Synchronous Generators BG 132 and BG 160 - gts generator ...

Synchronous GeneratorsSeries DGG, DWG and WGSize BG 132 and BG 160Operating and Installation InstructionsEnglish 08/2002

Synchronous Generators BG 132 / BG 160Copyright, general information, manufacturer's addressCopyrightNo part of this Operation Manual may be reproduced, published or transmitted inany form or by any means without the express permission of Generator-TechnikSchwäbisch Gmünd GmbH &Co. KG.© 2002 Generator-Technik Schwäbisch Gmünd GmbH & Co. KG. All rightsreserved.General informationTechnical modifications after date of printing are not considered. Subject tochange without notice.Issue date: August 2002Validity of the manualThis manual applies to all synchronous generators of the types DGG (three-phaseDC generators), DWG (three-phase AC generators) and WG (single-phase ACgenerators). However, for reasons of clarity only three-phase AC generators arerepresented and mentioned in the manual. In their general sense the givenexplanations are however also applicable for single-phase AC generators of theseries WG and appropriate generators with special voltages and frequencies.Further information about the designation system for the various generator typescan be found in chapter 1 on page 11.Manufacturer's addressFor any information and support concerning technical problems, services andorders please contact us.Generator-Technik Schwäbisch Gmünd GmbH & Co. KGZiegelfeldstraße 18D-73563 Mögglingen, GermanyPhone +49 7174 89 80 0 0Fax +49 7174 89 80 0 252 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Table of contentsTable of contentsSome important and valuable information .................................................. 5Warranty ............................................................................................... 5Proper use ............................................................................................ 6Preconditions and requirements to be met by the place of installation ........... 6Safety precautions ................................................................................. 71 Designation system for generator types .............................................. 111.1 Type codes .............................................................................. 111.2 Examples for designations .......................................................... 122 Description .................................................................................... 132.1 Use of different sizes (BG 132 and BG 160) .................................. 132.2 Overview of features and options for different sizes and designs ...... 132.3 General functionality ................................................................ 152.4 Generator governor ................................................................... 172.5 Mechanical designs ................................................................... 192.6 Drive types .............................................................................. 212.7 Terminal box (standard version) .................................................. 222.8 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 233 Technical data ................................................................................ 253.1 Generators ............................................................................... 253.2 Control box (optional, only for 8 kVA and 13 kVA generators) .......... 253.3 Generator governor ................................................................... 254 Installation .................................................................................... 274.1 Safety precautions for installation ............................................... 274.2 Requirements to be met by the place of installation and use ........... 294.3 General regulations for installation ............................................. 294.4 Permissible mounting positions and drain holes for cond. water ....... 314.5 Installation for single-bearing generators ..................................... 35Issue date: August 2002 3

Synchronous Generators BG 132 / BG 160Table of contents4.6 Installation of two-bearing generators (BG 132) ........................... 494.7 Installation of two-bearing generators (BG 160) ........................... 624.8 Electrical connection of the generators ........................................ 705 Operation ...................................................................................... 735.1 Safety information for operation ................................................. 735.2 Permissible operating conditions ................................................ 755.3 Electric protection equipment, protective measures and grounding ... 755.4 Connection to an existing power distribution network(e.g. house wiring) ................................................................... 775.5 Operating information for safe working with electric devices ........... 785.6 Operation of the generator ......................................................... 806 Maintenance .................................................................................. 856.1 Maintenance overview ............................................................... 866.2 Safety precautions .................................................................... 876.3 Visual inspections and cleaning to be performed by the user ........... 886.4 Maintenance to be performed by authorized qualified personnel ...... 897 Reconditioning ............................................................................... 928 Removal ........................................................................................ 938.1 Safety precautions .................................................................... 938.2 Removal of two-bearing generators (BG132 and BG160) ................. 938.3 Removal of single-bearing generators .......................................... 939 Transport and storage .....................................................................10310 Putting out of operation, storage after dismantling, disposal ................10410.1 Waste disposal information .......................................................10411 Spare parts ...................................................................................1054 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Some important and valuable informationSome important and valuable informationDear customer,Generator-Technik Schwäbisch Gmünd GmbH & Co. KG is a technically leadingmanufacturer of power generators in the best tradition and manufacturesgenerators with ratings of 4 to 30 kVA as well as its own design of electroniccontrol units for those generators. What makes GTS generators stand out is theirexcellent fitness for practical use and superior quality. They are maintenancefree,durable, precise and robust.Choosing a synchronous generator of this series was a decision for a technicallysuperior product. This product has been manufactured using only high-qualitycomponents which meet the requirements of VDE testing and comply withappropriate German (DIN) and European (EN) standards.All information contained in these operating instructions has been carefullycompiled and checked by us to the best of our knowledge and belief. Please besure to read and understand the operating instructions before installing,commissioning and using the generator.Generator-Technik Schwäbisch Gmünd GmbH & Co. KG does not assume anyliability for any applications which are contrary to the descriptions given inthese operating instructions, and for any loss or damage which has been causedby incorrect operation and handling, faulty installation, improper use, abuse,non-approved technical modifications or by any repairs performed byunauthorized personnel.If you have any questions, please contact Generator-Technik Schwäbisch GmündGmbH & Co. KG.WarrantyYours sincerely,Generator-Technik Schwäbisch Gmünd GmbH & Co. KGFor the generators of the series described in this manual, we issue warrantyaccording to the latest version of the "Allgemeine Lieferbedingungen fürErzeugnisse und Leistungen der Elektroindustrie (general conditions for thesupply of products and services of the electrical industry)" of the ZVEI.Issue date: August 2002 5

