Synchronous Generators BG 132 and BG 160
Synchronous Generators BG 132 and BG 160
Synchronous Generators BG 132 and BG 160
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<strong>Synchronous</strong> <strong>Generators</strong><br />
Series DGG, DWG <strong>and</strong> WG<br />
Size <strong>BG</strong> <strong>132</strong> <strong>and</strong> <strong>BG</strong> <strong>160</strong><br />
Operating <strong>and</strong> Installation Instructions<br />
English 08/2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Copyright, general information, manufacturer's address<br />
Copyright<br />
No part of this Operation Manual may be reproduced, published or transmitted in<br />
any form or by any means without the express permission of Generator-Technik<br />
Schwäbisch Gmünd GmbH &Co. KG.<br />
© 2002 Generator-Technik Schwäbisch Gmünd GmbH & Co. KG. All rights<br />
reserved.<br />
General information<br />
Technical modifications after date of printing are not considered. Subject to<br />
change without notice.<br />
Issue date: August 2002<br />
Validity of the manual<br />
This manual applies to all synchronous generators of the types DGG (three-phase<br />
DC generators), DWG (three-phase AC generators) <strong>and</strong> WG (single-phase AC<br />
generators). However, for reasons of clarity only three-phase AC generators are<br />
represented <strong>and</strong> mentioned in the manual. In their general sense the given<br />
explanations are however also applicable for single-phase AC generators of the<br />
series WG <strong>and</strong> appropriate generators with special voltages <strong>and</strong> frequencies.<br />
Further information about the designation system for the various generator types<br />
can be found in chapter 1 on page 11.<br />
Manufacturer's address<br />
For any information <strong>and</strong> support concerning technical problems, services <strong>and</strong><br />
orders please contact us.<br />
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG<br />
Ziegelfeldstraße 18<br />
D-73563 Mögglingen, Germany<br />
Phone +49 7174 89 80 0 0<br />
Fax +49 7174 89 80 0 25<br />
2 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Table of contents<br />
Table of contents<br />
Some important <strong>and</strong> valuable information .................................................. 5<br />
Warranty ............................................................................................... 5<br />
Proper use ............................................................................................ 6<br />
Preconditions <strong>and</strong> requirements to be met by the place of installation ........... 6<br />
Safety precautions ................................................................................. 7<br />
1 Designation system for generator types .............................................. 11<br />
1.1 Type codes .............................................................................. 11<br />
1.2 Examples for designations .......................................................... 12<br />
2 Description .................................................................................... 13<br />
2.1 Use of different sizes (<strong>BG</strong> <strong>132</strong> <strong>and</strong> <strong>BG</strong> <strong>160</strong>) .................................. 13<br />
2.2 Overview of features <strong>and</strong> options for different sizes <strong>and</strong> designs ...... 13<br />
2.3 General functionality ................................................................ 15<br />
2.4 Generator governor ................................................................... 17<br />
2.5 Mechanical designs ................................................................... 19<br />
2.6 Drive types .............................................................................. 21<br />
2.7 Terminal box (st<strong>and</strong>ard version) .................................................. 22<br />
2.8 Control box (optional, only for 8 kVA <strong>and</strong> 13 kVA generators) .......... 23<br />
3 Technical data ................................................................................ 25<br />
3.1 <strong>Generators</strong> ............................................................................... 25<br />
3.2 Control box (optional, only for 8 kVA <strong>and</strong> 13 kVA generators) .......... 25<br />
3.3 Generator governor ................................................................... 25<br />
4 Installation .................................................................................... 27<br />
4.1 Safety precautions for installation ............................................... 27<br />
4.2 Requirements to be met by the place of installation <strong>and</strong> use ........... 29<br />
4.3 General regulations for installation ............................................. 29<br />
4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water ....... 31<br />
4.5 Installation for single-bearing generators ..................................... 35<br />
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<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Table of contents<br />
4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>) ........................... 49<br />
4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>) ........................... 62<br />
4.8 Electrical connection of the generators ........................................ 70<br />
5 Operation ...................................................................................... 73<br />
5.1 Safety information for operation ................................................. 73<br />
5.2 Permissible operating conditions ................................................ 75<br />
5.3 Electric protection equipment, protective measures <strong>and</strong> grounding ... 75<br />
5.4 Connection to an existing power distribution network<br />
(e.g. house wiring) ................................................................... 77<br />
5.5 Operating information for safe working with electric devices ........... 78<br />
5.6 Operation of the generator ......................................................... 80<br />
6 Maintenance .................................................................................. 85<br />
6.1 Maintenance overview ............................................................... 86<br />
6.2 Safety precautions .................................................................... 87<br />
6.3 Visual inspections <strong>and</strong> cleaning to be performed by the user ........... 88<br />
6.4 Maintenance to be performed by authorized qualified personnel ...... 89<br />
7 Reconditioning ............................................................................... 92<br />
8 Removal ........................................................................................ 93<br />
8.1 Safety precautions .................................................................... 93<br />
8.2 Removal of two-bearing generators (<strong>BG</strong><strong>132</strong> <strong>and</strong> <strong>BG</strong><strong>160</strong>) ................. 93<br />
8.3 Removal of single-bearing generators .......................................... 93<br />
9 Transport <strong>and</strong> storage .....................................................................103<br />
10 Putting out of operation, storage after dismantling, disposal ................104<br />
10.1 Waste disposal information .......................................................104<br />
11 Spare parts ...................................................................................105<br />
4 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Some important <strong>and</strong> valuable information<br />
Some important <strong>and</strong> valuable information<br />
Dear customer,<br />
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG is a technically leading<br />
manufacturer of power generators in the best tradition <strong>and</strong> manufactures<br />
generators with ratings of 4 to 30 kVA as well as its own design of electronic<br />
control units for those generators. What makes GTS generators st<strong>and</strong> out is their<br />
excellent fitness for practical use <strong>and</strong> superior quality. They are maintenancefree,<br />
durable, precise <strong>and</strong> robust.<br />
Choosing a synchronous generator of this series was a decision for a technically<br />
superior product. This product has been manufactured using only high-quality<br />
components which meet the requirements of VDE testing <strong>and</strong> comply with<br />
appropriate German (DIN) <strong>and</strong> European (EN) st<strong>and</strong>ards.<br />
All information contained in these operating instructions has been carefully<br />
compiled <strong>and</strong> checked by us to the best of our knowledge <strong>and</strong> belief. Please be<br />
sure to read <strong>and</strong> underst<strong>and</strong> the operating instructions before installing,<br />
commissioning <strong>and</strong> using the generator.<br />
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG does not assume any<br />
liability for any applications which are contrary to the descriptions given in<br />
these operating instructions, <strong>and</strong> for any loss or damage which has been caused<br />
by incorrect operation <strong>and</strong> h<strong>and</strong>ling, faulty installation, improper use, abuse,<br />
non-approved technical modifications or by any repairs performed by<br />
unauthorized personnel.<br />
If you have any questions, please contact Generator-Technik Schwäbisch Gmünd<br />
GmbH & Co. KG.<br />
Warranty<br />
Yours sincerely,<br />
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG<br />
For the generators of the series described in this manual, we issue warranty<br />
according to the latest version of the "Allgemeine Lieferbedingungen für<br />
Erzeugnisse und Leistungen der Elektroindustrie (general conditions for the<br />
supply of products <strong>and</strong> services of the electrical industry)" of the ZVEI.<br />
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<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Proper use<br />
Proper use<br />
The generators described in this manual are intended for the generation of<br />
electrical energy within the context of emergency st<strong>and</strong>by operation for feeding<br />
in mobile distribution systems. The generators must only be used according to<br />
the voltage <strong>and</strong> power specifications listed on the type plate. Reverse feeding<br />
operation (e.g. connection of four-quadrant converters) is not planned <strong>and</strong> only<br />
conditionally possible after consulting the manufacturer.<br />
The generators have to be driven with the specified rated speed. The generator<br />
outputs have to be protected against overcurrent <strong>and</strong> short-circuit by adequate<br />
fuse equipment according to the specifications on the type plate.<br />
The generators must not be connected to other power distribution or electricity<br />
generation systems (such as other generators or the public electricity supply<br />
network, for example).<br />
The use of the generators is only allowed for applications described here <strong>and</strong> in<br />
conformity with the specifications given in this manual. Any other application is<br />
considered to be improper use <strong>and</strong> is not permitted.<br />
In case of improper use, misuse or abuse of the generators or of parts of them,<br />
Generator-Technik Schwäbisch Gmünd GmbH & Co. KG will not assume any<br />
liability.<br />
Preconditions <strong>and</strong> requirements to be met by the place of<br />
installation<br />
Single-bearing generators are mounted directly to the engine. These generators<br />
may only be mounted to engines which comply with the applicable regulations,<br />
rules <strong>and</strong> requirements.<br />
Two-bearing generators are usually installed right next to the engine. The<br />
generator has to be firmly <strong>and</strong> securely mounted on an absolutely flat base with<br />
a bearing capacity adequate to the weight class of the generator. When using a<br />
belt drive, it is advisable to mount the generator adjustable. For that purpose<br />
e.g. mounting rails can be used, providing the possibility of adjusting the belt<br />
tension.<br />
All generators are splash-proof according to IP54 specifications <strong>and</strong> can thus<br />
also be mounted <strong>and</strong> used outdoor. The generators are not explosion-protected<br />
<strong>and</strong> thus must no be used in explosive atmospheres. Further regulations on this<br />
have to be observed!<br />
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<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Safety precautions<br />
When selecting the place of installation <strong>and</strong> use, the required minimum<br />
clearances have to be observed, adequate ventilation has to be ensured at any<br />
time, <strong>and</strong> the temperature of the cooling air must not exceed 40 °C. Further<br />
information can be found in chapter 4 on page 27.<br />
The generators <strong>and</strong> the parts mounted to them must not be sprayed with highpressure<br />
cleaners. Therefore, the generators should preferably be installed in a<br />
way <strong>and</strong> place which makes it impossible to even inadvertently spray the<br />
generator with high-pressure cleaners.<br />
Safety precautions<br />
This section summarizes the safety precautions of relevance. Read <strong>and</strong><br />
underst<strong>and</strong> the safety precautions before installing, commissioning <strong>and</strong><br />
operating the generator <strong>and</strong> observe the precautions. You will find the safety<br />
precautions in the relevant passages through the manual as well.<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
<br />
performed by adequately trained qualified personnel <strong>and</strong> in<br />
conformity with the applicable national rules <strong>and</strong> regulations<br />
(in Germany: VDE regulations, among others).<br />
DANGER<br />
Risk of<br />
personal injury<br />
or death<br />
<strong>and</strong><br />
destruction<br />
hazard<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
performed in the off <strong>and</strong> de-energized state. Mortal danger by<br />
electric shock! Engines that have been turned off must be<br />
secured against accidental restarting (e.g. by removing the<br />
ignition key <strong>and</strong> keeping it safe)!<br />
Installation <strong>and</strong> commissioning of the generator as well as any<br />
maintenance, service <strong>and</strong> replacement work may only be<br />
performed by authorized <strong>and</strong> qualified personnel.<br />
Do not operate the generator in explosive environments.<br />
Further regulations on this have to be observed!<br />
Do not perform any visual inspections for maintenance<br />
purposes <strong>and</strong> cleaning work on the generator during operation.<br />
Always turn off the engine first <strong>and</strong> make sure that it cannot be<br />
restarted accidentally (e.g. by removing the ignition key <strong>and</strong><br />
keeping it safe). Mortal danger by electric shock!<br />
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<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Safety precautions<br />
DANGER<br />
Risk of<br />
personal injury<br />
or death<br />
<strong>and</strong><br />
destruction<br />
hazard<br />
Never connect the generator to the public electricity supply<br />
network or to any other systems for power generation. Risk of<br />
death, fire <strong>and</strong> destruction hazard!<br />
Never connect several generators to each other. Risk of death,<br />
fire <strong>and</strong> destruction hazard!<br />
If the generator shall be connected to an existing power<br />
distribution network (e.g. a house wiring), it has to be<br />
ensured, that the system is completely <strong>and</strong> reliably<br />
disconnected from the public electricity supply network of the<br />
energy supply company. Reverse feeding into the public<br />
electricity supply network or network interconnection is not<br />
allowed. Reverse feeding involves mortal danger by electric<br />
shock for persons possibly working at the de-energized public<br />
electricity supply network. Due to network interconnection<br />
with the public electricity supply network, the generator can be<br />
damaged, burn or cause fire in electrical cables of the system.<br />
Grounding the neutral conductor of the generator (N, midpoint<br />
conductor) supersedes the protective measure "protection<br />
separation" <strong>and</strong> should therefore be avoided. If the neutral<br />
conductor N shall be grounded anyway, this may only be<br />
performed by an electrically qualified person. In this case, a<br />
current-operated earth-leakage circuit breaker has to be<br />
connected on the load side of the generator output. The<br />
efficiency of the electrical protective measure has to be<br />
confirmed by an appropriate measurement.<br />
The generator supplies highly dangerous voltages during<br />
operation! Never touch the generator or the devices connected<br />
to the generator with wet h<strong>and</strong>s during operation. Mortal<br />
danger by electric shock!<br />
Generator components may be very hot, not just during but also<br />
after operation. Burning hazard!<br />
The generator may only be operated with the protective covers<br />
