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).

Page 11Issue 05/2013
Safety instructions
Danger
Danger to life through electric shock
yA grounding of the neutral conductor of the generator
(N,neutral conductor) invalidates the “electrical separation”
protective measure.
►Never ground the neutral conductor of the generator.
Danger
Danger to life through electric shock
yInsulation monitors can mutually inuence each other.
►Do not connect any other insulation monitors downstream
of the power generation system.
Warning
Risk of injury and risk of damage!
yInadequately qualied persons are at risk when working
on the generator or switch cabinet and may damage the
generator.
►The assembly, connection and commissioning of the power
generation system and work on the electrical systems may
only be carried out by authorised, qualied and specially
trained personnel.
►Carry out all connection work according to applicable
national regulations (in Germany: these include VDE
specications).

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 12
Safety instructions
Warning
Risk of injury
yWhen protective coverings are not in use, there is arisk of
injury through electric shock, moving parts and hot surfaces.
►Only operate the generator with the tted protective
coverings proscribed for the drive in the regulations.
Warning
Risk of explosion
yA discharge of sparks during operation is possible.
►Do not operate the generator in environments where there
is arisk of explosion.
Warning
Risk of accident
yDevices which start up in an uncontrolled fashion can put
persons at risk or injury them or cause damage or themselves
be damaged.
►Switch o all devices before you connect them to the power
generation system.
Warning
Danger to life caused by electric shock and risk of damage.
yJets from ahigh-pressure cleaner can lead
to the destruction of the switch cabinet or
electric shock.
►Never expose the generator or switch
cabinet with aprotection class lower than
IP69k to high-pressure cleaner.

Page 13Issue 05/2013
Safety instructions
Caution
Burn hazard
yParts of the generator can become very hot during and after
the operation.
►Allow the generator or parts of the generator to cool down
before you touch them.
Important
yThese generators are not suitable for supplies to xed
distribution networks.
yThese generators are designed for acertain performance and
speed. They can be destroyed by voltage peaks and overloads.
►Do not use the generator to supply building-site distribution
boards or other xed distribution networks (e.g.domestic
installations).
►Never connect the generator to the public electricity grid or
combine with other power generation systems.
►Never combine multiple generators.

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 14
References to norms and directives
3 References to norms and directives
The generator has been manufactured in accordance with the following
norms and directives.
yDIN 6280-10, Reciprocating internal combustion engines; generating sets
with reciprocating internal combustion engines; small power generating
sets; requirements and tests
yDIN EN 60034, Rotating electrical machines
yDIN VDE 0100 (VDE 0100), requirements for the installation of
high-voltage systems with nominal voltages of up to 1,000V
yDIN VDE 0100-430 (VDE 0100, Part 430), installing high-voltage machines
with nominal voltages of up to 1,000V protective measures- protecting
cables and lines in the event of an overcurrent
yDIN VDE 0100-551 (VDE 0100, Part 551), electrical installations of buildings
- Part 5: selection and installation of electrical equipment-Chapter 55:
other equipment-main section 551: low-voltage power supply systems
yDIN VDE 0105-100, operating electrical installations
yDIN VDE 0470-1 (VDE 0470, Part1), protection class provided by
enclosures (IP code)
yBGV A2, Electrical installations and equipment
yGUV 2.10, Accident prevention requirement “Electrical installations and
equipment” with instructions for implementation

Page 15Issue 05/2013
Description
Models (BG132and BG160)
4 Description
4.1 Models (BG132and BG160)
Depending on their nominal output and number of poles, the generators
are constructed in two dierent versions: BG132model means 132mm
measured from the base up to the shaft center; and 160mm for model 160.
BG132model
y2-pole generators
(drive speed 3000 1/min) with rated output of 3.2kVA up to 20kVA
These generators come in abrushless version or with carbon brushes.
Depending on the type of installation, generators of model 132can be
constructed as single-bearing or dual-bearing generators. Single-bearing
generators are designed for direct attachment to the drive unit. Here, the
bearing of the drive unit then operates as asecond bearing.
y4-pole generators
(drive speed 1500 1/min) with rated output of 5kVA up to 15kVA
These generators are only constructed as abrushless version. Depending
on the type of installation, generators of model 132can be constructed as
single-bearing or dual-bearing generators. Single-bearing generators are
designed for direct attachment to the drive unit. Here, the bearing of the
drive unit then operates as asecond bearing.
Model 160-BG160
y2-pole generators (drive speed 3000 1/min)
from arated output of 20kVA up to 40kVA
y4-pole generators (drive speed 1500 1/min)
from arated output of 10kVA up to 40kVA
Model 160generators are only available as abrushless version, and are only
constructed as dual-bearing generators
Dual-bearing generators are usually installed near the drive unit. There are
arange of options for providing drive power to the generator.
ÖDrive types, page25