Synchronous Generators BG 132 / BG 160Proper useProper useThe generators described in this manual are intended for the generation ofelectrical energy within the context of emergency standby operation for feedingin mobile distribution systems. The generators must only be used according tothe voltage and power specifications listed on the type plate. Reverse feedingoperation (e.g. connection of four-quadrant converters) is not planned and onlyconditionally possible after consulting the manufacturer.The generators have to be driven with the specified rated speed. The generatoroutputs have to be protected against overcurrent and short-circuit by adequatefuse equipment according to the specifications on the type plate.The generators must not be connected to other power distribution or electricitygeneration systems (such as other generators or the public electricity supplynetwork, for example).The use of the generators is only allowed for applications described here and inconformity with the specifications given in this manual. Any other application isconsidered to be improper use and is not permitted.In case of improper use, misuse or abuse of the generators or of parts of them,Generator-Technik Schwäbisch Gmünd GmbH & Co. KG will not assume anyliability.Preconditions and requirements to be met by the place ofinstallationSingle-bearing generators are mounted directly to the engine. These generatorsmay only be mounted to engines which comply with the applicable regulations,rules and requirements.Two-bearing generators are usually installed right next to the engine. Thegenerator has to be firmly and securely mounted on an absolutely flat base witha bearing capacity adequate to the weight class of the generator. When using abelt drive, it is advisable to mount the generator adjustable. For that purposee.g. mounting rails can be used, providing the possibility of adjusting the belttension.All generators are splash-proof according to IP54 specifications and can thusalso be mounted and used outdoor. The generators are not explosion-protectedand thus must no be used in explosive atmospheres. Further regulations on thishave to be observed!6 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Safety precautionsWhen selecting the place of installation and use, the required minimumclearances have to be observed, adequate ventilation has to be ensured at anytime, and the temperature of the cooling air must not exceed 40 °C. Furtherinformation can be found in chapter 4 on page 27.The generators and the parts mounted to them must not be sprayed with highpressurecleaners. Therefore, the generators should preferably be installed in away and place which makes it impossible to even inadvertently spray thegenerator with high-pressure cleaners.Safety precautionsThis section summarizes the safety precautions of relevance. Read andunderstand the safety precautions before installing, commissioning andoperating the generator and observe the precautions. You will find the safetyprecautions in the relevant passages through the manual as well.Work on electrical installations and equipment may only beperformed by adequately trained qualified personnel and inconformity with the applicable national rules and regulations(in Germany: VDE regulations, among others).DANGERRisk ofpersonal injuryor deathanddestructionhazardWork on electrical installations and equipment may only beperformed in the off and de-energized state. Mortal danger byelectric shock! Engines that have been turned off must besecured against accidental restarting (e.g. by removing theignition key and keeping it safe)!Installation and commissioning of the generator as well as anymaintenance, service and replacement work may only beperformed by authorized and qualified personnel.Do not operate the generator in explosive environments.Further regulations on this have to be observed!Do not perform any visual inspections for maintenancepurposes and cleaning work on the generator during operation.Always turn off the engine first and make sure that it cannot berestarted accidentally (e.g. by removing the ignition key andkeeping it safe). Mortal danger by electric shock!Issue date: August 2002 7