for the drive mounted as specified. Risk of personal injury!<br />
8 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Safety precautions<br />
Be sure to read <strong>and</strong> underst<strong>and</strong> the operating instructions<br />
<br />
completely before using the generator. The generator may only<br />
be used for applications described in section "Proper use"<br />
above <strong>and</strong> in conformity with the specifications in this manual.<br />
DANGER<br />
Risk of<br />
personal injury<br />
or death<br />
<strong>and</strong><br />
destruction<br />
hazard<br />
Before connecting devices to the generator, ensure that the<br />
devices are switched off. Accident hazard! Unsupervised<br />
starting devices can endanger or injure persons as well as cause<br />
damages or damage themselves.<br />
Infants <strong>and</strong> animals must never have admittance to the<br />
generator, not just during but also after operation. Make<br />
appropriate precautions. Mortal danger by electric shock, injury<br />
<strong>and</strong> burning hazard!<br />
The generator or its components must never be<br />
exposed to the jet of high-pressure cleaners.<br />
Mortal danger by electric shock <strong>and</strong><br />
destruction hazard!<br />
CAUTION<br />
Destruction<br />
hazard<br />
or<br />
damage<br />
Be sure to observe the permissible operating conditions given in<br />
section 5.2 on page 75. The generator may only be operated in<br />
conformity with the operating conditions <strong>and</strong> data specified there.<br />
This particularly applies to the ambient <strong>and</strong> cooling conditions <strong>and</strong><br />
the permissible current load.<br />
For installation <strong>and</strong> repair only genuine components or external<br />
components expressly approved by the manufacturer may be used.<br />
It is not permitted to perform any modifications on the generator<br />
or on individual components or the control box. Any modification,<br />
improper repair or use of unsuitable external components will<br />
terminate all <strong>and</strong> any claims under a warranty as well as the type<br />
approval according to the German Equipment Safety Law <strong>and</strong> the<br />
certification to EU / EEC directives. In this case the manufacturer<br />
will not assume any liability.<br />
Issue date: August 2002 9
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Safety precautions<br />
10 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 1, Designation system for generator types<br />
1 Designation system for generator types<br />
This chapter provides information about the designation system for the<br />
individual generator types as well as examples of generator designations.<br />
1.1 Type codes<br />
DWG (BL) 17 / 7,0 - 2ZE<br />
E: Electronic generator governor<br />
Z: Two-bearing design<br />
E: Single-bearing design<br />
Number of poles:<br />
2 poles (rated speed 3000 rpm)<br />
or<br />
4 poles (rated speed 1500 rpm)<br />
Single-phase output power in kVA, e.g. 7 kVA<br />
Three-phase output power in kVA, e.g. 17 kVA.<br />
Power determines size:<br />
• 2-pole generator: up to 17 kVA = <strong>BG</strong> <strong>132</strong>,<br />
20 kVA <strong>and</strong> higher = <strong>BG</strong> <strong>160</strong><br />
• 4-pole generator: 10 kVA <strong>and</strong> higher = <strong>BG</strong> <strong>160</strong><br />
With specification (BL): Brushless generator<br />
Without specification (BL): Brush-type generator<br />
DWG: Three-phase AC generator<br />
WG: Single-phase AC generator<br />
DGG: Three-phase DC generator<br />
Issue date: August 2002 11
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 1, Designation system for generator types<br />
1.2 Examples for designations<br />
Type<br />
DWG 8,0/5,0-2EE<br />
Features<br />
Three-phase AC generator, brush-type machine, 8 kVA<br />
three-phase power, 5 kVA single-phase power, 2-pole<br />
machine, single-bearing design, electronic governor, size<br />
<strong>BG</strong> <strong>132</strong> (2-pole generator < 17 kVA).<br />
DWG (BL) 10/6-4ZE Three-phase AC generator, brushless, 10 kVA three-phase<br />
power, 6 kVA single-phase power, 4-pole machine, twobearing<br />
design, electronic governor, size <strong>BG</strong> <strong>160</strong> (10 kVA,<br />
4-pole generator).<br />
12 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 2, Description<br />
2 Description<br />
2.1 Use of different sizes (<strong>BG</strong> <strong>132</strong> <strong>and</strong> <strong>BG</strong> <strong>160</strong>)<br />
Depending on the rated output power <strong>and</strong> the number of poles the generators<br />
are produced in two different sizes: <strong>BG</strong> <strong>132</strong> or <strong>BG</strong> <strong>160</strong>.<br />
<strong>BG</strong> <strong>132</strong><br />
Size <strong>BG</strong> <strong>132</strong> is used for<br />
• 2-pole generators (driving speed 3000 rpm) with rated power outputs smaller<br />
than 17 kVA.<br />
<strong>BG</strong> <strong>160</strong><br />
Size <strong>BG</strong> <strong>160</strong> is used for<br />
• 2-pole generators (driving speed 3000 rpm) with rated power outputs greater<br />
than <strong>and</strong> including 20 kVA or<br />
• 4-pole generators (driving speed 1500 rpm) with rated power outputs greater<br />
than <strong>and</strong> including 10 kVA.<br />
2.2 Overview of features <strong>and</strong> options for different sizes <strong>and</strong><br />
designs<br />
The following table shows an overview of features <strong>and</strong> possible options for the<br />
different generator sizes <strong>and</strong> types.<br />
Key for the table:<br />
x = possible or "yes"<br />
- = not possible or "no"<br />
Issue date: August 2002 13
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 2, Description<br />
Version / Option <strong>BG</strong> <strong>132</strong><br />
2-pole up to<br />
17 kVA<br />
Generator directly mounted to<br />
engine<br />
Engine-/manufacturer-depending<br />
sealing betw. engine <strong>and</strong> generator<br />
<strong>BG</strong> <strong>160</strong><br />
2-pole ≥ 20 kVA<br />
4-pole ≥ 10 kVA<br />
1-bear. 2-bear. 2-bearing<br />
x - -<br />
x - -<br />
Direct coupling via flange - x x<br />
Belt or hydraulic drive - x x<br />
Brushless Generator x x x<br />
Brush-type generator x x -<br />
Supply without terminal box,<br />
cable directly lead out in a hose<br />
Terminal box mounted,<br />
no governor/filter functions<br />
Terminal box mounted,<br />
governor/filter functions partly<br />
implemented<br />
Terminal box mounted,<br />
governor/filter functions completely<br />
implemented<br />
Option "Exp<strong>and</strong>ed generator<br />
governor with no-load automatic"<br />
Control box mounted,<br />
aluminum cast or sheet metal<br />
x x x<br />
x x x<br />
x x x<br />
x x x<br />
x x x<br />
x 1 x 1 -<br />
Option hour meter in control box x 1 x 1 -<br />
Option insulation monitoring in<br />
control box<br />
x 1 x 1 -<br />
1. Only available for versions with rated power output of 8 kVA or 13 kVA.<br />
14 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 2, Description<br />
2.3 General functionality<br />
All generators of these series are self-excited synchronous inner-pole generators.<br />
The generator consists of the functional groups main machine, exciter <strong>and</strong><br />
rotating rectifier mounted in a common housing. The electronic generator<br />
governor can be placed in a terminal box mounted on the generator, an external<br />
control box or in the optional control box mounted on the generator instead of<br />
the terminal box.<br />
Due to various constructional measures, an amortisseur <strong>and</strong> a balancing control<br />
the generators have an extreme asymmetric load capability.<br />
Cooling of the generators is performed by a rotating direction-independent selfventilation.<br />
For this purpose, the cooling air is sucked on the rear side by a fan<br />
impeller <strong>and</strong> then blown to the front outside along the generator.<br />
The supplied generator voltage is regulated by the electronic generator governor,<br />
so that the output voltage fulfills the requirements of IEC 38 for the entire range<br />
between no-load <strong>and</strong> rated load condition. This corresponds to the quality<br />
st<strong>and</strong>ard of the public electricity supply network. The output frequency<br />
constancy depends on the speed constancy of the engine.<br />
In case of short generator overload conditions (below the reaction time of the<br />
circuit breakers) or if devices with a too high power consumption or a too high<br />
starting power are connected to the generator, the generator governor<br />
automatically limits the output power (by limiting the exciter field current) <strong>and</strong><br />
reduces the output voltage.<br />
Optionally an exp<strong>and</strong>ed generator governor with no-load automatic is available.<br />
Further information about the generator governor can be found in section 2.4 on<br />
page 17.<br />
If the generator is not equipped with the option "Insulation monitoring with<br />
switching-off", it fulfills the protective measure "Protection separation with<br />
equipotential bonding" according to VDE 0100 part 728. The used power system<br />
is the IT system with neutral conductor N <strong>and</strong> equipotential bonding conductor<br />
PE (see Figure 1).<br />
If the generator is equipped with the option "Insulation monitoring with<br />
switching-off", it fulfills the better protective measure "Protection separation<br />
with insulation monitoring" according to VDE 0100, part 728.<br />
The generators of this series comply with the EMC regulations EN ISO 14982, ISO<br />
TC 127 / ISO FDIS 13766 / DIN EN 13909 <strong>and</strong> further EMC regulations referenced<br />
in these regulations.<br />
Issue date: August 2002 15
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 2, Description<br />
Generator<br />
L1<br />
L2<br />
L3<br />
N<br />
PE<br />
Load<br />
Figure 1<br />
Power system of the generator: Principle diagram for protection<br />
separation<br />
16 Issue date: August 2002
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Chapter 2, Description<br />
2.4 Generator governor<br />
Figure 2<br />
Generator governor LCAR3LIM for brush-type generators<br />
(simplified schematic representation)<br />
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Chapter 2, Description<br />
Figure 3<br />
Generator governor LCAR3LIM for brushless generators<br />
(simplified schematic representation)<br />
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Chapter 2, Description<br />
2.5 Mechanical designs<br />
Depending on the rated power output <strong>and</strong> the number of poles the generators<br />
are produced in two different sizes: <strong>BG</strong> <strong>132</strong> or <strong>BG</strong> <strong>160</strong>.<br />
Size <strong>BG</strong> <strong>132</strong> is used for 2-pole generators with rated power outputs up to 17<br />
kVA. These generators are available as brushless type or with carbon brushes.<br />
Depending on the kind of use, generators of the size <strong>BG</strong> <strong>132</strong> can either be built<br />
as single-bearing generators or as two-bearing generators. Single-bearing<br />
generators are directly mounted to the engine. In this case the engine bearing is<br />
used as second bearing.<br />
Size <strong>BG</strong> <strong>160</strong> is used for<br />
• 2-pole generators with rated power outputs starting from 20 kVA or for<br />
• 4-pole generators with rated power outputs starting from 10 kVA.<br />
<strong>Generators</strong> of the size <strong>BG</strong> <strong>160</strong> are exclusively available as brushless generators<br />
<strong>and</strong> are only produced as two-bearing generators.<br />
Two-bearing generators are usually installed right next to the engine. Regarding<br />
the generator drive, there are various options to choose from (refer to section<br />
2.6 on page 21).<br />
To cover a wide range of applications, the generators can be delivered in<br />
different versions regarding the electrical connection.<br />
• Generator with terminal box mounted (st<strong>and</strong>ard type):<br />
The terminal box mounted on the generator contains a connection terminal<br />
plate for the connecting cables as well as the generator governor.<br />
Furthermore, a suppression filter can be installed in the terminal box.<br />
However, the suppression filter can also be located in an external control<br />
cabinet, if desired. Further information about the terminal box can be found<br />
in section 2.7 on page 22.<br />
• Cable directly lead out of the generator in a hose without a terminal box<br />
mounted:<br />
For this version, all connecting cables of the generator as well as the cables<br />
for the generator governor are led out of the generator housing using a hose.<br />
This version offers the special advantage, that the generator can also be used<br />
in relatively hot environments. In this case, the generator governor as well as<br />
the complete current distribution <strong>and</strong> the electrical fuse protection has to be<br />
installed in an external control cabinet.<br />
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Chapter 2, Description<br />
• Generator with a control box mounted (only applicable for 8 kVA <strong>and</strong> 13 kVA<br />
versions):<br />
In the st<strong>and</strong>ard version the control box optionally mounted on the generator<br />
contains the generator governor, a suppression filter, the sockets for<br />
connecting the loads as well as an all-pole circuit breaker for protecting the<br />
installed sockets against overcurrent <strong>and</strong> short-circuit. As additional options<br />
an hour meter <strong>and</strong> an insulation monitoring can be installed. Further<br />
information about the optional control box can be found in section 2.8 on<br />
page 23.<br />
Terminal box<br />
Drive shaft<br />
Mounting profile<br />
(all around with 45°<br />
spacing)<br />
Drain hole for<br />
condensation water<br />
(if available)<br />
Angle brackets<br />
(fitted on both sides)<br />
Cooling<br />
profiles<br />
Cooling air intake<br />
Fan impeller shroud<br />
Drain hole for condensation water<br />
(if available)<br />
Figure 4<br />
Two-bearing generator, size <strong>BG</strong> <strong>132</strong> with terminal box<br />
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Chapter 2, Description<br />
2.6 Drive types<br />
2.6.1 Single-bearing generators (only <strong>BG</strong> <strong>132</strong>)<br />
Single-bearing generators are exclusively intended for direct mounting to the<br />
engine. The shafts of the generator <strong>and</strong> the engine are directly connected to<br />
each other <strong>and</strong> the bearing of the engine is used as second bearing for the<br />
generator. Therefore, the generator always runs at the same speed as the engine.<br />
With this type of drive, it has to be ensured that the engine has an appropriate<br />
speed rating. Otherwise the generator is operated at underspeed or overspeed<br />
which can restrict the functionality of the generator.<br />
For information regarding the installation of the generator please refer to<br />
chapter 4 on page 27.<br />
2.6.2 Two-bearing generators<br />
Two-bearing generators can be driven in different ways as described below. For<br />
information regarding the installation of components necessary for the<br />
corresponding type of driving, please refer to chapter 4 on page 27.<br />
Belt pulley drive<br />
The generator is mechanically connected to the engine via a belt pulley <strong>and</strong> a<br />
belt. The belt drive is a particularly simple <strong>and</strong> inexpensive type of drive.<br />
Moreover it offers the advantage that the speeds of the engine <strong>and</strong> the generator<br />
can be optimally balanced by selecting the transmission ratio.<br />
Direct coupling of the generator via flange<br />
Using direct flange mounting, the shafts of the generator <strong>and</strong> the engine are<br />
connected by a flange. Therefore, the generator always runs at the same speed as<br />
the engine. With this type of drive, it has to be ensured that the engine has an<br />
appropriate speed rating. Otherwise the generator is operated at underspeed or<br />
overspeed which can restrict the functionality of the generator.<br />
Hydraulic motor drive<br />
In this case, the generator is driven by a hydraulic motor supplied from a<br />
hydraulic system. When using this type of drive, attention must be particularly<br />
drawn to the fact that the generator is not operated at overspeed. This may have<br />
adverse effects on the functionality of the generator as well.<br />
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Chapter 2, Description<br />
2.7 Terminal box (st<strong>and</strong>ard version)<br />
The terminal box mounted to the generator contains a connection terminal plate<br />
for the connecting cables. Inside the terminal box cover the completely sealedin<br />
generator governor is installed. The terminal box can furthermore contain a<br />
suppression filter which, however, can also be placed in an external control<br />
cabinet, if desired.<br />
The generator governor in the terminal box cover can also be replaced by an<br />
optionally available exp<strong>and</strong>ed generator governor with a no-load automatic<br />
function. Further information about this can be found in section 2.4 on page 17.<br />
Generator governor<br />
Connection terminal plate<br />
