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.

Page 11Issue 07/2011
Safety instructions
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).
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.

Issue 07/2011Page 12
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Safety instructions
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).
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.

Page 13Issue 07/2011
Safety instructions
Warning
Danger to life caused by electric shock and risk of damage.
yWater from ahigh-pressure cleaner can lead
to the destruction of the switch cabinet or
electric shock.
►Never expose the generator or switch
cabinet to high-pressure cleaner.
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.

Issue 07/2011Page 14
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
References to norms and directives
References to norms and directives
The generator has been manufactured in accordance with the following
norms and directives.
yDIN 14686 “Fireghting equipment - Switch cabinets for xed generators
(generating sets) >= 12kVA in re-brigade vehicles”. As well as the
DIN14686mentioned above, the following norms and directives are also
of importance and are to be followed during the operation.
These are also referenced within DIN 14686.
yDIN 14555-3 “Vehicles carrying tools and gears ”
yDIN 6280-10, Reciprocating internal combustion engines; generating sets
with reciprocating internal combustion engines; small power generating
sets; requirements and tests
yDIN 49442, Two-pole watertight power sockets with earthing-contact,
10A, 250V and 10A, 250V-, 16A, 250V; principal dimensions
yDIN EN 50014 (VDE 0170/0171, Part1) Electrical equipment for use in
potentially explosive atmospheres- general requirements:
yDIN EN 60051-1, Direct acting indicating analogue electrical measuring
instruments and their accessories
yDIN EN 60309-1 (VDE 0623, Part1), Plugs, power sockets and couplers for
industrial purposes -Part 1:
general requirements
yDIN EN 60309-2 (VDE 0623, Part 20), Plugs, power sockets and couplers
for industrial purposes-Part 2: dimensional interchangeability
requirements for pin and contact-tube accessories
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

Page 15Issue 07/2011
References to norms and directives
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

Issue 07/2011Page 16
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Description of power generation system
Components
1 Description of power generation system
1.1 Components
The power generation system comprises the following units
yGenerator ðsection 1.4, page19
ySwitch cabinet ðsection 1.5, page21
1.2 Circuit diagram
The circuit diagram shown below shows the minimum equipment as per DIN
14686. Your power generation system may be dierent featuring additional
options.
The exact equipment of your generator
ðin the Appendix, or
ðswitch cabinet of the enclosed circuit diagram.

Page 17Issue 07/2011
Description of power generation system
Circuit diagram
I> I> I> I>
U
V
W
N
PE
L1 L2 L3 N PE
A AA
Hz
h
V
Figure 1 Circuit diagram, power generation system
(minimum equipment as per DIN 14686)
Switch cabinet form AA
Switch cabinet form BB and CC
Power contactor
Main circuit breaker
Switch cabinet lighting
supplied from on-board vehicle power supply
Ammeter
CEE Power sockets, 400V/16A, 3L + N+ PE
2Power sockets 230V/16A
Emergency power socket 230V/16A Only 1connect device!
Insulation monitorVoltmeter and
selection switch
Protective earth test device

Issue 07/2011Page 18
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Description of power generation system
Drive types, generator
1.3 Drive types, generator
The generator can be powered in various ways.
Installation and required components depend on the drive type
ðchapter “Installation of generator”, page 26.
1.3.1 Connection via drive shaft
The shaft on the generator is joined to the drive shaft of the drive unit via
acardan shaft. The generator runs at the same speed as the drive unit. The
drive unit must have asuitable and constantly regulated speed in order to
avoid operating the generator at an under or overspeed which can impair the
function of the generator or may even damage it.
1.3.2 Drive via hydraulic motor
The generator is driven by ahydraulic motor. The hydraulic motor is fed from
ahydraulic system. Do not operate the generator at an overspeed. Operation
at an overspeed can have negative consequences for the functioning of the
generator or may damage it.
1.3.3 Drive via belt pulley
The generator is joined to the drive unit via abelt pulley and abelt. The belt
drive is an especially simple and cost-eective means of transmission. It also
oers the advantage that, by selecting the transmission ratio, it is possible to
optimally adjust the speeds of the drive unit and generator to each other.

Page 19Issue 07/2011
Description of power generation system
Generator
1.4 Generator
1.4.1 Function
yThe generators are brushless, self-excited synchronous inner-pole
generators, which are electronically-controlled.
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 IEC 38.
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.
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 EN ISO 14982, ISO TC 127/ISO FDIS
13766/DIN EN 13909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.
1.4.2 Mechanical versions
Depending on their nominal output, the generators are constructed
in various model sizes. Depending on the model, there installation of
the generator may vary. Reference is made to these deviations in the
corresponding sections of this manual.
The following table and Figure 2give an overview of the most important
features of the generators.

Issue 07/2011Page 20
Built-in generators with switch cabinet for permanently installed power generation systems ≥ 12kVA in re engines
Description of power generation system
Generator
2-pole generators
DWG (BL)
13/7-2ZE
DWG (BL)
17/7-2ZE
DWG (BL)
23/12-2ZE
DWG (BL)
30/15-2ZE
DWG (BL)
40/14-2ZE
Output 13kVA 17kVA 23kVA 30kVA 40kVA
Model BG 132 BG 132 BG 160 BG 160 BG 160
Number
of poles
22222
Drive
speed
3000 1/min 3000 1/min 3000 1/min 3000 1/min 3000 1/min
4-pole generators
DWG (BL)
13/7-4ZE
DWG (BL)
17/7-4ZE
DWG (BL)
23/12-4ZE
DWG (BL)
30/15-4ZE
DWG (BL)
40/14-4ZE
Output 13kVA 17kVA 23Kva 30kVA 40kVA
Model BG 132 BG 160 BG 160 BG 160 BG 160
Number
of poles
44444
Drive
speed
1500 1/min 1500 1/min 1500 1/min 1500 1/min 1500 1/min
Figure 2 Generator
(shown: DWG (BL) 13/7-2-ZE, output 13kVA)
7
56
1Drive shaft
2Mounting prole
(all around, every 45°)
3Drain hole for condensation
water (if present)
4Mounting proles (both sides)
5Cooling proles
6Fan wheel cover
7Cooling air inlet
8Terminal box with generator
controller
1
2
4
8
3