GTS DGG Series User manual

Issue 05/2013
Synchronous generators of series
DGG, DWG and WG
Models BG132and BG160
Installation and operating manual
English 05/2013

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 2
Legend, safety instructions
Legend, safety instructions
This operating manual contains information you must observe for your own
personal safety and to prevent material or property damage. The information
concerning your own personal safety is emphasised with awarning triangle.
Information about material or property damage without personal injury
appears without awarning triangle. Depending on the hazard class, the
warning information is shown as follows in descending order.
Danger
Means that death or serious bodily injury will occur if the
appropriate precautionary measures are not met.
Warning
Means that death or serious bodily injury can occur if the
appropriate precautionary measures are not met.
Caution
Means that minor bodily injury can occur if the appropriate
precautionary measures are not met.
Important
Means that property damage can occur if the appropriate
precautionary measures are not met.
Note
Means that an unexpected event or condition can arise if the
appropriate information is not followed.
If more than one hazard class arises, the warning level with the highest level
is always the one used. If awarning of injury to personnel in awarning notice
with warning triangle appears, an additional warning about material or
property damage can be attached to the same warning notice.

Page 3Issue 05/2013
Legend, safety instructions
Contents
Legend, safety instructions 2
1 Important information and notes 6
1.1 Qualied personnel 6
1.2 Intended use 6
1.3 Validity of the manual 7
1.4 Copyright 8
1.5 General safety instruction 8
1.6 Manufacturer's address 8
1.7 Warranty 8
2 Safety instructions 10
3 References to norms and directives 14
4 Description 15
4.1 Models (BG132and BG160) 15
4.1.1 Features and options of the models 16
4.2 General functions 17
4.3 Generator 17
4.3.1 Function 17
4.3.2 Generator controller 19
4.3.3 Mechanical versions 21
4.4 Variants for the electrical connection 21
4.4.1 Generator with attached terminal box (standard version) 21
4.4.2 Generator with attached corrugated pipe,
controller electronics installed externally 23
4.4.3 Generator with attached switch box 23
4.5 Drive types 25
4.5.1 Single-bearing generators (only BG132) 25
4.5.2 Dual-bearing generators 25
4.5.3 Direct connection via acoupling 25
4.5.4 Drive via hydraulic motor 25
4.5.5 Drive via belt pulley 26
5 Technical data 27
5.1 Generators 27
5.2 Switch box 27
5.3 Generator controller 27
6 Installation of generator 28
6.1 General safety instructions, installation 28
6.2 Requirements on the installation position 30
6.3 General provisions for installation 31
6.4 Permissible installation positions 33
6.4.1 Single-bearing generators 33
6.4.2 Dual-bearing generators (BG132an BG160) 34
Contents

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 4
Legend, safety instructions
6.5 Holes for condensation water discharge 35
6.6 Installation of single-bearing generators 37
6.6.1 Delivery scope 37
6.6.2 Installation dimensions 38
6.6.3 Minimum clearances and cooling provisions 38
6.6.4 Assembly to engine 40
6.6.5 Additional assembly instructions for shaft attachment withtension bolt 48
6.7 Installation of dual-bearing generators (BG132) 52
6.7.1 Installation dimensions and assembly 52
6.7.2 Minimum clearances and cooling provisions 53
6.7.3 Assembly instructions for belt drive 55
6.7.4 Assembly instructions for ange mount 57
6.7.5 Assembly instructions for hydraulic drive 61
6.8 Installation of dual-bearing generators (BG160) 64
6.8.1 Installation dimensions and assembly 65
6.8.2 Minimum clearances and cooling provisions 66
6.8.3 Assembly instructions belt drive 67
6.8.4 Assembly instructions for ange mount 69
6.8.5 Assembly instructions hydraulic drive 71
6.9 Electrical generator connection 73
6.9.1 General 74
6.9.2 Version with terminal box 74
6.9.3 Version without terminal box, cable is routed in the tube 75
7 Operation 76
7.1 General safety instructions, operation 76
7.2 Operating conditions 80
7.3 Electrical safety devices, safety measures and earthing 81
7.3.1 Electrical protection and earth/potential equalization 81
7.3.2 Protection against overcurrent 82
7.4 Connection to an existing distribution network (e.g.company installation) 83
7.5 Working safely with electrical devices 84
7.6 Generator operation 86
7.6.1 Control elements in the optional switch box 86
7.6.2 Electricity distribution and the connection of devices 87
7.6.3 Check insulation monitor 91
8 Maintenance and care 92
8.1 General safety instructions, maintenance and care 93
8.2 Maintenance overview 95
8.3 Visual checks/cleaning work, users 96
8.4 Maintenance work, authorised technicians 97
8.4.1 Check/replace carbon brushes (only for brush generators) 98
8.4.2 Check carbon brush holder 99
8.4.3 Install the carbon brush holder 99
8.4.4 Replacement of the ball bearing 100
Contents