Terminal box<br />
Suppression filter (optional)<br />
Figure 5<br />
Terminal box with connection terminal plate, generator governor<br />
<strong>and</strong> suppression filter<br />
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Chapter 2, Description<br />
2.8 Control box (optional, only for 8 kVA <strong>and</strong> 13 kVA generators)<br />
2.8.1 General<br />
The control box mounted on the generator is only available for generators with<br />
rated power outputs of 8 kVA <strong>and</strong> 13 kVA. In the st<strong>and</strong>ard version it contains the<br />
generator governor, a suppression filter, the sockets for connecting the loads as<br />
well as an all-pole circuit breaker for protecting the installed sockets against<br />
overcurrent <strong>and</strong> short-circuit. As additional options an hour meter <strong>and</strong> an<br />
insulation monitoring with switching-off can be installed.<br />
The generator governor in the control box can also be replaced by an optional<br />
exp<strong>and</strong>ed generator governor with no-load automatic function. Further<br />
information about this can be found in section 2.4 on page 17.<br />
Hour meter<br />
(optional)<br />
Insulation monitoring unit<br />
(optional)<br />
Circuit breaker<br />
(4-pole)<br />
Socket 400 V<br />
Sockets 230 V<br />
Figure 6<br />
Control box with installed options hour meter <strong>and</strong> insulation<br />
monitoring<br />
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Chapter 2, Description<br />
2.8.2 Option insulation monitoring with switching-off<br />
If the generator is equipped with the option "Insulation monitoring with<br />
switching-off", it fulfills the protective measure "Protection separation with<br />
insulation monitoring" according to VDE 0100, part 728.<br />
The insulation monitoring unit (see Figure 6) monitors the insulation of the<br />
devices connected to the sockets. If it detects a defective insulation of a<br />
connected device or extension cord, the insulation monitoring unit immediately<br />
switches off all sockets <strong>and</strong> the red signal lamp "FAULTY INSULATION" lights up<br />
to indicate the fault. In this case the defective device has to be disconnected<br />
<strong>and</strong> taken out of operation <strong>and</strong> the insulation monitoring unit has to be reset.<br />
<strong>Generators</strong> which are equipped with an insulation monitoring unit<br />
must not be connected to further insulation monitoring units,<br />
since the insulation monitoring units can mutually interact.<br />
CAUTION<br />
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Chapter 3, Technical data<br />
3 Technical data<br />
3.1 <strong>Generators</strong><br />
The technical data of the generator can be found on the type plate mounted on<br />
the generator.<br />
3.2 Control box (optional, only for 8 kVA <strong>and</strong> 13 kVA generators)<br />
Type of enclosure<br />
Connectors<br />
Features<br />
Optional features<br />
Permissible length of<br />
connected cables<br />
IP54 (all covers closed <strong>and</strong> locked)<br />
1 CEE socket 5 x 16 A (3P + N + PE)<br />
3 protective contact sockets 16 A (1P + N + PE)<br />
4-pole circuit breaker B 16 A<br />
Governor, filter <strong>and</strong> noise suppression installed<br />
Hour meter<br />
Insulation monitoring unit with signal lamp<br />
Fulfills protective measure "Protection separation<br />
with insulation monitoring" according to DVGW 308<br />
Total length of all connected cables:<br />
250 m max. at conductor cross section 2.5 mm 2<br />
100 m max. at conductor cross section 1.5 mm 2<br />
3.3 Generator governor<br />
Governor type<br />
LCAR3<br />
Pin assignment Pin Color Function<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
red<br />
gray<br />
yellow<br />
yellow<br />
yellow<br />
F1<br />
F2<br />
1/2 U<br />
1/2 V<br />
1/2 W<br />
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Chapter 3, Technical data<br />
26 Issue date: August 2002
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Chapter 4: 4.1 Safety precautions for installation<br />
4 Installation<br />
The installation procedures may differ depending on the generator version <strong>and</strong><br />
type. Where applicable, such differences are mentioned in the concerning texts.<br />
Prior to installation of the generator, read <strong>and</strong> underst<strong>and</strong> the safety precautions<br />
in section 4.1 as well as all other applicable sections of this chapter <strong>and</strong> observe<br />
the instructions <strong>and</strong> information given therein.<br />
CAUTION<br />
The installation work described in this chapter<br />
may only be performed by authorized <strong>and</strong><br />
qualified personnel.<br />
Do not open or disassemble the generator <strong>and</strong>/or<br />
the control box mounted on the generator<br />
(depending on the version)! The generator may<br />
only be opened by the manufacturer or an agency<br />
authorized by the manufacturer. It is not allowed<br />
to perform any work or operations not described<br />
in this manual.<br />
4.1 Safety precautions for installation<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
<br />
performed by adequately trained qualified personnel <strong>and</strong> in<br />
conformity with the applicable national rules <strong>and</strong> regulations<br />
(in Germany: VDE regulations, among others).<br />
DANGER<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
performed in the off <strong>and</strong> de-energized state. Mortal danger by<br />
electric shock!<br />
Engines that have been turned off have to be secured against<br />
accidental restarting (e.g. by removing the ignition key <strong>and</strong><br />
keeping it safe)!<br />
Installation of the generator as well as any maintenance,<br />
service <strong>and</strong> replacement work may only be performed by<br />
authorized <strong>and</strong> qualified personnel.<br />
Never connect the generator to the public electricity supply<br />
network or to any other systems for power generation. Risk of<br />
death, fire <strong>and</strong> destruction hazard!<br />
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Chapter 4: 4.1 Safety precautions for installation<br />
DANGER<br />
CAUTION<br />
Never connect several generators to each other. Risk of death,<br />
fire <strong>and</strong> destruction hazard!<br />
Grounding the neutral conductor of the generator (N, midpoint<br />
conductor) supersedes the protective measure "protection<br />
separation" <strong>and</strong> should therefore be avoided. If the neutral<br />
conductor N shall be grounded anyway, this may only be<br />
performed by an electrically qualified person. In this case, a<br />
current-operated earth-leakage circuit breaker has to be<br />
connected on the load side of the generator output. The<br />
efficiency of the electrical protective measure has to be<br />
confirmed by an appropriate measurement.<br />
The generator may only be operated with the protective covers<br />
for the drive mounted as specified. Risk of personal injury!<br />
Be sure to completely read <strong>and</strong> underst<strong>and</strong> the operating<br />
instructions before installing <strong>and</strong> using the generator. The<br />
generator may only be used for applications described in<br />
section "Proper use" <strong>and</strong> in conformity with the specifications<br />
given in this manual.<br />
For installation only genuine components or external components<br />
expressly approved by the manufacturer may be used.<br />
It is not permitted to perform any modifications on the generator<br />
or on individual components or the control box. Any modification,<br />
improper repair or use of unsuitable external components will<br />
terminate all <strong>and</strong> any claims under a warranty as well as the type<br />
approval according to the German Equipment Safety Law <strong>and</strong> the<br />
certification to EU / EEC directives. In this case the manufacturer<br />
will not assume any liability.<br />
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Chapter 4: 4.2 Requirements to be met by the place of installation <strong>and</strong> use<br />
4.2 Requirements to be met by the place of installation <strong>and</strong> use<br />
Single-bearing generators are mounted directly to the engine. These generators<br />
may only be mounted to engines which comply with the applicable regulations,<br />
rules <strong>and</strong> requirements.<br />
Two-bearing generators are usually installed right next to the engine. The<br />
generator has to be firmly <strong>and</strong> securely mounted on an absolutely flat base with<br />
a bearing capacity adequate to the weight class of the generator. When using a<br />
belt drive, it is advisable to mount the generator adjustable. For that purpose<br />
e.g. mounting rails can be used, providing the possibility of adjusting the belt<br />
tension.<br />
All generators are splash-proof according to IP54 specifications <strong>and</strong> can thus<br />
also be mounted <strong>and</strong> used outdoor. The generators are not explosion-protected<br />
<strong>and</strong> thus must no be used in explosive atmospheres. Further regulations on this<br />
have to be observed!<br />
When selecting the place of installation <strong>and</strong> use, the required minimum<br />
clearances have to be observed, adequate ventilation has to be ensured at any<br />
time, <strong>and</strong> the temperature of the cooling air must not exceed 40 °C.<br />
The generators <strong>and</strong> the parts mounted to them must not be sprayed with highpressure<br />
cleaners. Therefore, the generators should preferably be installed in a<br />
way <strong>and</strong> place which makes it impossible to even inadvertently spray the<br />
generator with high-pressure cleaners.<br />
4.3 General regulations for installation<br />
A correct <strong>and</strong> proper installation of the generator is a prerequisite for a safe,<br />
reliable <strong>and</strong> error-free operation as well as the electrical <strong>and</strong> mechanical safety.<br />
Usually the generators are operated with a counterclockwise direction of<br />
rotation. In this case the output voltage has a "clockwise rotating field".<br />
However, the generators can also be operated with a clockwise direction of<br />
rotation. Then the output voltage has a "counterclockwise rotating field".<br />
Due to the dynamic processes during the switching of electric loads, the engine<br />
must have adequate power reserves <strong>and</strong> its governor system must be able to deal<br />
with such processes.<br />
The constructional form <strong>and</strong> design of the generator must not be changed.<br />
Mounting surfaces must be precisely flat. Misalignments during installation have<br />
to be avoided.<br />
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Chapter 4: 4.3 General regulations for installation<br />
After installation, a test finger according to EN 60034, part 5, or a foreign part<br />
with a diameter greater than 12 mm (e.g. a sphere) must not come in contact<br />
with rotating parts, if a risk could result from this. Especially the protective<br />
covers of the power transmission have to be constructed stable <strong>and</strong> mounted<br />
firmly. It must not be possible to remove protective covers without using tools.<br />
The cooling air must be supplied <strong>and</strong> eliminated in a way, that the accumulating<br />
dissipation heat is eliminated definitively. Only harmless amounts of dust <strong>and</strong><br />
water may be sucked with the cooling air. Short-circuits of the air have to be<br />
avoided.<br />
<strong>Generators</strong> with a second shaft end must not be operated without a machine or<br />
protective cover correctly installed to this end.<br />
If the generator is not already equipped ex works with a control box containing<br />
electric protection equipment <strong>and</strong> sockets, adequate fuse equipment has to be<br />
installed in an external control cabinet to protect the circuits (sockets) against<br />
overcurrent <strong>and</strong> short-circuit. Observe that the neutral conductor N has to be<br />
fused as well. Consult the generator manufacturer GTS for the correct types <strong>and</strong><br />
nominal currents of the circuit breakers to be used. Further information about<br />
this can be found in section 4.8 on page 70.<br />
If the generator is not already equipped ex works with a control box containing<br />
electric protection equipment <strong>and</strong> sockets, the generator, the control cabinet<br />
<strong>and</strong> the complete electric installation have to be checked by visual inspection,<br />
testing <strong>and</strong> measurement according to DIN VDE 0100, part 610, before bringing<br />
the generator into operation for the first time.<br />
Observe the specific installation rules <strong>and</strong> instructions for the individual<br />
generator types listed in the following sections of this manual. There you<br />
can also find particular installation notes for the different drive types of the<br />
generators.<br />
• Refer to section 4.5 on page 35 for single-bearing generators of the size<br />
<strong>BG</strong> <strong>132</strong>.<br />
• Refer to section 4.6 on page 49 for two-bearing generators of the size<br />
<strong>BG</strong> <strong>132</strong>.<br />
• Refer to section 4.7 on page 62 for two-bearing generators of the size<br />
<strong>BG</strong> <strong>160</strong>.<br />
• Refer to section 4.8 on page 70 for notes <strong>and</strong> instructions concerning the<br />
electrical connection of the generators.<br />
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Chapter 4: 4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water<br />
4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water<br />
4.4.1 Permissible mounting positions for single-bearing<br />
generators<br />
Single-bearing generators are mounted directly to the<br />
engine. Thus, a horizontal mounting position is<br />
predetermined by the engine.<br />
When ordering the generator, the position of the<br />
terminal box has to be specified (or the position of<br />
the cable lead-out or the control box, depending on<br />
the version).<br />
The following mounting positions are possible:<br />
• Terminal box on top<br />
• Terminal box turned by 45° or 90° to the left or<br />
to the right<br />
No other mounting positions are permitted!<br />
ok<br />
ok<br />
ok<br />
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Chapter 4: 4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water<br />
4.4.2 Permissible mounting positions for two-bearing generators<br />
(<strong>BG</strong> <strong>132</strong> <strong>and</strong> <strong>BG</strong> <strong>160</strong>)<br />
The generator has to be mounted on a horizontal flat<br />
base st<strong>and</strong>ing on its angle brackets, as shown in<br />
the accompanying figure.<br />
When mounted in normal position, the terminal box<br />
is positioned on the top of the generator (or the<br />
cable lead-out or the control box, depending on the<br />
version).<br />
It is also possible to install the generator turned by<br />
45° or 90° to the left or to the right, as shown in the<br />
accompanying figure. For this purpose, the angle<br />
brackets have to be removed <strong>and</strong> mounted again to<br />
the corresponding mounting profiles.<br />
ok<br />
ok<br />
ok<br />
No other mounting position is permitted!<br />
no<br />
no<br />
no<br />
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Chapter 4: 4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water<br />
4.4.3 Drain holes for condensation water (<strong>BG</strong> <strong>132</strong> <strong>and</strong> <strong>BG</strong> <strong>160</strong>)<br />
NOTE<br />
This section is only applicable, if drain holes are available in the<br />
generator housing.<br />
The drain holes for condensation water are not available at all<br />
generators. Depending on the intended field of application of the<br />
generator, these holes can also be missing. In case of doubt, please<br />
check the generator.<br />
Under unfortunate circumstances, possibly<br />
condensation water can occur inside the<br />
generator. To provide an outlet for this<br />
condensation water, the generator housing<br />
possibly has several drain holes (4 holes<br />
each on the front <strong>and</strong> on the rear, 90°<br />
spacing).<br />
If these drain holes are available in the<br />
housing, the holes at the lowest point in<br />
mounting position has always to be<br />
opened.<br />
All other holes (on both sides <strong>and</strong> on the<br />
top) have to be closed by screws.<br />
NOTE: The holes on the rear side are<br />
covered by the fan impeller shroud. The<br />
holes are only accessible after removing<br />
the shroud.<br />
Max. thread length 8 mm!<br />
Make sure that the two drain holes located<br />
on the bottom are opened. If necessary,<br />
remove the screws to open the<br />
condensation water drain holes.<br />
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Chapter 4: 4.4 Permissible mounting positions <strong>and</strong> drain holes for cond. water<br />
Make sure that the holes on both sides <strong>and</strong><br />
on the top are closed with screws.<br />
If you are installing the generator turned<br />
from the mid position, remove the screws<br />
from the holes located at the bottom side<br />
in order to open the condensation water<br />
drain holes <strong>and</strong> then use these screws to<br />