Synchronous Generators BG 132 / BG 160Safety precautionsDANGERRisk ofpersonal injuryor deathanddestructionhazardNever connect the generator to the public electricity supplynetwork or to any other systems for power generation. Risk ofdeath, fire and destruction hazard!Never connect several generators to each other. Risk of death,fire and destruction hazard!If the generator shall be connected to an existing powerdistribution network (e.g. a house wiring), it has to beensured, that the system is completely and reliablydisconnected from the public electricity supply network of theenergy supply company. Reverse feeding into the publicelectricity supply network or network interconnection is notallowed. Reverse feeding involves mortal danger by electricshock for persons possibly working at the de-energized publicelectricity supply network. Due to network interconnectionwith the public electricity supply network, the generator can bedamaged, burn or cause fire in electrical cables of the system.Grounding the neutral conductor of the generator (N, midpointconductor) supersedes the protective measure "protectionseparation" and should therefore be avoided. If the neutralconductor N shall be grounded anyway, this may only beperformed by an electrically qualified person. In this case, acurrent-operated earth-leakage circuit breaker has to beconnected on the load side of the generator output. Theefficiency of the electrical protective measure has to beconfirmed by an appropriate measurement.The generator supplies highly dangerous voltages duringoperation! Never touch the generator or the devices connectedto the generator with wet hands during operation. Mortaldanger by electric shock!Generator components may be very hot, not just during but alsoafter operation. Burning hazard!The generator may only be operated with the protective coversfor the drive mounted as specified. Risk of personal injury!8 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Safety precautionsBe sure to read and understand the operating instructionscompletely before using the generator. The generator may onlybe used for applications described in section "Proper use"above and in conformity with the specifications in this manual.DANGERRisk ofpersonal injuryor deathanddestructionhazardBefore connecting devices to the generator, ensure that thedevices are switched off. Accident hazard! Unsupervisedstarting devices can endanger or injure persons as well as causedamages or damage themselves.Infants and animals must never have admittance to thegenerator, not just during but also after operation. Makeappropriate precautions. Mortal danger by electric shock, injuryand burning hazard!The generator or its components must never beexposed to the jet of high-pressure cleaners.Mortal danger by electric shock anddestruction hazard!CAUTIONDestructionhazardordamageBe sure to observe the permissible operating conditions given insection 5.2 on page 75. The generator may only be operated inconformity with the operating conditions and data specified there.This particularly applies to the ambient and cooling conditions andthe permissible current load.For installation and repair only genuine components or externalcomponents expressly approved by the manufacturer may be used.It is not permitted to perform any modifications on the generatoror on individual components or the control box. Any modification,improper repair or use of unsuitable external components willterminate all and any claims under a warranty as well as the typeapproval according to the German Equipment Safety Law and thecertification to EU / EEC directives. In this case the manufacturerwill not assume any liability.Issue date: August 2002 9

Synchronous Generators BG 132 / BG 160Safety precautions10 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 1, Designation system for generator types1 Designation system for generator typesThis chapter provides information about the designation system for theindividual generator types as well as examples of generator designations.1.1 Type codesDWG (BL) 17 / 7,0 - 2ZEE: Electronic generator governorZ: Two-bearing designE: Single-bearing designNumber of poles:2 poles (rated speed 3000 rpm)or4 poles (rated speed 1500 rpm)Single-phase output power in kVA, e.g. 7 kVAThree-phase output power in kVA, e.g. 17 kVA.Power determines size:• 2-pole generator: up to 17 kVA = BG 132,20 kVA and higher = BG 160• 4-pole generator: 10 kVA and higher = BG 160With specification (BL): Brushless generatorWithout specification (BL): Brush-type generatorDWG: Three-phase AC generatorWG: Single-phase AC generatorDGG: Three-phase DC generatorIssue date: August 2002 11

