The hand lamp lights up).
– The alarm LEDs "AL1"and "AL2"go out.
2. After successful testing, the power generator can be used as normal.
CAUTION
Risk of malfunction!
If the power generator is not switched off after pressing the combined
test/reset button "T/R", a fault exists. Protect the power generator
against accidental switch-on. Please contact Bender.

Commissioning and continous operation
18 VG12_D00032_03_M_XXEN/01.2019
5.4 Regular tests
Observe the deadlines for regular testing of the power generator and the connected
electrical equipment according to the accident prevention regulation BGV A3.
5.5 Troubleshooting
Of course, an insulation fault can also occur during the daily use of the power generator.
Thus, all loads plugged into the VG12 are suddenly shut down and the LEDs AL1 and
AL2 light up. What is to be done in this case?
Fault description Presumed cause Actions
LEDs "AL1"/"AL2" light
up.
Combined
test/reset button
"T/R"was pressed
deliberately or acci-
dentally.
Press the combined test/reset button "T/R"
for 1 s.
LEDs "AL1"/"AL2" light
up
(no loads connected).
Insulation fault
power generator
Turn off power generator immediately.
Arrange checking by skilled person.
LEDs "AL1"/"AL2" light
up
(loads are connected).
Insulation fault load
or power generator
Unplug plugs of all loads. Then press com-
bined test/reset button "T/R".
a)
LEDs "AL1"/"AL2" do not go out:
Arrange checking of the power generator by
electrically skilled person.
b)
LEDs "AL1"/"AL2" go out:
A load has an insulation fault. Plug in plugs of
the loads one after the other until alarm and
shutdown occur again.
Remove damaged load again and press reset
button "R".
Arrange checking of damaged load by elec-
trically skilled person.

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VG12_D00032_03_M_XXEN/01.2019
6. Technical data
Monitored IT system
Nominal system voltage Un............................................................................................ AC 192…276 V
Nominal frequency fn.............................................................................................................. 42…60 Hz
Response values
Response value Ran1 (ALARM 1) ............................................................................ 1…200 kΩ (46 kΩ)*
Response value Ran2 (ALARM 2) ............................................................................ 1…200 kΩ (23 kΩ)*
Relative uncertainty 1 kΩ…5 kΩ/5 kΩ…200 kΩ ....................................................... ±0.5 kΩ/±15 %
Hysteresis .......................................................................................................................................... 25 %
Time response
Response time tan at RF= 0.5 x Ran and Ce= 1 μF ......................................................................... < 1 s
Start-up delay (start time) t.............................................................................................. 0…10 s (2 s)*
Response delay ton ............................................................................................................ 0…99 s (0 s)*
Measuring circuit
Measuring voltage Um........................................................................................................................ 12 V
Measuring current Im(at RF= 0 Ω) .......................................................................................... < 200 μA
Internal resistance DC Ri ............................................................................................................... > 62 kΩ
Impedance Zi at 50 Hz .................................................................................................................. > 60 kΩ
Permissible extraneous DC voltage Ufg .................................................................................. < DC 300 V
Permissible system leakage capacitance Ce................................................................................... < 5 μF
Displays, memory
Display range measured value ............................................................................................ 1 kΩ…1 MΩ
Operating uncertainty 1 kΩ…5 kΩ/5 kΩ…1 MΩ....................................................... ±0.5 kΩ/±15 %
Password ..................................................................................................................... off/0…999 (off)*
Fault memory signalling relay................................................................................................ on/off (on)*
Switching element socket-outlets:
Nominal current.................................................................................................................................. 16 A
Nominal voltage .......................................................................................................................... AC 250 V
Max. switching capacity AC......................................................................................................... 7,500 VA
Recommended minimum load ...................................................................................... 500 mA/AC 12 V
Electrical endurance, number of cycles........................................................................................... 10,000

Technical data
20 VG12_D00032_03_M_XXEN/01.2019
Environment/EMC
EMC ............................................................................................................................................ IEC 61326
Operating temperature .................................................................................................. -25 °C…+55 °C
Classification of climatic conditions acc. to IEC 60721:
Stationary use (IEC 60721-3-3) .......................................... 3K5 (no condensation, no formation of ice)
Transport (IEC 60721-3-2) .................................................................................................................. 2K3
Long-term storage (IEC 60721-3-1) .................................................................................................. 1K4
Classification of mechanical conditions acc. to IEC 60721:
Stationary use (IEC 60721-3-3) ......................................................................................................... 3M4
Transport (IEC 60721-3-2) ................................................................................................................. 2M2
Long-term storage (IEC 60721-3-1) ................................................................................................. 1M3
Vibration resistance acc. to IEC 60068-2-6:
DIN rail ........................................................................................................................... 3 g/30…150 Hz
Screw mounting............................................................................................................. 6 g/30…150 Hz
Connection/Socket-outlets
Input:
Connecting cable with Schuko plug ....................................................................... H07RN-F3G2,5 black
Wire diameter......................................................................................................................... 3 x 2.5 mm2
Cable length....................................................................................................................................... 0.7 m
Output........................................................................ Schuko socket, protected against splashing water
Other
Operating mode......................................................................................................... continous operation
Mounting.............................................................................................. any position, but display oriented
Degree of protection, enclosure (DIN EN 60529) .............................................................................. IP54
Enclosure material .............................................................................................................. polycarbonate
Screw mounting ............................................................................................................................. 4 x M4
Weight ........................................................................................................................................... 1,300 g
( )*: factory setting