close the open holes which are now<br />
located on the side.<br />
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Chapter 4: 4.5 Installation for single-bearing generators<br />
4.5 Installation for single-bearing generators<br />
For installing the generator proceed according to the descriptions in this section<br />
4.5. Prior to installation, read <strong>and</strong> underst<strong>and</strong> the safety precautions in section<br />
4.1 as well as the sections 4.2 to 4.4 <strong>and</strong> observe the instructions <strong>and</strong><br />
information given there.<br />
Optionally, lifting eye bolts are provided on the top or on both sides of the<br />
generator (45° from the vertical) for attaching lifting equipment. Lifting<br />
equipment may only be attached to the generator using these lifting eye bolts.<br />
Only appropriate lifting equipment may be used.<br />
4.5.1 Scope of delivery (single-bearing generators)<br />
The scope of delivery may differ depending on the generator version <strong>and</strong> the<br />
engine type. The type of sealing against the engine depends on the engine/<br />
manufacturer. For this reason, the appropriate sealings have to be ordered<br />
together with the generator.<br />
4.5.2 Dimensions (single-bearing generators)<br />
The dimensions of the generator can be found in the drawing sheet included in<br />
the annex.<br />
No other parts may be mounted to the mounting<br />
profiles of the generator housing.<br />
CAUTION<br />
4.5.3 Minimum clearances <strong>and</strong> regulations for cooling (singlebearing<br />
generators)<br />
In order to provide sufficient cooling the generator needs adequate ventilation.<br />
The cooling air is sucked on the rear side by the fan impeller <strong>and</strong> then blown to<br />
the front side through the cooling profiles along the housing. If necessary,<br />
adequate openings for cooling air inlet <strong>and</strong> outlet have to be provided.<br />
It is absolutely important to observe the following regulations for minimum<br />
clearances <strong>and</strong> cooling.<br />
Issue date: August 2002 35
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
Minimum clearances (single-bearing)<br />
The following minimum clearances towards<br />
parts or walls have to be observed for<br />
installation (see also the accompanying<br />
figures on the right):<br />
• All sides: a = 100 mm<br />
• Rear side: b = 170 mm<br />
Cooling (single-bearing)<br />
It is absolutely important to observe the<br />
following regulations for cooling. Danger<br />
of overheating!<br />
The temperature of the supplied cooling air<br />
must not exceed 40 °C.<br />
In the cooling air intake area on the rear<br />
side of the generator a maximum partial<br />
vacuum of P max =4Pa may arise.<br />
Otherwise the fan impeller cannot suck<br />
enough cooling air.<br />
In the cooling air blow out area on the<br />
front side of the generator a maximum<br />
overpressure of P max = 7 Pa may arise.<br />
Otherwise the circulation of the cooling air<br />
is not sufficient.<br />
Cooling air circulation must not be<br />
impaired by other air flows (e.g.<br />
directed from the side or from the front<br />
to the generator).<br />
a<br />
a<br />
b<br />
P max = 7 Pa<br />
a<br />
b<br />
P max = 4 Pa<br />
36 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
4.5.4 Installation to the engine (single-bearing generators)<br />
The minimum clearances <strong>and</strong> regulations for cooling given in the section above<br />
have to be met for installation.<br />
4.5.4.1 Sealing of the generator against the engine<br />
During installation a sealing has to be attached between the generator <strong>and</strong> the<br />
engine. The type of sealing depends on the used engine. The sealings prescribed<br />
for the different engines are listed in the following table.<br />
Engine Type of sealing Installation instructions<br />
B&S 12.5 HP / 14 HP VE1/877 or VE1/977 Press the sealing into the<br />
shaft opening in the end<br />
shield.<br />
Honda GX 390 K1V VE1/871 Bond the sealing into the<br />
Yamaha MZ 360 K<br />
corresponding clearance in the<br />
end shield.<br />
Yanmar L90 / L100 Fluid sealing Apply liquid sealant into the<br />
corresponding clearance in the<br />
end shield.<br />
Hatz 1D 60C<br />
No sealing required.<br />
Issue date: August 2002 37
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
4.5.4.2 Installation of brush-type generators<br />
Removal prior to installation <strong>and</strong> removal of the carbon brushes holder<br />
1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 7/2) <strong>and</strong><br />
detach the sleeve (1).<br />
2. Remove both connection cables from the connection lugs of the carbon<br />
brushes holder (4). The connection cables are coded by the width of the<br />
connection lugs <strong>and</strong> therefore secured against interchanging.<br />
3. Unscrew the fastening screw of the carbon brushes holder <strong>and</strong> detach the<br />
carbon brushes holder (4).<br />
4. Pull out the transport locking (wooden chock).<br />
5. Remove the fan impeller shroud (3) from the generator.<br />
1<br />
2<br />
3<br />
4<br />
Flange represented<br />
turned by 45°<br />
Figure 7<br />
Removal prior to installation of single-bearing brush-type<br />
generators<br />
38 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
Installation<br />
NOTE<br />
For differing installation instructions for shaft fastening by tension<br />
bolt (instead of the grub-screw described here), please refer to<br />
section 4.5.4.4 on page 45.<br />
1. Screw the supplied grub-screw (Figure 8/1) into the engine shaft as far as it<br />
will go using an Allen wrench.<br />
2. Apply the sealing to the front end shield of the generator as described in<br />
section 4.5.4.1 on page 37.<br />
3. Align the generator in front of the engine in a way, that the generator shaft<br />
lies in one line with the engine shaft. If necessary, support the generator<br />
accordingly.<br />
4. Push the generator against the engine flange <strong>and</strong> align the threaded hole of<br />
the generator shaft with the grub-screw screwed into the engine shaft.<br />
5. Screw the generator shaft by turning the fan impeller onto the grub-screw in<br />
the engine shaft as far as it will go. This pulls the generator against the<br />
engine flange.<br />
NOTE<br />
While screwing the generator shaft onto the grub-screw, align<br />
the mounting holes in the end shield with the drillings in the<br />
engine flange.<br />
It is not necessary to tighten the generator shaft on the grubscrew.<br />
It is sufficient, if the shaft is screwed onto the grubscrew<br />
as far as it will go, since the screw-connection tightens<br />
itself when the generator is loaded.<br />
For installation instructions for shaft fastening by tension bolt,<br />
please refer to section 4.5.4.4 on page 45.<br />
6. Fasten the generator's end shield to the engine flange using four fastening<br />
screws (Figure 8/2).<br />
Issue date: August 2002 39
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
1<br />
Apply appropriate sealing<br />
depending on the engine<br />
2<br />
4x<br />
Figure 8<br />
Installation of single-bearing brush-type generators to the<br />
engine<br />
7. Insert the carbon brushes holder (Figure 9/4) correctly positioned into the<br />
generator <strong>and</strong> press it on to the collector rings on the shaft, so that the<br />
carbon brushes are pressed into the carbon brushes holder <strong>and</strong> the carbon<br />
brushes holder lies on its mounting base.<br />
8. Continue to press on the carbon brushes holder <strong>and</strong> screw in the fastening<br />
screw, but do not tighten it completely. While screwing in the fastening<br />
screw, the carbon brushes holder is automatically positioned on the<br />
mounting base.<br />
9. Check the proper seating of the carbon brushes holder <strong>and</strong> then tighten the<br />
fastening screw.<br />
10. Plug both connection cables onto the connection lugs of the carbon brushes<br />
holder according to the width of the connectors.<br />
40 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
11. Remount the sleeve (Figure 9/3) <strong>and</strong> fasten it by tightening the two screws<br />
(2).<br />
12. Remount the fan impeller shroud (Figure 9/1).<br />
Flange represented<br />
turned by 45°<br />
1<br />
4<br />
2<br />
3<br />
Figure 9<br />
Installing the carbon brushes holder<br />
Issue date: August 2002 41
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
4.5.4.3 Installation of brushless generators<br />
Removal prior to installation<br />
1. Remove the fan impeller shroud (Figure 10/1) from the generator.<br />
2. Unscrew the four fastening screws (3) at the generator <strong>and</strong> detach the front<br />
end shield (2).<br />
3<br />
2<br />
1<br />
Figure 10<br />
Removal prior to installation of brushless single-bearing<br />
generators<br />
42 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
Installation<br />
NOTE<br />
For additional installation instructions for shaft fastening by<br />
tension bolt (instead of the grub-screw described here), please<br />
refer to section 4.5.4.4 on page 45.<br />
1. Screw the supplied grub-screw (Figure 11/1) into the engine shaft as far as it<br />
will go using an Allen wrench.<br />
2. Apply the sealing to the removed front end shield of the generator as<br />
described in section 4.5.4.1 on page 37.<br />
3. Set the removed front end shield (Figure 11/2) with the sealing applied onto<br />
the engine flange <strong>and</strong> fasten it using the four screws (Figure 11/3).<br />
4. Align the generator in front of the engine in a way, that the generator shaft<br />
lies in one line with the engine shaft. If necessary, support the generator<br />
accordingly.<br />
5. Push the generator against the engine <strong>and</strong> align the threaded hole of the<br />
generator shaft to the grub-screw screwed into the engine shaft.<br />
6. Screw the generator shaft by turning the fan impeller onto the grub-screw in<br />
the engine shaft as far as it will go. This pulls the generator housing against<br />
the front end shield already mounted on the engine.<br />
NOTE<br />
While screwing the generator shaft onto the grub-screw, align<br />
the generator with the front end shield mounted on the engine.<br />
It is not necessary to tighten the generator shaft on the grubscrew.<br />
It is sufficient, if the shaft is screwed onto the grubscrew<br />
as far as it will go, since the screw-connection tightens<br />
itself when the generator is loaded.<br />
For installation instructions for shaft fastening by tension bolt,<br />
please refer to section 4.5.4.4 on page 45.<br />
7. Fasten the end shield to the generator using four fastening screws (Figure<br />
12/2).<br />
8. Remount the fan impeller shroud (Figure 12/1).<br />
Issue date: August 2002 43
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
1<br />
Apply appropriate sealing<br />
depending on the engine<br />
2<br />
3<br />
4x<br />
Figure 11<br />
Installation of brushless single-bearing generators to the<br />
engine (1)<br />
1<br />
2<br />
4x<br />
Figure 12<br />
Installation of brushless single-bearing generators to the<br />
engine (2)<br />
44 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
4.5.4.4 Additional installation instructions for shaft fastening by<br />
tension bolt<br />
Instead of the grub-screw described in the sections 4.5.4.2 <strong>and</strong> 4.5.4.3,<br />
optionally a tension bolt can be used to connect the shafts. In this case the<br />
generator shaft is drilled hollow.<br />
In this case proceed as follows instead of using the particular installation<br />
instructions.<br />
When installing single-bearing brush-type generators<br />
The following descriptions assume that you have already performed the removal<br />
prior to installation <strong>and</strong> the removal of the carbon brushes holder according to<br />
section 4.5.4.2 on page 38.<br />
The steps listed here replace the steps 1. to 6. on page 39.<br />
1. Apply the sealing to the front end shield of the generator as described in<br />
section 4.5.4.1 on page 37 (see also Figure 13).<br />
2. As shown in Figure 13, align the generator in front of the engine in a way,<br />
that the generator shaft lies in one line with the engine shaft. If necessary,<br />
support the generator accordingly.<br />
3. Push the generator against the engine flange, so that the shafts hit each<br />
other.<br />
4. Insert the tension bolt (Figure 13/1) from the rear side through the generator<br />
shaft <strong>and</strong> screw it into the engine shaft, but do not yet tighten it.<br />
NOTE<br />
While screwing in the tension bolt, align the mounting holes in<br />
the end shield of the generator according to the drillings in the<br />
engine flange.<br />
5. Fasten the end shield of the generator to the engine flange using four<br />
fastening screws (Figure 13/2).<br />
6. Secure the engine shaft against twisting <strong>and</strong> tighten the tension bolt.<br />
7. Continue with the further steps described in section 4.5.4.2: Start with step<br />
7. on page 40.<br />
Issue date: August 2002 45
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
Apply appropriate sealing<br />
depending on the engine<br />
1<br />
2<br />
4x<br />
Figure 13<br />
Installation of single-bearing brush-type generators fastened<br />
with tension bolt<br />
When installing brushless single-bearing generators<br />
The following descriptions assume that you have already performed the removal<br />
prior to installation according to section 4.5.4.3 on page 42.<br />
The steps listed here replace the steps 1. to 8. on page 43.<br />
1. Apply the sealing to the removed front end shield of the generator as<br />
described in section 4.5.4.1 on page 37 (see also Figure 14).<br />
2. Set the removed front end shield with the sealing applied onto the engine<br />
flange <strong>and</strong> fasten it using the four screws (Figure 14/2).<br />
3. As shown in Figure 14, align the generator in front of the engine in a way,<br />
that the generator shaft lies in one line with the engine shaft. If necessary,<br />
support the generator accordingly.<br />
46 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
4. Push the generator against the engine, so that the shafts hit each other.<br />
5. Insert the tension bolt (Figure 14/1) from the rear side through the generator<br />
shaft <strong>and</strong> screw it into the engine shaft, but do not yet tighten it. By<br />
screwing in the tension bolt, the generator shaft is pushed onto the engine<br />
shaft.<br />
NOTE<br />
While screwing in the tension bolt, align the generator<br />
according to the front end shield mounted at the engine.<br />
6. Fasten the end shield to the generator using four fastening screws (Figure<br />
15/2).<br />
7. Secure the engine shaft against twisting <strong>and</strong> tighten the tension bolt. Be<br />
sure to use the correct torque! Please contact the manufacturer, if you do not<br />
know the correct torque for the tension bolt.<br />
8. Remount the fan impeller shroud (Figure 15/1).<br />
Apply appropriate sealing<br />
depending on the engine<br />
2<br />
4x<br />
1<br />
Figure 14<br />
Installation of brushless single-bearing generators with tension<br />
bolt (1)<br />
Issue date: August 2002 47
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.5 Installation for single-bearing generators<br />
1<br />
2<br />
4x<br />
Figure 15<br />
Installation of brushless single-bearing generators with tension<br />
bolt (2)<br />
48 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
For installing two-bearing generators of the size <strong>BG</strong> <strong>132</strong> proceed according to<br />
the descriptions in this section 4.6. Prior to installation, read <strong>and</strong> underst<strong>and</strong><br />
the safety precautions in section 4.1 as well as the sections 4.2 to 4.4 <strong>and</strong><br />
observe the instructions <strong>and</strong> information given there.<br />
CAUTION<br />
On both sides of the generator, a lifting eye bolt is provided for<br />
attaching lifting equipment. Lifting equipment may only be<br />
attached to the generator using these lifting eye bolts. Only<br />
appropriate lifting equipment may be used.<br />
4.6.1 Dimensions <strong>and</strong> mounting (two-bearing type, <strong>BG</strong> <strong>132</strong>)<br />
The minimum clearances <strong>and</strong> regulations for cooling given in the following<br />
section 4.6.2 have to be met for installation.<br />
The dimensions of the generator can be found in the drawing sheet included in<br />
the annex.<br />
The generator has to be fastened using four<br />
screws (min. requirements: M8 or<br />
comparable, quality 8.8). The fastening must<br />
be durable as well as shock <strong>and</strong> vibration<br />
resistant. The screws must be secured<br />
against self-acting unscrewing by suitable<br />
measures, e.g. a clamp collar according to<br />
4 fastening screws<br />
DIN 128.<br />
Tightening torque for fastening screws:<br />
M = 25 Nm<br />
Issue date: August 2002 49
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
Permissible load on the shaft:<br />
• St<strong>and</strong>ard end shield (shaft ø 28 mm):<br />
Fr max = 2000 N (measured at an axial<br />
distance of 50 mm from the shaft outlet<br />
in the end shield)<br />
Fa max = 200 N<br />
Fa max<br />
Fr max<br />
• Reinforced end shield (shaft ø 32 mm):<br />
Fr max = 3800 N (measured at an axial<br />
distance of 50 mm from the shaft outlet<br />