Synchronous Generators BG 132 / BG 160Chapter 1, Designation system for generator types1.2 Examples for designationsTypeDWG 8,0/5,0-2EEFeaturesThree-phase AC generator, brush-type machine, 8 kVAthree-phase power, 5 kVA single-phase power, 2-polemachine, single-bearing design, electronic governor, sizeBG 132 (2-pole generator < 17 kVA).DWG (BL) 10/6-4ZE Three-phase AC generator, brushless, 10 kVA three-phasepower, 6 kVA single-phase power, 4-pole machine, twobearingdesign, electronic governor, size BG 160 (10 kVA,4-pole generator).12 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2 Description2.1 Use of different sizes (BG 132 and BG 160)Depending on the rated output power and the number of poles the generatorsare produced in two different sizes: BG 132 or BG 160.BG 132Size BG 132 is used for• 2-pole generators (driving speed 3000 rpm) with rated power outputs smallerthan 17 kVA.BG 160Size BG 160 is used for• 2-pole generators (driving speed 3000 rpm) with rated power outputs greaterthan and including 20 kVA or• 4-pole generators (driving speed 1500 rpm) with rated power outputs greaterthan and including 10 kVA.2.2 Overview of features and options for different sizes anddesignsThe following table shows an overview of features and possible options for thedifferent generator sizes and types.Key for the table:x = possible or "yes"- = not possible or "no"Issue date: August 2002 13

Synchronous Generators BG 132 / BG 160Chapter 2, DescriptionVersion / Option BG 1322-pole up to17 kVAGenerator directly mounted toengineEngine-/manufacturer-dependingsealing betw. engine and generatorBG 1602-pole ≥ 20 kVA4-pole ≥ 10 kVA1-bear. 2-bear. 2-bearingx - -x - -Direct coupling via flange - x xBelt or hydraulic drive - x xBrushless Generator x x xBrush-type generator x x -Supply without terminal box,cable directly lead out in a hoseTerminal box mounted,no governor/filter functionsTerminal box mounted,governor/filter functions partlyimplementedTerminal box mounted,governor/filter functions completelyimplementedOption "Expanded generatorgovernor with no-load automatic"Control box mounted,aluminum cast or sheet metalx x xx x xx x xx x xx x xx 1 x 1 -Option hour meter in control box x 1 x 1 -Option insulation monitoring incontrol boxx 1 x 1 -1. Only available for versions with rated power output of 8 kVA or 13 kVA.14 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.3 General functionalityAll generators of these series are self-excited synchronous inner-pole generators.The generator consists of the functional groups main machine, exciter androtating rectifier mounted in a common housing. The electronic generatorgovernor can be placed in a terminal box mounted on the generator, an externalcontrol box or in the optional control box mounted on the generator instead ofthe terminal box.Due to various constructional measures, an amortisseur and a balancing controlthe generators have an extreme asymmetric load capability.Cooling of the generators is performed by a rotating direction-independent selfventilation.For this purpose, the cooling air is sucked on the rear side by a fanimpeller and then blown to the front outside along the generator.The supplied generator voltage is regulated by the electronic generator governor,so that the output voltage fulfills the requirements of IEC 38 for the entire rangebetween no-load and rated load condition. This corresponds to the qualitystandard of the public electricity supply network. The output frequencyconstancy depends on the speed constancy of the engine.In case of short generator overload conditions (below the reaction time of thecircuit breakers) or if devices with a too high power consumption or a too highstarting power are connected to the generator, the generator governorautomatically limits the output power (by limiting the exciter field current) andreduces the output voltage.Optionally an expanded generator governor with no-load automatic is available.Further information about the generator governor can be found in section 2.4 onpage 17.If the generator is not equipped with the option "Insulation monitoring withswitching-off", it fulfills the protective measure "Protection separation withequipotential bonding" according to VDE 0100 part 728. The used power systemis the IT system with neutral conductor N and equipotential bonding conductorPE (see Figure 1).If the generator is equipped with the option "Insulation monitoring withswitching-off", it fulfills the better protective measure "Protection separationwith insulation monitoring" according to VDE 0100, part 728.The generators of this series comply with the EMC regulations EN ISO 14982, ISOTC 127 / ISO FDIS 13766 / DIN EN 13909 and further EMC regulations referencedin these regulations.Issue date: August 2002 15

Synchronous Generators BG 132 / BG 160Chapter 2, DescriptionGeneratorL1L2L3NPELoadFigure 1Power system of the generator: Principle diagram for protectionseparation16 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.4 Generator governorFigure 2Generator governor LCAR3LIM for brush-type generators(simplified schematic representation)Issue date: August 2002 17

