Endress EZG 24/2 User manual

OPERATING INSTRUCTIONS
Power take-off generators
EZG 24/2 Article No. 511037
EZG 33/4 Article No. 511038
EZG 46/4 Article No. 511039
EZG 66/4 Article No. 511040
ENDRESS Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Tel.: + 49 (0) 71 23 / 9737-0
Fax: + 49 (0) 71 23 / 9737-50
E-mail: [e-mail]
www: http://www.endress-stromerzeuger.de

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ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Tel.: + 49 (0) 71 23 / 9737-0
Fax: + 49 (0) 71 23 / 9737 –50
E-mail: [e-mail]
www: http://www.endress-stromerzeuger.de
E135014 / i02
June 2017
© 2017, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copyright. Any use or modification
beyond the restrictions of the Copyright Act is forbidden and subject to penalty without the
consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming, as well as storage and
processing in electronic systems.
Manufacturer and
publisher
Document number
Publication date
Copyright

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Table of Contents
1. INTRODUCTION ................................................................................................. 4
1.1 Documentation and accessories................................................................... 4
2. SAFETY............................................................................................................... 5
3. NOTE FOR THE OPERATING COMPANY (ONLY IN COMBINATION WITH RCD) .... 7
4. TECHNICAL INFORMATION.............................................................................. 8
5. INSTALLATION................................................................................................... 9
6. USE.................................................................................................................... 13
7. INSPECTIONS................................................................................................... 15
8. MAINTENANCE ................................................................................................ 15
FINAL DISPOSAL.................................................................................................... 17

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1. INTRODUCTION
ENDRESS ACCEPTS NO LIABILITY FOR PERSONAL INJURY OR DAMAGE
ATTRIBUTABLE TO UNINTENDED, INCORRECT OR ILLOGICAL USE OR
FAILURE TO COMPLY WITH THE APPLICABLE ACCIDENT PREVENTION
REGULATIONS.
This operating manual is a supplementary part of the machine and must be
consulted before and after commissioning.
Read the following pages carefully to ensure that the device you have purchased will
provide the best possible performance and trouble-free use.
This operating manual together with the user's expertise will ensure that the product
is used correctly.
This operating manual has been created in compliance with the regulations stipulated
in Machine Directive 2006/42/EU and its later amendments. Special attention has
been given to any aspect related to safety and accident prevention.
The operating manual must be retained for future until the machine is scrapped. It
must always be kept available near the machine and stored properly (in a dry,
protected place, away from direct sunlight, etc.).
The instructions in this manual do not replace applicable legal regulations on
safety and accident prevention, but supplement them.
1.1 Documentation and accessories
In addition to this manual, these documents also come with the power take-off generator:
The generator's operating manual and maintenance instructions (LINZ Electric)

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2. Safety
Always follow these basic safety instructions before commissioning the axle shaft
generator.
Hazards are defined as follows:
DANGER!
High risk!
Failure to comply can cause injury or death.
CAUTION!
Moderate risk!
Failure to comply can cause property damage.
ATTENTION!
Mild risk!
Instructions that must be observed when using the device.
General safety instructions:
-Keep the operating manual at hand during operation
-Always keep children and pets away from the generator.
-Operate the device only on a level, non-skid surface. If necessary, secure the
device further.
-Keep at a minimum safety distance of one metre from buildings or objects.
-It is forbidden to make technical changes.
-Repairs must be made only by a professional workshop. (Safety-related
components must be replaced only with original replacement parts!)
-Do not operate the generator if it is visibly damaged.

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DANGER! RISK OF DEATH!
Shock hazard! Electrical safety
-Protect the device from dampness and moisture.
-Do not grasp the electrical plug with wet hands.
-Devices and feed cables must be in perfect condition.
-Make sure that the power supply cable does not come into contact
with hot components and that the insulation is not damaged by them.
-Use only appliances whose voltage data on the model plate conform
to the output voltage of the generator.
-For greater safety, use only protectively insulated devices
-The circuit breakers match the output of the generator and are
triggered by overload or short circuit. For your own safety, these
components must not be replaced with ordinary commercial ones.
-A feed into the existing power grid must be installed only by a
licensed electrician. The responsible energy supplier's guidelines
must be followed.
DANGER! RISK OF DEATH!
Asphyxiation hazard!
-(Tractor) exhaust is poisonous and hazardous to health! Do not
inhale!
-Always make sure there is adequate ventilation.
-In well-ventilated spaces, use an exhaust hose to guide exhaust
outdoors.