Page 5Issue 05/2013
Legend, safety instructions
9 Repairs 101
10 Disassembly 102
10.1 Safety instructions 102
10.2 Disassembly 102
10.3 Disassembly of dual-bearing generators
(BG132and BG160models) 103
10.4 Disassembly of single-bearing generators 103
10.4.1 Disassembly of single-bearing brush generators 104
10.4.2 Disassembly of brushless single-bearing generators 108
11 Transport and storage 113
11.1 Generator 113
12 Decommissioning, storage after disassembly of, disposal 114
12.1 Disposal instructions 114
13 Designation system for generator types 115
13.1 Type code 115
13.2 Examples of designations 116
14 Spare parts 117
14.1 Generator 117
14.2 Explosion drawing BG132 118
14.3 Explosion drawing BG160 120
16 Index of gures 122
17 Index 124
Contents

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 6
Important information and notes
1 Important information and notes
1.1 Qualied personnel
The unit or system may be installed and operated in connection with this
manual. Installation, commissioning and operation of aunit or system must
only be performed by qualied personnel.
Qualied personnel within the meaning of the technical safety information
in this manual are persons with the authorization to put devices, systems
and circuits into service, to ground them, and to label them, according to
technical safety standards.
1.2 Intended use
yOnly use the generator for mains backup operations or for providing
current to mobile distribution systems. Only use the generator in
accordance with the performance data on the rating plate.
yThe system is not designed for feedback mode (e.g.connection of
4-quadrant converters), so this mode is only available to alimited extent
after consultation with the manufacturer.
ySecure the generator outputs against overcurrent and short circuit using
suitable safety devices, according to the information on the rating plate.
yDo not connect the generator to supply other energy distribution or
generator systems (e.g.domestic installations, distribution boards on
building sites, other generators, or the public electricity supply network).
yOnly operate the generator at the nominal speed indicated on the rating
plate.
yOnly use the generator for the uses indicated here and only in accordance
with the information in this manual.
All other uses are not as intended and are not allowed.
In the event of improper use or misuse of the current generator or individual
components thereof, the Generator. Technik. Systeme. GmbH&Co. KG
cannot take any responsibility.

Page 7Issue 05/2013
Important information and notes
1.3 Validity of the manual
This operating manual applies for synchronous generators with the type
designations DGG (three phase AC generators), DWG (AC-DC generators) and
WG (AC generators). For reasons of clarity, only AC generators are indicated in
the operating manual and explicitly named. The specied descriptions apply
analogously for WG series AC generators and for generators with special
voltages and special frequencies.

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 8
Important information and notes
1.4 Copyright
Without the express approval of
Generator. Technik. Systeme. GmbH&Co. KG, no part of this operating
manual may be distributed, published or transmitted, irrespective of the type
and the means by which this occurs.
© 2003-2013Generator. Technik. Systeme. GmbH&Co. KG.
All rights reserved.
1.5 General safety instruction
Technical changes after going to press are not taken into account.
We reserve the right to make changes.
Version: May 2013
1.6 Manufacturer's address
We are more than happy to provide information, assistance, service and
ordering assistance.
Generator. Technik. Systeme. GmbH&Co. KG
Ziegelfeldstraße 62 + 65
73563Mögglingen (Germany)
Tel [phone]
Fax [phone]
www.gts-generator.com
[e-mail]
1.7 Warranty
We provide awarranty on generators of the series described here, according
to the latest version of the “General for products and services of the
electronic industry” of the ZVEI.

Page 9Issue 05/2013
Important information and notes
Dear customer,
Generator. Technik. Systeme. GmbH&Co. KG is atechnically leading
manufacturer of generators from 3.2to 40kVA and electronic control units of
its own design. GTS generators are highly durable and of the highest quality.
They are maintenance-free, long-lasting, precise and robust.
Only high-quality parts that meet the requirements of VDE tests and DIN and
European norms are used in the manufacture of the generator.
All information in this operating manual has been composed and veried
carefully to the best of our knowledge. Before installation, commissioning
and use of the current generator please read the operating manual closely.
Generator. Technik. Systeme. GmbH&Co. KG cannot take any responsibility
for any application contrary to the descriptions in this operating manual nor
for damage arising from incorrect operation and management, incorrect
installation, failing to use the unit as intended, prohibited technical
modications or due to repairs by unauthorised personnel.
If you have questions, please get in touch with
Generator. Technik. Systeme. GmbH&Co. KG.
Best regards
Generator. Technik. Systeme. GmbH&Co. KG

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 10
Safety instructions
2 Safety instructions
This section contains acompilation of generally valid safety instructions.
Please read and heed the safety instructions before installation,
commissioning and operation of the generator carefully. This safety
instructions also appears in the relevant areas of the text in the manual.
Important
►Before installing and using the generator, please read the
operating manual fully and carefully.
►Only use the generator for the uses listed in the sections on
“intended use” and only in accordance with the information in
the operating manuals.
Danger
Danger to life through electric shock
yDuring operation, the power generation system generates
voltages that are potentially fatal.
►Never touch the generator, the switch cabinet or the
devices attached to the power generation system with wet
hands during operation.
Danger
Danger to life through electric shock
yWorking on the generator or switch cabinet, visual inspections
for maintenance purposes or cleaning work on the power
generation system during operation can lead to potentially
fatal injuries through electric shock.
►Switch o the drive unit before performing any inspection
or maintenance work on the generator or switch cabinet.
Prevent the drive unit from being switched back on
by accident (e.g.remove the ignition key and keep
somewheresafe).