in the end shield)<br />
Fa max = 380 N<br />
No other parts may be mounted to the mounting<br />
profiles of the generator housing.<br />
CAUTION<br />
4.6.2 Minimum clearances <strong>and</strong> regulations for cooling (twobearing<br />
types, <strong>BG</strong> <strong>132</strong>)<br />
In order to provide sufficient cooling the generator needs adequate ventilation.<br />
The cooling air is sucked on the rear side by the fan impeller <strong>and</strong> then blown to<br />
the front side through the cooling profiles along the housing. If necessary,<br />
adequate openings for cooling air inlet <strong>and</strong> outlet have to be provided.<br />
It is absolutely important to observe the following regulations for minimum<br />
clearances <strong>and</strong> cooling.<br />
50 Issue date: August 2002
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
Minimum clearances (<strong>BG</strong> <strong>132</strong>, twobearing<br />
types)<br />
The following minimum clearances towards<br />
parts or walls have to be observed for<br />
installation (see also the accompanying<br />
figures on the right):<br />
• Both sides <strong>and</strong> top: a = 100 mm<br />
• Front side: b = 200 mm<br />
• Rear side: c = 170 mm<br />
Cooling (<strong>BG</strong> <strong>132</strong>, two-bearing types)<br />
It is absolutely important to observe the<br />
following regulations for cooling. Danger<br />
of overheating!<br />
The temperature of the supplied cooling air<br />
must not exceed 40 °C.<br />
In the cooling air intake area on the rear<br />
side of the generator a maximum partial<br />
vacuum of P max = 4 Pa may arise.<br />
Otherwise the fan impeller cannot suck<br />
enough cooling air.<br />
In the cooling air blow out area on the<br />
front side of the generator a maximum<br />
overpressure of P max = 7 Pa may arise.<br />
Otherwise the circulation of the cooling air<br />
is not sufficient.<br />
Cooling air circulation must not be<br />
impaired by other air flows (e.g.<br />
directed from the side or from the front<br />
to the generator).<br />
a<br />
a<br />
b<br />
b<br />
P max = 7 Pa<br />
c<br />
a<br />
P max = 4 Pa<br />
Issue date: August 2002 51
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6.3 Installation instructions for belt drive (two-bearing<br />
types, <strong>BG</strong> <strong>132</strong>)<br />
Belt pulleys <strong>and</strong> belts must be covered by a<br />
<br />
protective cover. Never operate the generator<br />
without the protective covers correctly<br />
mounted. Risk of personal injury!<br />
DANGER<br />
Never touch a running belt. Risk of personal<br />
injury!<br />
Do not knock the belt pulley onto the shaft.<br />
Taper bushes must be preferred for fastening.<br />
CAUTION<br />
To prevent the belt pulley against twisting,<br />
it is protected on the shaft by a feathered<br />
key. The belt pulley is fastened by a screw to<br />
the front end of the shaft. This screw has to<br />
be protected against accidental loosening<br />
using a suitable lock washer.<br />
• Threaded hole in the shaft:<br />
M10 x 22 mm<br />
• Tightening torque: M = 50 Nm<br />
The axis of the driving shaft must be<br />
absolutely parallel to the shaft of the<br />
generator.<br />
The belt pulleys on both shafts must be<br />
flush to each other so that the belt runs<br />
absolutely straight.<br />
52 Issue date: August 2002
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
The belt must not sag loosely.<br />
When using slim SPA-type V-belts, the<br />
distance between the shafts must not<br />
exceed 600 mm. Permissible shaft distances<br />
for other belts can be obtained from the<br />
manufacturer.<br />
Maximum tractive force (tension) of the<br />
drive belt on the shaft:<br />
• F max = 2000 N for st<strong>and</strong>ard end shield<br />
(shaft ø28mm)<br />
• F max = 3800 N for reinforced end shield<br />
(shaftø32mm)<br />
The specified maximum tractive force is<br />
applicable at an axial distance of max. 50<br />
mm from the shaft outlet in the end shield.<br />
If the belt is to be mounted with a greater<br />
distance to the end shield, the belt tension<br />
must be reduced in order to compensate the<br />
higher leverage to the shaft.<br />
Type <strong>and</strong> number of used belts<br />
The type <strong>and</strong> number of used belts have to<br />
be adapted to the power of the generator.<br />
The maximum belt tension force has to be<br />
observed!<br />
F max<br />
l max<br />
Issue date: August 2002 53
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6.4 Installation instructions for flange mounting (two-bearing<br />
types, <strong>BG</strong> <strong>132</strong>)<br />
4.6.4.1 Flange mounting for <strong>BG</strong> <strong>132</strong> with st<strong>and</strong>ard end shield<br />
Removal prior to installation<br />
1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 16/2) <strong>and</strong><br />
detach the sleeve (1).<br />
2. Unscrew the four screws M12 x 12 (3) <strong>and</strong> detach them together with the<br />
washers.<br />
1<br />
2<br />
3<br />
4x<br />
Figure 16<br />
Removal prior to installation for flange mounting (two-bearing<br />
types, <strong>BG</strong> <strong>132</strong> with st<strong>and</strong>ard end shield)<br />
54 Issue date: August 2002
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
Installation<br />
1. Set the flange (Figure 17/1) onto the generator <strong>and</strong> fasten it using the four<br />
screws (4a) with nuts (3a). Underlay the screw head with a blocking disk<br />
(4b) <strong>and</strong> apply threadlocking adhesive to the thread of the screw. Underlay<br />
the nuts with toothed disks (3b).<br />
2. Remount the sleeve (Figure 17/2) <strong>and</strong> fasten it by tightening the two screws.<br />
3. Plug the clutch-plate (5) onto the generator shaft <strong>and</strong> protect it against<br />
twisting on the shaft by means of a feathered key.<br />
4. Fasten the driving side of the clutch (6) to the engine <strong>and</strong> insert it into the<br />
clutch-plate. When inserting, twist the clutch a little bit until the gearing<br />
locks, if necessary.<br />
5. Fasten the flange (1) to the engine.<br />
1<br />
4x<br />
6<br />
5<br />
4a<br />
4b<br />
2<br />
3b<br />
3a<br />
4x<br />
Figure 17 Installation for flange mounting (two-bearing types, <strong>BG</strong> <strong>132</strong><br />
with st<strong>and</strong>ard end shield)<br />
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6.4.2 Flange mounting for <strong>BG</strong> <strong>132</strong> with reinforced end shield<br />
Removal prior to installation<br />
Unscrew the four headless setscrews M12 x 25 (Figure 18/1).<br />
1<br />
Figure 18<br />
Removal prior to installation for flange mounting (two-bearing<br />
types, <strong>BG</strong> <strong>132</strong> with reinforced end shield)<br />
56 Issue date: August 2002
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
Installation<br />
1. Set the flange (Figure 19/1) onto the generator <strong>and</strong> fasten it using the four<br />
screws (2a). Underlay the screw head with a toothed disk (2b) <strong>and</strong> apply<br />
threadlocking adhesive to the thread of the screw.<br />
2. Plug the clutch-plate (3) onto the generator shaft <strong>and</strong> protect it against<br />
twisting on the shaft by means of a feathered key.<br />
3. Fasten the driving side of the clutch (4) to the engine <strong>and</strong> insert it into the<br />
clutch-plate. When inserting, twist the clutch a little bit until the gearing<br />
locks, if necessary.<br />
4. Fasten the flange (1) to the engine.<br />
1<br />
4x<br />
4<br />
3<br />
2a<br />
2b<br />
Figure 19 Installation for flange mounting (two-bearing types, <strong>BG</strong> <strong>132</strong><br />
with reinforced end shield)<br />
Issue date: August 2002 57
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6.5 Installation instructions for hydraulic drive (two-bearing<br />
types, <strong>BG</strong> <strong>132</strong>)<br />
4.6.5.1 Hydraulic drive for <strong>BG</strong> <strong>132</strong> with st<strong>and</strong>ard end shield<br />
Removal prior to installation<br />
At the generator perform the removal prior to installation as described on page<br />
54 (see Figure 16).<br />
Installation<br />
1. Set the flange (Figure 20/2) onto the generator <strong>and</strong> fasten it using the four<br />
screws (4a) with nuts (3a). Underlay the screws with a blocking disk (4b) <strong>and</strong><br />
apply threadlocking adhesive to the thread of the screws. Underlay the nuts<br />
with a toothed disk (3b).<br />
2. Remount the sleeve (1) <strong>and</strong> fasten it by tightening the two screws.<br />
3. Plug the first part of the clutch (5) onto the generator shaft <strong>and</strong> protect it<br />
against twisting on the shaft by means of a feathered key.<br />
4. Mount the disc (6) to the hydraulic motor (8).<br />
5. Set the second part of the clutch (5) onto the hydraulic motor.<br />
6. Set the hydraulic motor (8) together with the disc (6) <strong>and</strong> the second part of<br />
the clutch onto the generator. When inserting, twist the clutch a little bit<br />
until the gearing locks, if necessary.<br />
7. Underlay the eight screws (7a) with a blocking disc (7b) <strong>and</strong> use them to<br />
fasten the disc (6) to the flange (2).<br />
8. Place the sleeve (9) to the clutch assembly <strong>and</strong> fasten it by tightening the<br />
two screws.<br />
58 Issue date: August 2002
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
2x<br />
9<br />
8x<br />
1<br />
8<br />
7a<br />
7b 2<br />
6<br />
5<br />
2x<br />
4x<br />
4a<br />
4b<br />
3b<br />
3a<br />
4x<br />
Figure 20<br />
Installation of the flange mounting for hydraulic drive (twobearing<br />
types, <strong>BG</strong> <strong>132</strong> with st<strong>and</strong>ard end shield)<br />
Issue date: August 2002 59
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
4.6.5.2 Hydraulic drive for <strong>BG</strong> <strong>132</strong> with reinforced end shield<br />
Removal prior to installation<br />
At the generator perform the removal prior to installation as described on page<br />
56 (see Figure 18).<br />
Installation<br />
1. Set the flange (Figure 21/1) onto the generator <strong>and</strong> fasten it using the four<br />
screws (2a). Underlay the screws with a blocking disk (2b) <strong>and</strong> apply<br />
threadlocking adhesive to the thread of the screws.<br />
2. Plug the first part of the clutch (3) onto the generator shaft <strong>and</strong> protect it<br />
against twisting on the shaft by means of a feathered key.<br />
3. Mount the disc (4) to the hydraulic motor (6).<br />
4. Set the second part of the clutch (3) onto the hydraulic motor.<br />
5. Set the hydraulic motor (6) together with the disc (4) <strong>and</strong> the second part of<br />
the clutch onto the generator. When inserting, twist the clutch a little bit<br />
until the gearing locks, if necessary.<br />
6. Underlay the eight screws (5a) with a blocking disc (5b) <strong>and</strong> use them to<br />
fasten the disc (4) to the flange (1).<br />
7. Place the sleeve (7) to the clutch assembly <strong>and</strong> fasten it by tightening the<br />
two screws.<br />
60 Issue date: August 2002
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Chapter 4: 4.6 Installation of two-bearing generators (<strong>BG</strong> <strong>132</strong>)<br />
2x<br />
7<br />
6<br />
8x<br />
5a<br />
5b<br />
4<br />
3<br />
2a<br />
2b<br />
4x<br />
1<br />
Figure 21<br />
Installation of the flange mounting for hydraulic drive (twobearing<br />
types, <strong>BG</strong> <strong>132</strong> with reinforced end shield)<br />
Issue date: August 2002 61
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
For installing generators of the size <strong>BG</strong> <strong>160</strong> proceed according to the<br />
descriptions in this section 4.7. Prior to installation, read <strong>and</strong> underst<strong>and</strong> the<br />
safety precautions in section 4.1 as well as the sections 4.2 to 4.4 <strong>and</strong> observe<br />
the instructions <strong>and</strong> information given there.<br />
CAUTION<br />
On both sides of the generator, a lifting eye bolt is provided for<br />
attaching lifting equipment. Lifting equipment may only be<br />
attached to the generator using these lifting eye bolts. Only<br />
appropriate lifting equipment may be used.<br />
4.7.1 Dimensions <strong>and</strong> mounting (<strong>BG</strong> <strong>160</strong>)<br />
The minimum clearances <strong>and</strong> regulations for cooling given in section 4.7.2 must<br />
be met for installation. The dimensions of the generator can be found in the<br />
drawing sheet included in the annex.<br />
The generator has to be fastened using<br />
four screws (min. requirements: M12 or<br />
comparable, quality 8.8). The fastening<br />
must be durable as well as shock <strong>and</strong><br />
vibration resistant. The screws must be<br />
secured against self-acting unscrewing by<br />
suitable measures, e.g. a clamp collar<br />
according to DIN 128.<br />
4 fastening screws<br />
• Tightening torque for fastening screws:<br />
M = 87 Nm<br />
Fr max<br />
• Permissible load on the shaft:<br />
Fa max<br />
Fr max = 5000 N (measured at an axial<br />
distance of 60 mm from the shaft<br />
outlet in the end shield)<br />
Fa max = 500 N<br />
No other parts may be mounted to the mounting<br />
profiles of the generator housing.<br />
CAUTION<br />
62 Issue date: August 2002
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
4.7.2 Minimum clearances <strong>and</strong> regulations for cooling (<strong>BG</strong> <strong>160</strong>)<br />
In order to provide sufficient cooling the generator needs adequate ventilation.<br />
The cooling air is sucked on the rear side by the fan impeller <strong>and</strong> then blown to<br />
the front side through the cooling profiles along the housing. If necessary,<br />
adequate openings for cooling air inlet <strong>and</strong> outlet have to be provided.<br />
It is absolutely important to observe the following regulations for minimum<br />
clearances <strong>and</strong> cooling.<br />
Minimum clearances (<strong>BG</strong> <strong>160</strong>)<br />
The following minimum clearances towards<br />
parts or walls have to be observed for<br />
a<br />
installation (see also the accompanying<br />
a<br />
a<br />
figures on the right):<br />
b<br />
• Both sides <strong>and</strong> top: a = 100 mm<br />
• Front side: b = 300 mm<br />
• Rear side: c = 200 mm<br />
Cooling (<strong>BG</strong> <strong>160</strong>)<br />
It is absolutely important to observe the<br />
b<br />
following regulations for cooling. Danger<br />
of overheating!<br />
P max = 4 Pa<br />
The temperature of the supplied cooling air<br />
must not exceed 40 °C.<br />
In the cooling air intake area on the rear<br />
P max = 7 Pa<br />
side of the generator a maximum partial<br />
vacuum of P max = 4 Pa may arise.<br />
c<br />
Otherwise the fan impeller cannot suck<br />
enough cooling air.<br />
In the cooling air blow out area on the<br />
front side of the generator a maximum<br />
overpressure of P max = 7 Pa may arise.<br />
Otherwise the circulation of the cooling air<br />
is not sufficient.<br />
Cooling air circulation must not be<br />
impaired by other air flows (e.g.<br />
directed from the side or from the front<br />
to the generator).<br />
Issue date: August 2002 63
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
4.7.3 Installation instructions for belt drive (<strong>BG</strong> <strong>160</strong>)<br />
Belt pulleys <strong>and</strong> belts must be covered by a<br />
<br />
protective cover. Never operate the generator<br />
without the protective covers correctly<br />
mounted. Risk of personal injury!<br />
DANGER<br />
Never touch a running belt. Risk of personal<br />
injury!<br />
Do not knock the belt pulley onto the shaft.<br />
Taper bushes must be preferred for fastening.<br />
CAUTION<br />
To prevent the belt pulley against twisting,<br />
it is protected on the shaft by a feathered<br />
key. The belt pulley is fastened by a screw to<br />
the front end of the shaft. This screw has to<br />
be protected against accidental loosening<br />
using a suitable lock washer.<br />
• Threaded hole in the shaft:<br />
M16 x 36 mm<br />
• Tightening torque: M = 200 Nm<br />
The axis of the driving shaft must be<br />
absolutely parallel to the shaft of the<br />
generator.<br />
The belt pulleys on both shafts must be<br />
flush to each other so that the belt runs<br />
absolutely straight.<br />
64 Issue date: August 2002
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
The belt must not sag loosely.<br />
When using slim SPA-type V-belts, the<br />
distance between the shafts must not<br />
exceed 800 mm. Permissible shaft distances<br />
for other belts can be obtained from the<br />
manufacturer.<br />
Maximum tractive force (tension) of the<br />
drive belt on the shaft:<br />
F max. = 5000 N at an axial distance of max.<br />
60 mm from the shaft outlet in the end<br />
shield. If the belt is to be mounted with a<br />
greater distance to the end shield, the belt<br />
tension must be reduced in order to<br />
compensate the higher leverage to the<br />
shaft.<br />
F max<br />
l max<br />
Type <strong>and</strong> number of used belts<br />
The type <strong>and</strong> number of used belts have to<br />
be adapted to the power of the generator.<br />
The maximum belt tension force has to be<br />
observed!<br />
Issue date: August 2002 65
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