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DANGER! RISK OF DEATH!
Fire / explosion hazard!
During operation, the generator's gearbox can become very hot.
-Do not operate the device in areas with easily combustible materials.
-Allow the device to cool before use.
-Always make sure there is adequate ventilation.
-Wear safety gloves and safety shoes.
DANGER!
Beware of hot surface
During operation, the generator's gearbox can get hot.
3. Note for the operating company (only in combination with
RCD)
Before commissioning portable power take-off generators, the protective earth
(power take-off generator housing) must be properly connected. After the power
take-off generator is started up, before connecting the appliance, the residual current
circuit breaker (RCCB) must be tested for correct operation —press the test button.

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4. TECHNICAL INFORMATION
Using the generator
Axle shaft generators EZG 24/2 to EZG 66/4 are designed for mobile use,
independent of the power grid, with one more electrical/electronic appliances (230V /
50Hz or 400V / 50Hz) in continuous operation.
They are driven through a standard shaft connection (450 rpm), and attached at 3
points for flanging to the tractor.
Only operate in a dust-free and dry environment!
Design and operation
The three-phase generator is an electrical machine intended to convert mechanical
energy into electrical energy. In the application presented here, the mechanical
energy from the axle shaft of a tractor is reduced by a cardan joint. The cardan joint
is coupled to a speed converter that matches the tractor's speed to the speed
required for the three-phase generator.
The generator's voltage depends directly on the rotational speed: The system for
regulating the tractor's speed shows a mild drop in speed between idle and operation under
load. Therefore the idle speed should be set 3–4% higher than the rated speed. This means
the voltage should be 400–410V, and the frequency 51 Hz. We recommend checking the
speed if any other voltage is produced.
Frequency monitoring
In idle, the frequency must be set to 51 Hz. Under load, this drops to about 49 Hz. The
tolerance is +/- 2.5 Hz.
The three-phase generator is self-exciting in that it uses residual magnetism and
regulates itself using a combined system (serial/parallel excitation). The control
system allows a precise voltage of ±5% to be achieved (when run up to speed, at
constant rpm and with balanced loads). The three-phase generator's output
connections have been set up as a star connection at the factory. This type of
EZG 24/2 EZG 33/4, EZG 46/4

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connection allows a three-phase voltage of 400V to be generated from the three U1,
V1 and W1 terminals as well as a single-phase voltage of 230V from any of the three
aforementioned terminals and the neutral line. The rated power can be delivered only
for three-phase use. For single-phase use, the maximum deliverable power is 40% of
rated power. A single-phase load will result in a noticeable imbalance between the
rotational phases: If the load is not balanced, make sure that connected appliances
are not damaged.
The alternator as well as the distribution cabinet are supplied in the Protection Class
IP23.
Technical specifications
Designation
Value
Type
EZG 24/2
EZG 33/4
EZG 46/4
EZG 66/4
Generator
synchronous
synchronous
synchronous
synchronous
Continuous output
[COP]
kVA / kW
22,0 / 17,6
30,0 / 24,0
42,0 / 33,6
60,0 / 48,0
Rated voltage
400 V 3~ /
230 V 1~
400 V 3~ /
230 V 1~
400 V 3~ /
230 V 1~
400 V 3~ /
230 V 1~
Rated current
32 A 3~
43 A 3~
61 A 3~
87 A 3~
Power factor
cos (phi)
0,8
0,8
0,8
0,8
Frequency /
Protection Class
50 Hz / IP 23
50 Hz / IP 23
50 Hz / IP 23
50 Hz / IP 23
Power requirement
(idle) Power take-off
shaft app. kW / HP
35 / 48
45 / 61
60 / 81
87 / 118
Power take-off shaft
speed in revs/min
430
430
430
430
Generator speed in
revs/min
3000
1500
1500
1500
Weight kg
160
262
300
362
Dimensions LxBxH in
mm
930x800x900
930x800x900
1020x800x900
1020x800x900
Fig. 1: Technical specifications
5. INSTALLATION
The power take-off generator is an electrical machine.
which is exclusively to be moved, installed and put into operation, inspected
and repaired by specialist personnel
where these persons
must have the following:
- specific technical training
- knowledge / use of the accident prevention regulations (BGV A3), the safety
instructions, and this operating manual
Only operate in a dust-free and dry environment!

