GTS DWG (BL) 13/7-2 ZE User manual

Issue 07/2011
Built-in generators with switch cabinet
for permanently installed
power generation systems ≥ 12kVA
in re engines
DWG (BL) 13/7-2ZE
to
DWG (BL) 40/14-4ZE
AAA V k
Ω
Hz
Installation and operating manual
English 07/2011

Issue 07/2011Page 2
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
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 07/2011
Contents
Legend, safety instructions 2
Important information and notes 6
Qualied personnel 6
Intended use 6
Validity of the manual 7
Copyright 8
General note 8
Manufacturer's address 8
Safety instructions 10
References to norms and directives 14
1 Description of power generation system 16
1.1 Components 16
1.2 Circuit diagram 16
1.3 Drive types, generator 18
1.3.1 Connection via drive shaft 18
1.3.2 Drive via hydraulic motor 18
1.3.3 Drive via belt pulley 18
1.4 Generator 19
1.4.1 Function 19
1.4.2 Mechanical versions 19
2-pole generators 20
4-pole generators 20
1.5 Switch cabinet 21
Legend for gures 3, 4and 5: 22
2 Technical data 24
2.1 Generators 24
2.2 Generator controller 25
2.3 Switch cabinet 25
3 Installation of generator 26
3.1 General safety instructions 26
3.2 Requirements on the installation position 28
3.3 General provisions for installation 28
3.4 Permissible installation positions 30
Contents

Issue 07/2011Page 4
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
3.5 Installation of generators of model 132 31
3.5.1 Installation dimensions and assembly 31
3.5.2 Minimum clearances and cooling provisions 32
Minimum clearances 32
Temperature and pressures of the cooling air 33
3.5.3 Assembly instructions, coupling via drive shaft 34
Assembly example 1: R+W drive shaft with clamping hub connection 36
Assembly example 2: R+W drive shaft with cone hub connection 37
3.5.4 Assembly instructions for hydraulic drive 38
Preparatory disassembly 38
Assembly 38
3.5.5 Assembly instructions for belt drive 40
3.6 Installation of generators of model 160 42
3.6.1 Installation dimensions andassembly 42
3.6.2 Minimum clearances and cooling provisions 43
Minimum clearances 43
3.6.3 Temperature and pressures of the cooling air 44
3.6.4 Assembly instructions, coupling via drive shaft 45
3.6.5 Assembly instructions for hydraulic drive 45
3.6.6 Assembly instructions for belt drive 47
4 Installation of switch cabinet and electrical connection 49
4.1 General safety instructions 49
4.2 Requirements for the installation location 52
4.3 General provisions for installation 52
4.4 Installation 52
4.5 Electrical connection 53
4.5.1 Instructions, laying of cables 53
4.5.2 Instructions, connecting the generator 54
4.5.3 Instructions for connecting the switch cabinet 55
5 Operation 56
5.1 General safety instructions, operation 56
5.2 Permissible operating conditions 59
5.3 Working safely with electrical devices 60
5.4 Electrical safety devices, safety measures 62
5.5 Power generation system operation 63
5.5.1 Power sockets, controls and displays 63
5.5.2 Power distribution and connection of devices 65
5.5.3 Warning/disconnect with faulty insulation 69
5.5.4 Check insulation monitor 70
5.5.5 Protective earth check for devices of protection class I 71
5.6 Checking the generator 72
5.6.1 Description 72
5.6.2 Procedure 73
Contents

Page 5Issue 07/2011
6 Care and maintenance 74
6.1 Maintenance overview 75
6.2 General safety instructions, care and maintenance 76
6.3 Visual check/cleaning work performed by the user 77
6.4 Maintenance work carried out by authorised personnel 78
6.4.1 Replacing the ball bearings 79
7 Repairs 79
8 Disassembly 80
8.1 Safety instructions 80
8.2 Disassembly 80
9 Transport and storage 81
9.1 Generator 81
9.2 Switch cabinet 82
10 Decommissioning, storage, disposal 83
10.1 Disposal instructions 83
Generator 83
Switch cabinet 83
11 Spare parts 84
11.1 Generator 84
12 Index 85
Contents

Issue 07/2011Page 6
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Important information and notes
Important information and notes
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.
Intended use
The power generation systems described in this manual comprise
agenerator with controller and the associated switch cabinet. These power
generation systems are designed exclusively for use as permanently installed
power generation systems in re engines.
yOnly use the generators for mains backup operations or for providing
current to mobile distribution systems. Only use the power generation
system in accordance with the voltage and performance data on the rating
plate.
yDo not connect the power generation system 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.
yOnly use the power generation system for the uses indicated here and
only in accordance with the information in this operating 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 07/2011
Important information and notes
Validity of the manual
This manual applies exclusively for built-in generators of the types listed
below which are delivered completely with the associated switch cabinets
and are designed exclusively for use as permanently installed power
generation systems in re engines. In this manual, the dierent generator
types are distinguished by their type designation and their model.
Two-pole execution
(nominal speed 3,000U/min)
Four-pole execution
(nominal speed 1,500U/min)
yDWG (BL) 13/7-2ZE yDWG (BL) 13/7-4ZE
yDWG (BL) 17/7-2ZE yDWG (BL) 17/7-4ZE
yDWG (BL) 23/12-2ZE yDWG (BL) 23/12-4ZE
yDWG (BL) 30/15-2ZE yDWG (BL) 30/15-4ZE
yDWG (BL) 40/14-2ZE yDWG (BL) 40/14-4ZE

Issue 07/2011Page 8
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Important information and notes
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.
© 2003-2011Generator. Technik. Systeme. GmbH&Co. KG.
All rights reserved.
General note
Technical changes after going to press are not taken into account.
We reserve the right to make changes.
Version: July 2011
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]

Page 9Issue 07/2011
Important information and notes
Dear customer,
Generator. Technik. Systeme. GmbH&Co. KG is atechnically leading
manufacturer of power generation systems and produces generators from
4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 power generation
system.
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 power generation system 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

Issue 07/2011Page 10
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Safety instructions
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 power generation system,
please read the operating manual fully and carefully.
Only use the generator and the switch cabinet 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
yThe emergency power socket which is given aspecial label is
not protected by the insulation monitor. For this reason, only
the “electrical separation” protective measure is eective for
this power socket.
►Only connect asingle consumer to the emergency power
socket. Failing to do so will suspend the protective measure.