4.7.4 Installation instructions for flange mounting (<strong>BG</strong> <strong>160</strong>)<br />
Removal prior to installation<br />
Unscrew the four headless setscrews M12 x 25 (Figure 22/1).<br />
1<br />
Figure 22 Removal prior to installation for flange mounting (<strong>BG</strong> <strong>160</strong>)<br />
66 Issue date: August 2002
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
Installation<br />
1. Set the flange (Figure 23/1) onto the generator <strong>and</strong> fasten it using the four<br />
screws (2a). Underlay the screw head with a toothed disk (2b) <strong>and</strong> apply<br />
threadlocking adhesive to the thread of the screw.<br />
2. Plug the clutch-plate (3) onto the generator shaft <strong>and</strong> protect it against<br />
twisting on the shaft by means of a feathered key.<br />
3. Fasten the driving side of the clutch (4) to the engine <strong>and</strong> insert it into the<br />
clutch-plate. When inserting, twist the clutch a little bit until the gearing<br />
locks, if necessary.<br />
4. Fasten the flange (1) to the engine.<br />
1<br />
4x<br />
4<br />
3<br />
2a<br />
2b<br />
Figure 23 Installation of the flange mounting (<strong>BG</strong> <strong>160</strong>)<br />
Issue date: August 2002 67
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
4.7.5 Installation instructions for hydraulic drive (<strong>BG</strong> <strong>160</strong>)<br />
Removal prior to installation<br />
At the generator perform the removal prior to installation as described on page<br />
66 (see Figure 22).<br />
Installation<br />
1. Set the flange (Figure 24/1) onto the generator <strong>and</strong> fasten it using the four<br />
screws (2a). Underlay the screws with a blocking disk (2b) <strong>and</strong> apply<br />
threadlocking adhesive to the thread of the screws.<br />
2. Plug the first part of the clutch (3) onto the generator shaft <strong>and</strong> protect it<br />
against twisting on the shaft by means of a feathered key.<br />
3. Mount the disc (4) to the hydraulic motor (6).<br />
4. Set the second part of the clutch (3) onto the hydraulic motor.<br />
5. Set the hydraulic motor (6) together with the disc (4) <strong>and</strong> the second part of<br />
the clutch onto the generator. When inserting, twist the clutch a little bit<br />
until the gearing locks, if necessary.<br />
6. Underlay the eight screws (5a) with a blocking disc (5b) <strong>and</strong> use them to<br />
fasten the disc (4) to the flange (1).<br />
7. Place the sleeve (7) to the clutch assembly <strong>and</strong> fasten it by tightening the<br />
two screws.<br />
68 Issue date: August 2002
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Chapter 4: 4.7 Installation of two-bearing generators (<strong>BG</strong> <strong>160</strong>)<br />
2x<br />
7<br />
6<br />
8x<br />
5a<br />
5b<br />
4<br />
3<br />
4x<br />
2a<br />
2b<br />
1<br />
Figure 24 Installation of the flange mounting for hydraulic drive (<strong>BG</strong> <strong>160</strong>)<br />
Issue date: August 2002 69
<strong>Synchronous</strong> <strong>Generators</strong> <strong>BG</strong> <strong>132</strong> / <strong>BG</strong> <strong>160</strong><br />
Chapter 4: 4.8 Electrical connection of the generators<br />
4.8 Electrical connection of the generators<br />
Prior to installation, read <strong>and</strong> underst<strong>and</strong> the safety precautions in section 4.1<br />
as well as the connection notes in this section 4.8 <strong>and</strong> observe the instructions<br />
<strong>and</strong> information given there.<br />
This section is only applicable for generators which are not equipped with a<br />
control box ex works.<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
<br />
performed by adequately trained qualified personnel <strong>and</strong> in<br />
conformity with the applicable national rules <strong>and</strong> regulations<br />
(in Germany: VDE regulations, among others).<br />
DANGER<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
performed in the off <strong>and</strong> de-energized state. Mortal danger by<br />
electric shock!<br />
Engines that have been turned off must be secured against<br />
accidental restarting (e.g. by removing the ignition key <strong>and</strong><br />
keeping it safe)!<br />
Grounding the neutral conductor of the generator (N, midpoint<br />
conductor) supersedes the protective measure "protection<br />
separation" <strong>and</strong> should therefore be avoided. If the neutral<br />
conductor N shall be grounded anyway, this may only be<br />
performed by an electrically qualified person. In this case, a<br />
current-operated earth-leakage circuit breaker has to be<br />
connected on the load side of the generator output. The<br />
efficiency of the electrical protective measure has to be<br />
confirmed by an appropriate measurement.<br />
4.8.1 General<br />
If the generator is not equipped with a control box ex works, adequate fuse<br />
equipment has to be installed in an external control cabinet to protect the<br />
connected circuits (sockets):<br />
• Short-circuit tripping: characteristic "B"<br />
• Protection against overcurrent: according to nominal current<br />
• The neutral conductor has also to be fused.<br />
70 Issue date: August 2002
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Chapter 4: 4.8 Electrical connection of the generators<br />
4.8.2 Version with terminal box<br />
Observe the following connection notes when connecting generators equipped<br />
with a terminal box:<br />
• When opening the terminal box, be careful not to tear-off or damage the<br />
connecting wires of the generator governor installed in the cover.<br />
• After opening the terminal box, remove the plug-<strong>and</strong>-socket connector to the<br />
generator governor installed in the terminal box cover. The plug-<strong>and</strong>-socket<br />
connector is mechanically coded <strong>and</strong> thus can not be plugged-in twisted.<br />
Plug-in the connector only immediately before closing the cover.<br />
• For leading cables into the terminal box only use appropriate waterproof<br />
IP54 cable gl<strong>and</strong>s.<br />
• Lay the connecting wires inside the terminal box with utmost care.<br />
• When closing the cover, be careful not to catch or squeeze any connecting<br />
wires.<br />
Figure 25<br />
Pin assignment of the connection terminal plate in the terminal<br />
box<br />
Issue date: August 2002 71
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Chapter 4: 4.8 Electrical connection of the generators<br />
4.8.3 Version without terminal box, cables are lead out in a hose<br />
Optionally the generator can also be delivered without a terminal box equipped.<br />
In this case, the connecting cables are lead out of the generator in a hose.<br />
This is a customized version. For this reason, the connection of the cables has to<br />
be discussed with the generator manufacturer.<br />
72 Issue date: August 2002
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Chapter 5, Operation<br />
5 Operation<br />
This chapter provides information about operating the generator. The operation<br />
can differ depending on the generator version <strong>and</strong> equipment. Where applicable,<br />
such differences are mentioned in the concerning texts.<br />
Prior to operating the generator, read <strong>and</strong> underst<strong>and</strong> the safety precautions<br />
listed in section 5.1 as well as the sections 5.2 through 5.6 below <strong>and</strong> observe<br />
the instructions <strong>and</strong> information given there.<br />
5.1 Safety information for operation<br />
This section summarizes all relevant safety precautions for operating the<br />
generator.<br />
DANGER<br />
Do not operate the generator in explosive environments.<br />
Further regulations on this have to be observed!<br />
Never connect the generator to the public electricity supply<br />
network or to any other systems for power generation. Risk of<br />
death, fire <strong>and</strong> destruction hazard!<br />
Never connect several generators to each other. Risk of death,<br />
fire <strong>and</strong> destruction hazard!<br />
The generator supplies highly dangerous voltages during<br />
operation! Never touch the generator or the devices connected<br />
to the generator with wet h<strong>and</strong>s during operation. Mortal<br />
danger by electric shock!<br />
Generator components may be very hot, not just during but also<br />
after operation. Burning hazard!<br />
The generator may only be operated with the protective covers<br />
for the drive mounted as specified. Risk of personal injury!<br />
Grounding the neutral conductor of the generator (N, midpoint<br />
conductor) supersedes the protective measure "protection<br />
separation" <strong>and</strong> should therefore be avoided. If the neutral<br />
conductor N shall be grounded anyway, this may only be<br />
performed by an electrically qualified person. In this case, a<br />
current-operated earth-leakage circuit breaker has to be<br />
connected on the load side of the generator output. The<br />
efficiency of the electrical protective measure has to be<br />
confirmed by an appropriate measurement.<br />
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Chapter 5, Operation<br />
If the generator shall be connected to an existing power<br />
<br />
distribution network (e.g. a house wiring), it has to be<br />
ensured, that the system is completely <strong>and</strong> reliably<br />
disconnected from the public electricity supply network of the<br />
DANGER<br />
energy supply company. Reverse feeding into the public<br />
electricity supply network or network interconnection is not<br />
allowed. Reverse feeding involves mortal danger by electric<br />
shock for persons possibly working at the de-energized public<br />
electricity supply network. Due to network interconnection<br />
with the public electricity supply network, the generator can be<br />
damaged, burn or cause fire in electrical cables of the system.<br />
Be sure to completely read <strong>and</strong> underst<strong>and</strong> these operating<br />
instructions before using the generator. The generator may only<br />
be used for applications described in section "Proper use" <strong>and</strong><br />
in conformity with the specifications given in this manual.<br />
Before connecting devices to the generator, ensure that the<br />
devices are switched off. Accident hazard! Unsupervised<br />
starting devices can endanger or injure persons as well as cause<br />
damages or damage themselves.<br />
Infants <strong>and</strong> animals must have no admittance to the generator,<br />
not just during but also after operation. Make appropriate<br />
precautions. Mortal danger by electric shock, injury <strong>and</strong><br />
burning hazard!<br />
The generator or its components must never be<br />
exposed to the jet of high-pressure cleaners.<br />
Mortal danger by electric shock <strong>and</strong><br />
destruction hazard!<br />
CAUTION<br />
Be sure to observe the operating conditions given in section 5.2.<br />
The generator may only be operated in conformity with the<br />
operating conditions <strong>and</strong> data specified there. This especially<br />
applies to the ambient <strong>and</strong> cooling conditions <strong>and</strong> the permissible<br />
current load.<br />
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5.2 Permissible operating conditions<br />
The generator may only be used, if the operation conditions listed below are<br />
kept.<br />
Only those devices may be connected, the voltage <strong>and</strong> frequency specifications<br />
of which meet the specifications given on the type plate of the generator. The<br />
generator may not be overloaded. The total power consumption of all connected<br />
devices must not exceed the output power specified for the generator.<br />
The generator must have a free cooling air supply as well as an unimpeded<br />
cooling air dissipation. The cooling air temperature must not exceed 40 °C. If<br />
the cooling conditions can not be met, the generator must not be loaded with<br />
its full rated output power.<br />
In case of inadequate cooling of the generator or under conditions other than<br />
permissible operation conditions, the generator output voltage is automatically<br />
reduced. In this case, the load connected to the generator has to be reduced to<br />
avoid damage of the connected devices.<br />
5.3 Electric protection equipment, protective measures <strong>and</strong><br />
grounding<br />
5.3.1 Electric protection <strong>and</strong> grounding/equipotential bonding<br />
If the generator is not equipped with the option "Insulation monitoring with<br />
switching-off", it fulfills the protective measure "Protection separation with<br />
equipotential bonding" according to VDE 0100, part 728.<br />
If the generator is equipped with the option "Insulation monitoring with<br />
switching-off", it fulfills the better protective measure "Protection separation<br />
with insulation monitoring" according to VDE 0100, part 728.<br />
For a proper function of the mentioned electrical protective measures, it is not<br />
required to ground the generator (e.g. using a grounding rod). If this is desired<br />
anyway or required for some special cases, a defined grounding of the generator<br />
housing can be performed or the generator housing can be included into an<br />
equipotential bonding with other devices. For this purpose, only the<br />
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Chapter 5, Operation<br />
corresponding earth connection points marked with the earth symbol<br />
be used.<br />
may<br />
DANGER<br />
Grounding the neutral conductor of the generator (N, midpoint<br />
conductor) supersedes the protective measure "protection<br />
separation" <strong>and</strong> should therefore be avoided. If the neutral<br />
conductor N shall be grounded anyway, this may only be<br />
performed by an electrically qualified person. In this case, a<br />
current-operated earth-leakage circuit breaker has to be<br />
connected on the load side of the generator output. The<br />
efficiency of the electrical protective measure has to be<br />
confirmed by an appropriate measurement.<br />
5.3.2 Protection against overcurrent<br />
If the generator is equipped with a control box ex works, the sockets of the<br />
control box mounted on the generator are protected against overcurrent <strong>and</strong><br />
short-circuit conditions using automatic circuit breakers. See Figure 26.<br />
Circuit breaker block<br />
(protection: 3P + N)<br />
Figure 26<br />
Circuit breaker in control box (only applicable for 8 kVA <strong>and</strong><br />
13 kVA generators)<br />
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If the generator is not equipped with a control box ex works, adequate fuse<br />
equipment has to be installed in an external control cabinet to protect the<br />
connected circuits (sockets):<br />
• Short-circuit tripping: characteristic "B"<br />
• Protection against overcurrent: according to nominal current<br />
• The neutral conductor has also to be fused.<br />
5.4 Connection to an existing power distribution network (e.g.<br />
house wiring)<br />
The connection of generators to an existing power distribution network (e.g.<br />
house wiring) may only be performed by a qualified electrically skilled person<br />
<strong>and</strong> only after permission of the energy supply company. Observe all relevant<br />
DIN <strong>and</strong> VDE regulations, especially DIN VDE 0100, part 728.6, as well as<br />
possibly existing additional technical connection regulations of the energy<br />
supply company.<br />
For this purpose, considerable changes at the generator can be necessary which<br />
may only be performed by a qualified electrically skilled person <strong>and</strong> after<br />
consultation of the generator system manufacturer.<br />
If the generator shall be connected to an existing power<br />
<br />
distribution network (e.g. a house wiring), it has to be<br />
ensured, that the system is completely <strong>and</strong> reliably<br />
disconnected from the public electricity supply network of the<br />
DANGER<br />
energy supply company. Reverse feeding into the public<br />
electricity supply network or network interconnection is not<br />
allowed. Reverse feeding involves mortal danger by electric<br />
shock for persons possibly working at the de-energized public<br />
electricity supply network. Due to network interconnection<br />
with the public electricity supply network, the generator can be<br />
damaged, burn or cause fire in electrical cables of the system.<br />
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Chapter 5, Operation<br />
5.5 Operating information for safe working with electric devices<br />
Observe the following operating information for a safe<br />
<br />
operation <strong>and</strong> h<strong>and</strong>ling of electric devices.<br />
Please also observe the safety precautions for operation given<br />
DANGER in section 5.1 on page 73.<br />
• Devices that caused the insulation monitoring unit to switch-off <strong>and</strong> to<br />
indicate a "FAULTY INSULATION" must also not be operated at other<br />
generators without insulation monitoring or in the public electricity supply<br />
network. Devices with defective insulation have to be immediately taken out<br />
of operation <strong>and</strong> replaced or repaired by the device manufacturer or an<br />
authorized electric company.<br />
• Only connect devices that are in a faultless <strong>and</strong> safe condition. The devices<br />