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The power take-off generator is a device that can be mechanically coupled to another
machine. It is the installer's task to instruct the user that adequate protection must be
ensured against moving parts or parts that carry current during operation.
DELIVERY - TRANSPORT - STORAGE
DANGER!
A device that slides away or falls can cause severe injury or death.
Consider the weight of 125 kg to 400 kg.
Do not put your feet under the device.
During transport, secure the device against sliding or tipping.
1. We wish to advise that the machine must be checked on arrival
in order to establish any damage which occurred during transport
.
Do not turn the package over or expose it
to rain or moisture.
2. Use lifting equipment with a suitable load capacity to move the machine.
The lifting ring on the generator or the
transport eye were realised exclusively for lifting the three-phase generator
.
3. Remove the packing from the machine. The packaging elements
(plastic bags, polystyrol foam, nails, cartons,
etc.) must not be left within in reach of children,
since they are potential sources of danger.
4. If the machine is not commissioned immediately,
it must be stored at a covered, clean location which free of
moisture. Before commissioning again after
a longer period of non-use it is advisable to check the insulation
for all windings. At room temperature measurements must be made
on the machine for a value greater than 1 MΩ.
Drying must be performed otherwise (at approx. 50 –60ºC).
.
5. The packaging materials delivered with the machine
must be disposed of according to the relevant standards
.
BEFORE COMMISSIONING
1. Before the machine is commissioned, the following must be checked:
a) the protective counter-hood (Fig. 2) must be in an undamaged and well

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fastened condition. The counter-hood must
cover the protection for the cardan joint over a surface of at least 50 mm
and prevent intentionanal contact of the hands with
elements which are moving (Fig. 2).
b) align the generator shaft and the cardan joint with the tractor's drive so that
they are linear.
c) the three anchoring points provided are fastened (Fig. 3) perfectly
and secured by the fastening elements provided.
2. For the first commissioning oil must be poured into the transmission unit
and changed after the first 50 operating hours;
check the level afterwards. For the version
with the level indicator the oil level must lie approximately
in the middle. For the version without a level indicator loosen the
lower side plug until one can sense oil coming out
. If the level is too low oil must be added through the
opening in the upper section of the transmission unit
. For a rapid and complete change of oil we
recommend unscrewing both the lower and the upper plug
on the body of the transmission unit. We draw your attention to the fact that
only oil for gearwheels type
SAE, 90EP may be used. Disposal of the old oil
should only be over specialist centres and by
observing the pertinent valid national regulations.
3. Before commissioning one must check that all connections are be in a perfect
condition
and that there should be no hindrances which
could impair rotation of the moving parts,
. Ensure that the suction in and und ejection openings
for cooling are free.
4. Abide by applicable safety standards for electrical connections.
Abide by the safety standards. Check that the
details on the nameplate correspond to the characteristics of
system to which the machine is to be connected.
-----------------------------------------------------------------------------------------------------------
The device must be earthed by connecting an earthing rod to the frame's
earthing terminal (only in combination with RCD).
5. Check that the switch is in the OFF position and
both the generator and the tractor have all
safety equipment installed and that it is fully functional. Abide by the safety
standards. Check that the details on the nameplate correspond to the
characteristics of the system to which the machine is to be connected.

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Fig. 2: Protective hood
Fig. 3: Anchor points

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6. USE
ATTENTION
Only operate in a dust-free and dry environment!
Electrical rotary machines contain dangerous parts which
are live or which move during operation,
so that:
- unintended use,
- removing the protective covers and disconnecting the safety devices,
- poor inspections and maintenance
can cause severe personal injuries or machine damage.
The following is essential for all operations performed of an electrical or
mechanical
nature by trained personnel.
ATTENTION!
Electric shocks cause injury or death.
DANGER!
Rotating parts
During operation, never reach into the machine , not with with hands or
tools.
Before any assembly or maintenance, make sure that the machine has
stopped and is disconnected from the tractor —or that the tractor has been
turned off, the switch is in OFF position and the ignition key has been
removed.
Before any start-up, make sure that the machine has been correctly and
securely fastened to the anchor points provided.
During all phases of disassembly, maintenance, lubrication and
assembly work on the cardan joint, safety must be maintained at all times according
to
the accident prevention standards.
1. Fasten the power take-off generator well using the pins in the scope of
delivery (possibly reducing sleeves for EZG24/2) and the splint on its three
anchoring points:
A faulty installation can cause injury to persons and damage to equipment
for which the manufacturer cannot be held liable