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 16
Description
Models (BG132and BG160)
4.1.1 Features and options of the models
Variant/option BG132 BG160
BG132 2-pole to 20kVA
4-pole to 15kVA
Single-bearing Dual-bearing Dual-bearing
BG160 1-pole from 20kVA
4-pole from 10kVA
Generator attached directly onto engine X - -
The type of the seal depends
onthedrivemotorused.
X - -
Direct coupling via ange X X X
Driven by belts or hydraulic system - X X
“Brushless” version X X X
“Brush generator” version 2-pole version
only
-
Delivery without terminal box, cable guided directly
in tube
X X X
Terminal box attached, without controller/lter
function.
X X X
Terminal box attached, controller/lter functions
included in part
X X X
Terminal box attached, controller/lter functions
fully included
X X X
“Extended generator controller with automatic idling
mode” option
X X X
Switch box attached:
Model in cast aluminium or sheet metal nish
X (1) X (1) X (1)
Operating hour counter in the switch box option X (1) X (1) X (1)
Insulation monitoring option in the switch box
option
X (1) X (1) X (1)
- = not possible or “no”
x = possible or “yes”
(1) Not available for the complete performance range.
If you have any questions, please get in touch with
Generator.Technik.Systeme GmbH&Co. KG.directly.

Page 17Issue 05/2013
Description
General functions
4.2 General functions
These generator series are self-excited synchronous inner-pole generators.
The generator comprises afunctional group consisting of the main machine,
exciter machine and, on brushless generators, co-rotating rectiers. These
groups are housed together in one housing. The electronic generator
controller can be housed in aterminal box attached to the generator or in an
external switch box.
The generators are extremely resistant to unbalanced loads due to
constructive measures such as adamping cage and balanced controller.
4.3 Generator
4.3.1 Function
yThe generators are electronically controlled, self-excited inner-pole
generators, in brush and brushless versions.
yThe voltage supplied by the generator is regulated by the built-in
electronic generator controller so that the output voltage between idle
speed and the nominal load meets the requirements of DIN EN 60038.
This equates to aquality standard which is comparable with the public
electricity supply network. The constancy of the output frequency is
dependent on the speed constancy of the drive unit. The frequency is
synchronous to the drive speed.
yIf the generator sustains atemporary overload (below the actuation
time of the protective circuit breaker) or if devices are connected to the
generator with excessive power draw or excessive start-up power draw,
the generator controller will automatically restrict the power output (by
reducing the exciter eld current) and reduce the output voltage.
yThe generators meet the EMC directives DIN EN 13309/DIN EN 55014and
other EMC standards referenced in these norms.
yThe generators are cooled by self-ventilation independent of the direction
of rotation. The cooling air is drawn through the cooling proles by the fan
wheel on the rear side of the generator and across the housing, towards
the front side.

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 18
Description
Generator
Generator without the “insulation monitor with disconnection” option
With this option, the generator meets the protective measure “electrical
separation with potential equalization connector” according to VDE 0100,
Part 410.
The mains conguration is the IT network with neutral conductor Nand
protective earth conductor PE.
ÖFig. 1, Mains conguration of generator, principle circuit diagram,
electrical separation, page18
L1
L2
L3
N
PE
Generator
Consumer
Fig. 1 Mains conguration of generator, principle circuit diagram,
electrical separation
Generator with “insulation monitor with disconnection” option
With this option, the generator meets the protective measure “electrical
separation with insulation monitor” according to VDE 0100, Part 410:702.

Page 19Issue 05/2013
Description
Generator
4.3.2 Generator controller
U_ZK
1 2 3 4 5
U_Feld
µC
U_REF
T_REG
U
ZU ZV ZW
V W N
F1
GND
Vdd +5V Ref +1V6 Ref
+5V Ref
U_GEN
U_P
f_GEN
I_K_Feld
J
GND
1
2
3
4
J3
Serial COM
GND
+5V Ref
R_Shunt
GND
LED1
+7V5
+14V +28V
+280V
I_F_n=2,2A
T1
DF
B6U
CS
P18F252
RC0 RA4 RA0 RA3 RA1 RA2
IO
RC2
RX TX
6
1
2
3
4
5
6
J5
ICD-Interface
(optional)
RB7
MCLR
RB6
2F2 2F1

F2
Fig. 2 Block circuit diagram, DWG-brushless generator with generator
controller LCAR4BASIC

Synchronous generators of series DGG, DWG and WG
Issue 05/2013Page 20
Description
Generator
U_ZK
1 2 3 4 5
U_Feld
µC
U_REF T_REG
LLA_t
U
ZU ZV ZW
V W N
F1
K1B
GND
Vdd +5V Ref +1V6 Ref
+5V Ref
U_GEN
U_P
f_GEN
LLA_Pmin
I_K_Feld
+1V6 Ref
J
GND
1
2
3
4
J3
Serial COM
GND
+5V Ref
S2M S1M
1R / 2W
K1A
V23092-A1012-A302
B
LLA AUS
Si. max 1A MT
1 2 3 4
R_Shunt
GND
LED1
LED2
+7V5
+14V +28V
+280V
I_F_n=2,2A
T1
DF
B6U
CS
P18F252
RC0 RC3 RA4 RA0 RA3 RB7 RA1 RA2
IO
RC2
RX TX
I_P>0,4A
6
1
2
3
4
5
6
J5
ICD-Interface
(optional)
RB7
RB7
MCLR
RB6
2F2 2F1

F2
Fig. 3 Block circuit diagram, DWG generator with brushes and
generator controller LCAR4STD (with connected electronic
idlingmechanism)