<strong>and</strong> connectors have to be clean <strong>and</strong> dry.<br />
• Before connecting devices to the generator, ensure that the devices are<br />
switched off. Accident hazard! Unsupervised starting devices can endanger or<br />
injure persons as well as cause damages or damage themselves.<br />
• Depending on the field of operating <strong>and</strong> application, regulations,<br />
prescriptions, requirements or recommendations of the professional<br />
associations <strong>and</strong> trade associations have to be observed when working with<br />
generators. Additionally, the Gerätesicherheitsgesetz (GSG, German<br />
Equipmant Safety Law), the relevant regulations for preventing accidents as<br />
well as the mine regulations of the countries have also to be considered.<br />
When using generators outside the scope of requirements of the Federal<br />
Republic of Germany, the suitability of the generator has to be proofed under<br />
consideration of the individual national requirements. If you have any<br />
questions, please contact the system manufacturer.<br />
• The generator may only be operated under the permissible operating<br />
conditions given in section 5.2 on page 75.<br />
• Many portable electric tools comply with protection class II (protective<br />
insulation, identification ). It is recommended to use such devices as far<br />
as possible. If devices of protection class I are used (i.e. with metal housing<br />
parts which are not insulation protected), these must be equipped with a<br />
connection cable <strong>and</strong> a connector with PE conductor.<br />
• When working in "conductive areas with limited freedom of movement", i.e.<br />
in areas within the scope of DIN VDE 0100 part 706 (e.g. in metal tanks),<br />
only one single device may be connected to the generator if it is a "h<strong>and</strong>-<br />
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held electric tool or a mobile measuring instrument". Otherwise for each<br />
device a separate isolating transformer or an isolating transformer with<br />
several separate secondary windings must be used. H<strong>and</strong>-held luminaires in<br />
conductive areas with limited freedom of movement may only be operated via<br />
an isolated transformer with protection low voltage (SELV).<br />
• Cables for distribution (e.g. extension cords <strong>and</strong> cord sets) must be<br />
extensively selected, laid <strong>and</strong> maintained. Electric cables have to be checked<br />
in regular intervals. Defective cables <strong>and</strong> cords have to be exchanged. When<br />
connecting extension cords, observe the following section 5.6.2 on page 81.<br />
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Chapter 5, Operation<br />
5.6 Operation of the generator<br />
CAUTION<br />
Only take the generator into operation after you have completely<br />
read <strong>and</strong> understood all sections of this chapter 5, particularly the<br />
safety precautions given in section 5.1 on page 73.<br />
If your generator is equipped with the option "Insulation<br />
monitoring with switching-off", the correct function of the<br />
insulation monitoring unit has to be checked every working day.<br />
The generator may only be taken into operation, if the correct<br />
function of the insulation monitoring unit has been confirmed.<br />
5.6.1 Control elements in the control box (if available)<br />
Figure 27 shows all possible control elements <strong>and</strong> indicators in the control box<br />
optionally mounted on the generator (insulation monitoring unit <strong>and</strong> hour meter<br />
are also optional).<br />
Insulation monitoring unit<br />
with switch <strong>and</strong> signal lamp<br />
(optional)<br />
Circuit breaker block<br />
(protection: 3P + N)<br />
Hour meter<br />
(optional)<br />
Socket 400 V<br />
3 sockets 230 V<br />
Figure 27<br />
Control elements <strong>and</strong> indicators in the control box (optional)<br />
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5.6.2 Current distribution <strong>and</strong> connection of devices<br />
DANGER<br />
CAUTION<br />
NOTE<br />
The generator must not be used for the supply of assemblies<br />
for construction sites.<br />
<strong>Generators</strong> which are equipped with an insulation monitoring<br />
unit must not be connected to further insulation monitoring<br />
units since the insulation monitoring units can mutually<br />
interact.<br />
The generator may not be overloaded. The total power consumption<br />
of all connected devices must not exceed the output power<br />
specified for the generator.<br />
Only those devices may be connected the voltage <strong>and</strong> frequency<br />
specifications of which meet the specifications listed on the type<br />
plate of the generator.<br />
If your generator is equipped with a control box:<br />
• Do not use the circuit breakers in the control box for switching<br />
the connected devices on <strong>and</strong> off. When using several devices<br />
connected to the single-phase AC voltage sockets at the same<br />
time (especially when using devices with different power<br />
consumptions), short-term over- or undervoltages may arise due<br />
to a turn-on delay of the neutral conductor.<br />
• The cover of the control box <strong>and</strong> the hinged lids of unused<br />
sockets have always to be kept correctly closed in order to<br />
guarantee IP54 protection (tighten the locking screws by<br />
h<strong>and</strong>).<br />
Current-operated earth-leakage circuit breakers are not functional<br />
in ungrounded networks (IT systems, as supplied by the generator),<br />
because there is no grounding. However, since the generator<br />
supplies the protective measure "protection separation", additional<br />
protection by means of current-operated earth-leakage circuit<br />
breakers is not necessary.<br />
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Proceed as follows to take the generator into operation <strong>and</strong> to connect the<br />
loads:<br />
1. If necessary, perform the daily check of the insulation monitoring unit. See<br />
section 5.6.3 on page 84.<br />
2. Make sure that no devices are connected to the generator.<br />
3. Switch off all devices which are to be connected later (switch in position<br />
"OFF" or "0"). Accident hazard by unsupervised starting devices!<br />
4. Start the engine. Wait until the engine has reached its rated speed.<br />
5. If necessary, switch on the circuit breakers in the control box (if equipped,<br />
see Figure 27) or in the control cabinet (position "ON" or "I").<br />
6. Connect (or switch on) the devices one after the other. First switch on the<br />
powerful devices with high current consumptions or high starting currents<br />
<strong>and</strong> then the less powerful devices.<br />
NOTE<br />
The total length of all connected extension cables may not<br />
exceed the following values:<br />
• 250 m max. at a conductor cross section of 2.5 mm 2<br />
• 100 m max. at a conductor cross section of 1.5 mm 2<br />
Devices driven by electric motors possibly require starting<br />
currents that are many times higher than the specified<br />
operating currents. In case of doubt, please contact the<br />
manufacturer.<br />
To ensure a safe operation of three-phase generators, the load<br />
currents should be distributed to all three phases as equal as<br />
possible.<br />
Take care that the maximum currents specified for each socket<br />
are not exceeded.<br />
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7. When switching off the connected devices, switch off the devices one after<br />
the other <strong>and</strong> unplug their mains plugs. If possible, first switch off the less<br />
powerful devices <strong>and</strong> finally the powerful devices with high current<br />
consumptions.<br />
NOTE<br />
Ensure that the hinged lids of the sockets are correctly closed<br />
again after unplugging the mains plugs.<br />
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5.6.3 Checking the insulation monitoring unit (if available)<br />
CAUTION<br />
If your generator is equipped with the option "Insulation<br />
monitoring with switching-off", the correct function of the<br />
insulation monitoring unit has to be checked every working day.<br />
The generator may only be taken into operation, if the correct<br />
function of the insulation monitoring unit has been confirmed.<br />
Proceed as follows to check the insulation monitoring unit (refer to Figure 27 for<br />
the location of the control elements <strong>and</strong> indicators):<br />
1. Unplug all devices <strong>and</strong> cables connected to the generator.<br />
2. Start the engine. The check must be performed while the generator is<br />
running.<br />
3. Open the cover of the control box <strong>and</strong> switch on the insulation monitoring<br />
unit (position "ON" or "I").<br />
4. Push the red test push-button which is at the same time used as an indicator.<br />
Now the insulation monitoring unit must trip.<br />
5. Check whether the insulation monitoring unit has tripped <strong>and</strong> the red<br />
indicator "FAULTY INSULATION" is on.<br />
NOTE<br />
If the insulation monitoring unit does not trip or if the "FAULTY<br />
INSULATION" indicator does not light, the generator must not<br />
be used any longer. In this case, mark the generator as<br />
defective <strong>and</strong> have it repaired (refer to section 7 on page 92).<br />
6. Stop the engine to reset the insulation monitoring unit.<br />
7. Switch on the insulation monitoring unit again (position "ON" or "I") <strong>and</strong><br />
correctly close the cover of the control box (tighten the locking screws by<br />
h<strong>and</strong>).<br />
8. If the check was successful the generator is now ready for operation.<br />
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Chapter 6, Maintenance<br />
6 Maintenance<br />
All components of the generator are maintenance-free in principle (exception:<br />
changing the carbon brushes holder for brush-type generators, see section 6.4.1<br />
on page 89). Nevertheless, the maintenance operations listed in section 6.1<br />
have to be performed regularly <strong>and</strong> on time to ensure reliable operation of the<br />
generator.<br />
CAUTION<br />
In addition to the work described in this chapter, the driving<br />
system/engine possibly has to be checked according to the<br />
guidelines <strong>and</strong> regulations of the driving system/engine<br />
manufacturer. This also includes the correct attachment of<br />
protective covers. Be sure to observe the maintenance instructions<br />
of the driving system/engine manufacturer.<br />
Do not open or disassemble the housing of the<br />
generator or the control box! The generator may<br />
only be opened by the manufacturer or an agency<br />
authorized by the manufacturer. It does not<br />
contain any components which can be replaced or<br />
repaired by the user. It is not allowed to perform<br />
any work or operations not described in this<br />
manual.<br />
Any damages <strong>and</strong> defects found on the generator have to be repaired<br />
immediately by authorized <strong>and</strong> qualified personnel independent of the<br />
maintenance intervals. The generator must not be taken into operation until any<br />
defects have been removed. Any repair work must only be carried out by<br />
adequately trained qualified personnel.<br />
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Chapter 6, Maintenance<br />
6.1 Maintenance overview<br />
Interval Maintenance operation To be performed by<br />
Every<br />
working day<br />
Monthly<br />
Every 1.000<br />
hours of<br />
operation<br />
Every 5.000<br />
hours of<br />
operation<br />
Every 20.000<br />
hours of<br />
operation<br />
Check the correct function of the insulation<br />
monitoring unit (if available).<br />
See section 5.6.3 on page 84.<br />
At the generator:<br />
• Visual inspection for contamination or<br />
damages. Cleaning if necessary.<br />
• If necessary, clean the plates <strong>and</strong> labels<br />
or replace them.<br />
• Check the cooling air openings for<br />
contamination or blocking <strong>and</strong> clean<br />
them, if necessary.<br />
See section 6.3 on page 88.<br />
At the control box (if mounted):<br />
• Visual inspection for contamination or<br />
damages. Cleaning if necessary.<br />
• Check the cover <strong>and</strong> the socket lids for<br />
waterproof locking.<br />
See section 6.3 on page 88.<br />
Only for brush-type generators:<br />
Check the carbon brushes<br />
See section 6.4.1 on page 89.<br />
Check the ball bearings by "listening".<br />
Replace, if necessary (rough noises at the<br />
bearings).<br />
User<br />
User<br />
User<br />
Qualified<br />
electrically skilled<br />
person<br />
Qualified<br />
skilled person<br />
Replace the ball bearings<br />
Manufacturer<br />
The st<strong>and</strong>ard maintenance interval for<br />
replacing the ball bearings is 20.000 hours.<br />
If necessary (see check every 5.000 hours),<br />
the ball bearings have to be replaced earlier.<br />
See section 6.4.2 on page 91.<br />
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Chapter 6, Maintenance<br />
6.2 Safety precautions<br />
This section summarizes the safety precautions relevant for maintenance<br />
operations.<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
<br />
performed by adequately trained qualified personnel <strong>and</strong> in<br />
conformity with the applicable national rules <strong>and</strong> regulations<br />
(in Germany: e.g. VDE regulations).<br />
DANGER<br />
Work on electrical installations <strong>and</strong> equipment may only be<br />
performed in the off <strong>and</strong> de-energized state. Mortal danger by<br />
electric shock!<br />
Engines that have been turned off must be secured against<br />
accidental restarting (e.g. by removing the ignition key <strong>and</strong><br />
keeping it safe)!<br />
Any maintenance, service <strong>and</strong> replacement operations on the<br />
generator may only be performed by authorized <strong>and</strong> qualified<br />
personnel.<br />
Generator components may be very hot, not just during but also<br />
after operation. Burning hazard!<br />
Do not perform any visual inspections for maintenance<br />
purposes <strong>and</strong> cleaning work on the generator during operation.<br />
Always turn off the engine first <strong>and</strong> make sure that it cannot be<br />
restarted accidentally (e.g. by removing the ignition key <strong>and</strong><br />
keeping it safe). Mortal danger by electric shock!<br />
The generator or its components must never be<br />
exposed to the jet of high-pressure cleaners.<br />
Mortal danger by electric shock <strong>and</strong><br />
destruction hazard!<br />
For repair <strong>and</strong> replacement operations, only genuine components or<br />
external components expressly approved by the manufacturer may<br />
be used.<br />
CAUTION<br />
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6.3 Visual inspections <strong>and</strong> cleaning to be performed by the user<br />
In addition to the safety precautions provided below, read <strong>and</strong> observe the<br />
safety precautions listed in section 6.2 above.<br />
Do not perform any visual inspections for maintenance<br />
<br />
purposes <strong>and</strong> cleaning work on the generator during operation.<br />
Always turn off the engine first <strong>and</strong> make sure that it cannot be<br />
restarted accidentally (e.g. by removing the ignition key <strong>and</strong><br />
DANGER<br />
keeping it safe). Mortal danger by electric shock!<br />
Generator components may be very hot, not just during but also<br />
after operation. Burning hazard!<br />
The following operations have to be performed by the user in monthly intervals.<br />
1. Check the generator housing for damages visible on the outside as well as for<br />
excessive contamination which could impair cooling. If necessary, use a wet<br />
cloth to clean the generator.<br />
2. If the generator is equipped with a control box, check the housing of the<br />
control box <strong>and</strong> the installed sockets for damages <strong>and</strong> contamination visible<br />
on the outside. If necessary, use a wet cloth to clean the control box. Check<br />
the transparent cover of the control box <strong>and</strong> the hinged lids of the sockets<br />
for damages <strong>and</strong> waterproof locking.<br />
3. Check whether the safety <strong>and</strong> warning label <strong>and</strong> the type plate attached to<br />
the generator are readable. If necessary, clean the plates <strong>and</strong> labels or<br />
replace them.<br />
4. Check the cooling air openings on the rear side of the generator for<br />
contamination which could obstruct the cooling air flow <strong>and</strong> use a wet cloth<br />
to clean the openings, if necessary.<br />
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6.4 Maintenance to be performed by authorized qualified<br />
personnel<br />
Any maintenance, service <strong>and</strong> replacement operations on the<br />
<br />
generator may only be performed by authorized <strong>and</strong> qualified<br />
personnel.<br />
DANGER<br />
In addition to the safety precautions listed below, read <strong>and</strong> observe the safety<br />
precautions given in section 6.2.<br />
6.4.1 Checking <strong>and</strong>/or replacing the carbon brushes (only brushtype<br />
generators)<br />