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.
6. Insert the cardan joint (not in the scope of delivery) between the generator and
the tractor (for a switched off tractor), whereby one must
ensure perfect coupling so that the machine both in idle and at a high speed is
completely free of vibrations.
7. Make sure that the generator's support structure sits
firmly on the ground: Rotation of a raised generator
is not permissible.The vibrations can cause inadequate
functionality of the three-phase generator and risk of causing
an accident
8. Safety inspection before commissioning (see p.10).
9. Start the tractor and
integrate the drive that provides the generator movement. Increase the rotational
speed step by step
until the frequency measuring device on the electrical control panel
reaches 52 Hz without a load.
10.Insert the plug in the corresponding socket.
Make sure the appliances connected to the generator
are suitable.
---------------------------------------------------------------------------------------------------------
Particularly ensure that there are no persons in the vicinity of the axial shaft
(within a distance of 1m) during the whole period of operation.
11.If the tractor does not deliver the required performance under load
and the frequency is significantly reduced (below 48Hz),
engage the accelerator in order to bring the frequency up to
the correct value (50 Hz). One must take account of the fact that
a tractor is connected to the three-phase generator
apart from the fact that it loses speed when under load
. When disconnecting the load from the three-phase generator overvoltages
and excessively high rotational speeds can occur,
and these voltage and frequency changes can
be damaging for other loads which are connected at the same time
.
Stopping the machine: Remove the individual loads, whereby
one starts with the lighter ones or set the main switch to
OFF/0, switch off the tractor and pull out the power plug.

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7. Inspections
a) Oil level
Generators running at 1,500 or 3,000 revs/min:
1. Unscrew the plugs from openings A and B.
2. Pour oil (SAE 90EP) into the upper opening A until it begins to come out
of opening B.
3. Screw the stoppers back in place.
Fig. 4: Oil check - 1
8. Maintenance
---------------------------------------------------------------------------------------------------------------------------
After repairs, the generator's electrical safety must be inspected at least once every 12
months. This work must be done only by an appropriately authorized electrician (per
EN 50 110-1).
---------------------------------------------------------------------------------------------------------------------------
DANGER!
Rotating parts
During operation, never reach into the machine , not with with hands or
tools.
Before any assembly or maintenance, make sure that the machine has
stopped and is disconnected from the tractor —or that the tractor has been
turned off, the switch is in OFF/0 position and the ignition key has been
removed.
DANGER!
Electric shocks cause injury or death.
The device must be operated only in dry, dust-free areas.
Never use a direct or pressurized water jet or damaging substances to
wash the machine.

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1. Mechanical checks:
At monthly intervals and at every commissioning, check the following:
Abnormal operating noises
Damage / functional limitations to the protective hood
The air intake and outlet openings must be clear
Check the sockets for mechanical damage and thermal overloads
Check the circuit breakers for damage to seals, and measuring instruments for
mechanical integrity
Designations / signs on display and operating instruments
Operating Manual
Oil level in transmission unit
2. Electrical checks:
Once a month, or at each commissioning, check the following:
the earthing connection for perfect condition
Every 500 operating hours but no less than once per year, check the following:
Check the brushes and the accumulator for wear, and the measuring
instruments mounted on the electrical control panel for correct operation.
Check the switch boxes for possible damage caused by condensation.
Electrical safety per DIN VDE 0701 and DIN VDE 0702
NOTES ON ACCESS TO THE SWITCH
The magnetic cut-out can be accessed for three purposes:
- if a device or a series of devices has been connected and they need higher current
than the switch's rated current
- if a short circuit occurs
In the first case, it is sufficient to reduce the load and then restart the generator,
whereas in the second case, the cause of the short-circuit must be found and
rectified.

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FINAL DISPOSAL
The packaging material must be recycled according to the environmental protection
regulations applicable at the place of use.
The workplace must be protected against contamination by leaking operating fluids.
Used or leftover fuels and lubricants must be recycled according to the environmental
regulations applicable at the place of use.
Electrical and electronic appliances, as well as batteries, must not be discarded with
domestic waste.
At the end of their service life, the user is required by law to hand over electrical and
electronic devices, as well as batteries, to suitably equipped public collection facilities
or to the place of purchase. The symbol on the product, the operating instructions or
the packaging refers to this.
Removable batteries must be taken from the devices and disposed of separately.
When you recycle, recover materials or otherwise reuse old devices, you make an
important contribution to protecting the environment.

Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Telefon: + 49 (0) 71 23 / 9737 –0
Telefax: + 49 (0) 71 23 / 9737 –50
E-Mail: [e-mail]
www: www.endress-stromerzeuger.de
© 2017, ENDRESS Elektrogerätebau GmbH