Synchronous Generators BG 132 / BG 160Chapter 2, DescriptionFigure 3Generator governor LCAR3LIM for brushless generators(simplified schematic representation)18 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.5 Mechanical designsDepending on the rated power output and the number of poles the generatorsare produced in two different sizes: BG 132 or BG 160.Size BG 132 is used for 2-pole generators with rated power outputs up to 17kVA. These generators are available as brushless type or with carbon brushes.Depending on the kind of use, generators of the size BG 132 can either be builtas single-bearing generators or as two-bearing generators. Single-bearinggenerators are directly mounted to the engine. In this case the engine bearing isused as second bearing.Size BG 160 is used for• 2-pole generators with rated power outputs starting from 20 kVA or for• 4-pole generators with rated power outputs starting from 10 kVA.Generators of the size BG 160 are exclusively available as brushless generatorsand are only produced as two-bearing generators.Two-bearing generators are usually installed right next to the engine. Regardingthe generator drive, there are various options to choose from (refer to section2.6 on page 21).To cover a wide range of applications, the generators can be delivered indifferent versions regarding the electrical connection.• Generator with terminal box mounted (standard type):The terminal box mounted on the generator contains a connection terminalplate for the connecting cables as well as the generator governor.Furthermore, a suppression filter can be installed in the terminal box.However, the suppression filter can also be located in an external controlcabinet, if desired. Further information about the terminal box can be foundin section 2.7 on page 22.• Cable directly lead out of the generator in a hose without a terminal boxmounted:For this version, all connecting cables of the generator as well as the cablesfor the generator governor are led out of the generator housing using a hose.This version offers the special advantage, that the generator can also be usedin relatively hot environments. In this case, the generator governor as well asthe complete current distribution and the electrical fuse protection has to beinstalled in an external control cabinet.Issue date: August 2002 19

Synchronous Generators BG 132 / BG 160Chapter 2, Description• Generator with a control box mounted (only applicable for 8 kVA and 13 kVAversions):In the standard version the control box optionally mounted on the generatorcontains the generator governor, a suppression filter, the sockets forconnecting the loads as well as an all-pole circuit breaker for protecting theinstalled sockets against overcurrent and short-circuit. As additional optionsan hour meter and an insulation monitoring can be installed. Furtherinformation about the optional control box can be found in section 2.8 onpage 23.Terminal boxDrive shaftMounting profile(all around with 45°spacing)Drain hole forcondensation water(if available)Angle brackets(fitted on both sides)CoolingprofilesCooling air intakeFan impeller shroudDrain hole for condensation water(if available)Figure 4Two-bearing generator, size BG 132 with terminal box20 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.6 Drive types2.6.1 Single-bearing generators (only BG 132)Single-bearing generators are exclusively intended for direct mounting to theengine. The shafts of the generator and the engine are directly connected toeach other and the bearing of the engine is used as second bearing for thegenerator. Therefore, the generator always runs at the same speed as the engine.With this type of drive, it has to be ensured that the engine has an appropriatespeed rating. Otherwise the generator is operated at underspeed or overspeedwhich can restrict the functionality of the generator.For information regarding the installation of the generator please refer tochapter 4 on page 27.2.6.2 Two-bearing generatorsTwo-bearing generators can be driven in different ways as described below. Forinformation regarding the installation of components necessary for thecorresponding type of driving, please refer to chapter 4 on page 27.Belt pulley driveThe generator is mechanically connected to the engine via a belt pulley and abelt. The belt drive is a particularly simple and inexpensive type of drive.Moreover it offers the advantage that the speeds of the engine and the generatorcan be optimally balanced by selecting the transmission ratio.Direct coupling of the generator via flangeUsing direct flange mounting, the shafts of the generator and the engine areconnected by a flange. Therefore, the generator always runs at the same speed asthe engine. With this type of drive, it has to be ensured that the engine has anappropriate speed rating. Otherwise the generator is operated at underspeed oroverspeed which can restrict the functionality of the generator.Hydraulic motor driveIn this case, the generator is driven by a hydraulic motor supplied from ahydraulic system. When using this type of drive, attention must be particularlydrawn to the fact that the generator is not operated at overspeed. This may haveadverse effects on the functionality of the generator as well.Issue date: August 2002 21