The carbon brushes of brush-type generators have to be removed <strong>and</strong> checked<br />
every 1.000 hours of operation by qualified personnel as described below. If the<br />
carbon brushes are used up more than half, the complete carbon holder must be<br />
replaced. It is not possible to replace only one single carbon brush.<br />
Removing the carbon brushes holder<br />
1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 28/2) <strong>and</strong><br />
detach the sleeve (1).<br />
2. Remove both connection cables from the connection lugs of the carbon<br />
brushes holder (Figure 28/3). The connection cables are coded by the width<br />
of the connection lugs <strong>and</strong> therefore protected against interchanging (see<br />
Figure 29).<br />
3. Unscrew the fastening screw of the carbon brushes holder <strong>and</strong> detach the<br />
carbon brushes holder (Figure 28/3).<br />
1<br />
2<br />
3<br />
Figure 28<br />
Removing the carbon brushes holder<br />
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Chapter 6, Maintenance<br />
Checking the carbon brushes<br />
The carbon brushes holder has to be replaced, if the carbon brushes are used up<br />
more than half, i.e. if they jut out of the carbon brushes holder less than 6 mm<br />
(see Figure 29).<br />
red<br />
gray<br />
6 mm min.<br />
Figure 29<br />
Checking/Replacing the carbon brushes<br />
Installing the carbon brushes holder<br />
1. Insert the carbon brushes holder (Figure 30/3) correctly positioned into the<br />
generator <strong>and</strong> press it onto the collector rings on the shaft, so that the<br />
carbon brushes are pressed into the carbon brushes holder <strong>and</strong> the carbon<br />
brushes holder lies on its mounting base.<br />
2. Continue to press on the carbon brushes holder <strong>and</strong> screw in the fastening<br />
screw, but do not tighten it completely. While screwing in the fastening<br />
screw, the carbon brushes holder is automatically positioned on the<br />
mounting base.<br />
3. Check the proper seating of the carbon brushes holder <strong>and</strong> then tighten the<br />
fastening screw.<br />
4. Plug both connection cables onto the connection lugs of the carbon brushes<br />
holder according to the width of the connectors (see Figure 30).<br />
5. Remount the sleeve (Figure 30/1) <strong>and</strong> fasten it by tightening the two screws<br />
(2).<br />
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Chapter 6, Maintenance<br />
1<br />
2<br />
red gray<br />
3<br />
Figure 30<br />
Installing the carbon brushes holder<br />
6.4.2 Replacing the ball bearings<br />
The ball bearings of the generator have to be replaced at least every 20.000<br />
hours of operation. However, if rough noises are detected at the ball bearings<br />
during the check prescribed every 5.000 hours of operation, the ball bearings<br />
have to be replaced earlier.<br />
We strongly recommend for these operations to remove the generator <strong>and</strong> to<br />
send it to the manufacturer or to an agency authorized by the manufacturer.<br />
Removing the generator is described in chapter 8 on page 93.<br />
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Chapter 7, Reconditioning<br />
7 Reconditioning<br />
Aside from the work described for maintenance in chapter 6, no other<br />
reconditioning operations can be carried out for the generators outside the<br />
manufacturer plant.<br />
If repair work is necessary, we recommend to remove the generator <strong>and</strong> to send<br />
it to the manufacturer or to an agency authorized by the manufacturer.<br />
Removing the generator is described in chapter 8 on page 93.<br />
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Chapter 8, Removal<br />
8 Removal<br />
To remove the generator, proceed according to the descriptions given in this<br />
chapter.<br />
8.1 Safety precautions<br />
DANGER<br />
Removing of the generator may only be performed by<br />
authorized <strong>and</strong> qualified personnel.<br />
Generator components may be very hot, not just during but also<br />
after operation. Burning hazard!<br />
For removing the generator make sure that the switched-off<br />
engine cannot be restarted accidentally (e.g. by removing the<br />
ignition key <strong>and</strong> keeping it safe). Mortal danger by electric<br />
shock, risk of personal injury!<br />
8.2 Removal of two-bearing generators (<strong>BG</strong><strong>132</strong> <strong>and</strong> <strong>BG</strong><strong>160</strong>)<br />
The removal of two-bearing generators has to be performed in accordance with<br />
the descriptions in chapter 4.<br />
8.3 Removal of single-bearing generators<br />
NOTE<br />
For the removal of single-bearing generators the following special<br />
tools are required:<br />
• Special tool of the engine manufacturer to hold the engine<br />
shaft.<br />
• For shaft fastening by grub-screw:<br />
Special hexagon nut for turning the generator shaft using a<br />
spanner as well as special sawing ring pliers for removing <strong>and</strong><br />
mounting the sawing ring which secures the fan impeller on the<br />
shaft.<br />
• For shaft fastening by tension bolt:<br />
Pushing rod <strong>and</strong> pushing screw.<br />
• Additionally for brush-type generators:<br />
Special wooden chock serving as transport locking for the rotor.<br />
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Chapter 8, Removal<br />
8.3.1 Removal of single-bearing brush-type generators<br />
Work prior to removal <strong>and</strong> removal of the carbon brushes holder<br />
1. Disconnect the electric connection cables of the generator as described in<br />
section 4.8 on page 70.<br />
2. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 31/2) <strong>and</strong><br />
detach the sleeve (1).<br />
3. Remove both connection cables from the connection lugs of the carbon<br />
brushes holder (Figure 31/5). The connection cables are coded by the width<br />
of the connection lugs <strong>and</strong> therefore secured against interchanging.<br />
4. Unscrew the fastening screw of the carbon brushes holder <strong>and</strong> detach the<br />
carbon brushes holder (Figure 31/5).<br />
5. Refer to the following descriptions to continue the removal:<br />
- For shaft fastening by grub-screw continue on page 95.<br />
- For shaft fastening by tension bolt continue on page 97.<br />
1 2<br />
3<br />
4<br />
5<br />
Figure 31<br />
Work prior to removal of single-bearing brush-type generators<br />
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Chapter 8, Removal<br />
Removal for shaft fastening by grub-screw<br />
1. Remove the fan impeller shroud (Figure 31/4) <strong>and</strong> the fan impeller (Figure<br />
31/3) from the generator. The fan impeller is secured against twisting on the<br />
shaft by means of a feathered key <strong>and</strong> a sawing ring.<br />
2. Attach the special hexagon nut (Figure 32/2) onto the generator shaft<br />
instead of the fan impeller <strong>and</strong> secure it against twisting by means of the<br />
feathered key (1).<br />
3. Hold the engine shaft using the special tool of the engine manufacturer.<br />
4. Attach the spanner to the special hexagon nut <strong>and</strong> undo the grub-screw<br />
connection between engine <strong>and</strong> generator shaft.<br />
5. Support the generator if necessary <strong>and</strong> unscrew the four end shield fastening<br />
screws (Figure 32/3) at the engine flange.<br />
6. Unscrew the generator shaft from the grub-screw screwed into the engine<br />
shaft <strong>and</strong> detach the generator.<br />
7. Unscrew the grub-screw (Figure 32/4) from the engine shaft using an Allen<br />
wrench.<br />
1<br />
4<br />
2<br />
3<br />
Figure 32 Removal of single-bearing brush-type generators (1)<br />
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Chapter 8, Removal<br />
8. Detach the special hexagon nut (Figure 33/1) from the generator shaft.<br />
9. Remount the carbon brushes holder (Figure 33/4) according to the<br />
descriptions on page 90 (section 6.4.1) into the generator <strong>and</strong> reconnect the<br />
connection cables.<br />
10. Insert the special wooden chock serving as transport locking for the rotor.<br />
11. Remount the sleeve (Figure 33/6) <strong>and</strong> fasten it by tightening the two<br />
screws (5).<br />
12. Remount the fan impeller (Figure 33/2) <strong>and</strong> secure it on the generator shaft<br />
by means of the feathered key (against twisting) <strong>and</strong> the sawing ring.<br />
13. Remount the fan impeller shroud (Figure 33/4).<br />
6<br />
5<br />
1<br />
2<br />
3<br />
4<br />
Figure 33 Removal of single-bearing brush-type generators (2)<br />
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Chapter 8, Removal<br />
Removal for shaft fastening by tension bolt<br />
1. Detach the cap (Figure 34/2) at the fan impeller shroud.<br />
2. Hold the engine shaft using the special tool of the engine manufacturer.<br />
3. Undo the tension bolt (Figure 34/1) <strong>and</strong> pull it out of the generator shaft.<br />
4. Support the generator if necessary <strong>and</strong> unscrew the four end shield fastening<br />
screws (Figure 34/3) at the engine flange.<br />
5. Insert the pushing rod (Figure 34/4) into the generator shaft instead of the<br />
tension bolt <strong>and</strong> screw the pushing screw (5) into the generator shaft. By<br />
screwing in the pushing screw, the generator shaft is detached from the<br />
engine shaft.<br />
6. Detach the generator from the engine.<br />
7. Remove the pushing screw <strong>and</strong> the pushing rod from the generator shaft.<br />
Remount the cap onto the fan impeller shroud.<br />
8. Remount the carbon brushes holder (Figure 33/5) according to the<br />
descriptions on page 90 (section 6.4.1) into the generator <strong>and</strong> reconnect the<br />
connection cables.<br />
9. Insert the special wooden chock serving as transport locking for the rotor.<br />
10. Remount the sleeve (Figure 33/7) <strong>and</strong> fasten it by tightening the two<br />
screws (6).<br />
1<br />
2<br />
4<br />
5<br />
3<br />
Figure 34<br />
Removal of single-bearing brush-type generators with tension<br />
bolt<br />
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Chapter 8, Removal<br />
8.3.2 Removal of brushless single-bearing generators<br />
Work prior to removal<br />
1. Disconnect the electric connection cables of the generator as described in<br />
section 4.8 on page 70.<br />
2. Refer to the following descriptions to continue the removal:<br />
- For shaft fastening by grub-screw continue with the following section on<br />
this side.<br />
- For shaft fastening by tension bolt continue on page 101.<br />
Removal for shaft fastening by grub-screw<br />
1. Remove the fan impeller shroud (Figure 35/3) <strong>and</strong> the fan impeller (Figure<br />
35/2) from the generator. The fan impeller is secured against twisting on the<br />
shaft by means of a feathered key <strong>and</strong> a sawing ring.<br />
2. Support the generator if necessary <strong>and</strong> unscrew the four end shield fastening<br />
screws (Figure 35/4) at the generator.<br />
3. Attach the special hexagon nut (Figure 36/2) onto the generator shaft<br />
instead of the fan impeller <strong>and</strong> secure it against twisting by means of the<br />
feathered key (Figure 36/1).<br />
4. Hold the engine shaft using the special tool of the engine manufacturer.<br />
5. Attach the spanner to the special hexagon nut <strong>and</strong> undo the grub-screw<br />
connection between engine <strong>and</strong> generator shaft.<br />
6. Unscrew the generator shaft from the grub-screw screwed into the engine<br />
shaft <strong>and</strong> detach the generator.<br />
7. Remove the front end shield of the generator which is still mounted on the<br />
engine. For this purpose, unscrew the four screws (Figure 36/3) <strong>and</strong> detach<br />
the end shield (Figure 36/4).<br />
8. Remount the front end shield (Figure 36/4) to the generator.<br />
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Chapter 8, Removal<br />
9. Unscrew the grub-screw (Figure 37/1) from the engine shaft using an Allen<br />
wrench.<br />
10. Detach the special hexagon nut (Figure 37/2).<br />
11. Remount the fan impeller (Figure 37/3) <strong>and</strong> the fan impeller shroud (Figure<br />
37/4). Secure the fan impeller on the generator shaft by means of the<br />
feathered key (against twisting) <strong>and</strong> the sawing ring.<br />
1<br />
4<br />
2<br />
3<br />
Figure 35 Removal of brushless single-bearing generators (1)<br />
1<br />
4<br />
2<br />
3<br />
Figure 36 Removal of brushless single-bearing generators (2)<br />
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Chapter 8, Removal<br />
1<br />
2<br />
3<br />
4<br />
Figure 37 Removal of brushless single-bearing generators (3)<br />
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Chapter 8, Removal<br />
Removal for shaft fastening by tension bolt<br />
1. Detach the cap (Figure 38/2) from the fan impeller shroud.<br />
2. Detach the front end shield from the generator. For this purpose, unscrew the<br />
four fastening screws (Figure 38/5) of the front end shield at the generator.<br />
3. Hold the engine shaft using the special tool of the engine manufacturer.<br />
4. Undo the tension bolt (Figure 38/1) <strong>and</strong> pull it out of the generator shaft.<br />
5. Insert the pushing rod (Figure 38/3) into the generator shaft instead of the<br />
tension bolt <strong>and</strong> then screw the pushing screw (Figure 38/4) into the<br />
generator shaft. By screwing in the pushing screw, the generator shaft is<br />
detached from the engine shaft.<br />
6. Detach the generator from the engine.<br />
7. Remove the pushing rod (Figure 38/3) <strong>and</strong> the pushing screw (Figure 38/4)<br />
from the generator shaft. Remount the cap (Figure 38/2) onto the fan<br />
impeller shroud.<br />
8. Remove the front end shield (Figure 39/1) of the generator which is still<br />
mounted to the engine. For this purpose, unscrew the four screws (Figure 39/<br />
2) <strong>and</strong> detach the end shield.<br />
9. Remount the front end shield to the generator.<br />
5<br />
1<br />
2<br />
3<br />
4<br />
Figure 38<br />
Removal of brushless single-bearing generators with tension bolt<br />
(1)<br />
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Chapter 8, Removal<br />
1<br />
2<br />
Figure 39<br />
Removal of brushless single-bearing generators with tension bolt<br />
(2)<br />
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Chapter 9, Transport <strong>and</strong> storage<br />
9 Transport <strong>and</strong> storage<br />
The generators are bolted onto a transport pallet <strong>and</strong> packed accordingly for<br />
protection against damages <strong>and</strong> penetrating humidity when leaving the factory.<br />
Single-bearing generators achieve IP54 protection only when they are mounted<br />
to the engine.<br />
The generators have to be transported <strong>and</strong> stored dry <strong>and</strong> protected<br />
against water. Transport <strong>and</strong> storage may only be performed in<br />
delivery state with the packaging <strong>and</strong> protective devices mounted.<br />
CAUTION<br />
On both sides of the generator, a lifting eye bolt is provided for attaching lifting<br />
equipment. Lifting equipment may only be attached to the generator using these<br />
lifting eye bolts. Only appropriate lifting equipment may be used.<br />
If no lifting eye bolts are provided at the generator ex works, these must be<br />
mounted later for lifting the generator.<br />
<strong>Generators</strong> <strong>BG</strong> <strong>132</strong> <strong>Generators</strong> <strong>BG</strong> <strong>160</strong><br />
Weight (mass) approx. 40 - 80 kg approx. 140 -180 kg<br />
Permissible temperatures:<br />
transport<br />
storage<br />
Permissible rel. humidity:<br />
transport<br />
storage<br />
-25 °C to +60 °C<br />
-20 °C to +50 °C<br />
95%, non-condensing<br />
95%, non-condensing<br />
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Chapter 10, Putting out of operation, storage after dismantling, disposal<br />
10 Putting out of operation, storage after dismantling,<br />
disposal<br />
Dismantling the generators <strong>and</strong> putting the generators out of operation have to<br />
be performed according to the descriptions in chapter 8.<br />
<strong>Generators</strong> which are still functional have to be packed <strong>and</strong> stored as described<br />
in chapter 9.<br />
<strong>Generators</strong> which are no longer functional have to be labeled accordingly <strong>and</strong><br />
disposed or supplied for recycling in accordance with the legal requirements. For<br />
more detailed information refer to the relevant environmental protection<br />
authority or to the manufacturer.<br />
10.1 Waste disposal information<br />
Generator housing<br />
Fan impeller shroud<br />
Fan impeller<br />
Rotor <strong>and</strong> shaft<br />
Windings<br />
Electronic components<br />
Aluminum<br />
Iron/steel<br />
Polypropylene<br />
Iron/steel<br />
Copper, impregnated by modified Ester-<br />
Imide (THEIC)<br />
Electronics scrap<br />
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Chapter 11, Spare parts<br />
11 Spare parts<br />
Companies authorized for repair <strong>and</strong> replacement work are asked to contact the<br />
manufacturer for the service manual.<br />
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Chapter 11, Spare parts<br />
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