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.7 Terminal box (standard version)The terminal box mounted to the generator contains a connection terminal platefor the connecting cables. Inside the terminal box cover the completely sealedingenerator governor is installed. The terminal box can furthermore contain asuppression filter which, however, can also be placed in an external controlcabinet, if desired.The generator governor in the terminal box cover can also be replaced by anoptionally available expanded generator governor with a no-load automaticfunction. Further information about this can be found in section 2.4 on page 17.Generator governorConnection terminal plateTerminal boxSuppression filter (optional)Figure 5Terminal box with connection terminal plate, generator governorand suppression filter22 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.8 Control box (optional, only for 8 kVA and 13 kVA generators)2.8.1 GeneralThe control box mounted on the generator is only available for generators withrated power outputs of 8 kVA and 13 kVA. In the standard version it contains thegenerator governor, a suppression filter, the sockets for connecting the loads aswell as an all-pole circuit breaker for protecting the installed sockets againstovercurrent and short-circuit. As additional options an hour meter and aninsulation monitoring with switching-off can be installed.The generator governor in the control box can also be replaced by an optionalexpanded generator governor with no-load automatic function. Furtherinformation about this can be found in section 2.4 on page 17.Hour meter(optional)Insulation monitoring unit(optional)Circuit breaker(4-pole)Socket 400 VSockets 230 VFigure 6Control box with installed options hour meter and insulationmonitoringIssue date: August 2002 23

Synchronous Generators BG 132 / BG 160Chapter 2, Description2.8.2 Option insulation monitoring with switching-offIf the generator is equipped with the option "Insulation monitoring withswitching-off", it fulfills the protective measure "Protection separation withinsulation monitoring" according to VDE 0100, part 728.The insulation monitoring unit (see Figure 6) monitors the insulation of thedevices connected to the sockets. If it detects a defective insulation of aconnected device or extension cord, the insulation monitoring unit immediatelyswitches off all sockets and the red signal lamp "FAULTY INSULATION" lights upto indicate the fault. In this case the defective device has to be disconnectedand taken out of operation and the insulation monitoring unit has to be reset.Generators which are equipped with an insulation monitoring unitmust not be connected to further insulation monitoring units,since the insulation monitoring units can mutually interact.CAUTION24 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 3, Technical data3 Technical data3.1 GeneratorsThe technical data of the generator can be found on the type plate mounted onthe generator.3.2 Control box (optional, only for 8 kVA and 13 kVA generators)Type of enclosureConnectorsFeaturesOptional featuresPermissible length ofconnected cablesIP54 (all covers closed and locked)1 CEE socket 5 x 16 A (3P + N + PE)3 protective contact sockets 16 A (1P + N + PE)4-pole circuit breaker B 16 AGovernor, filter and noise suppression installedHour meterInsulation monitoring unit with signal lampFulfills protective measure "Protection separationwith insulation monitoring" according to DVGW 308Total length of all connected cables:250 m max. at conductor cross section 2.5 mm 2100 m max. at conductor cross section 1.5 mm 23.3 Generator governorGovernor typeLCAR3Pin assignment Pin Color Function123456redgrayyellowyellowyellowF1F21/2 U1/2 V1/2 WIssue date: August 2002 25

Synchronous Generators BG 132 / BG 160Chapter 3, Technical data26 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.1 Safety precautions for installation4 InstallationThe installation procedures may differ depending on the generator version andtype. Where applicable, such differences are mentioned in the concerning texts.Prior to installation of the generator, read and understand the safety precautionsin section 4.1 as well as all other applicable sections of this chapter and observethe instructions and information given therein.CAUTIONThe installation work described in this chaptermay only be performed by authorized andqualified personnel.Do not open or disassemble the generator and/orthe control box mounted on the generator(depending on the version)! The generator mayonly be opened by the manufacturer or an agencyauthorized by the manufacturer. It is not allowedto perform any work or operations not describedin this manual.4.1 Safety precautions for installationWork on electrical installations and equipment may only beperformed by adequately trained qualified personnel and inconformity with the applicable national rules and regulations(in Germany: VDE regulations, among others).DANGERWork on electrical installations and equipment may only beperformed in the off and de-energized state. Mortal danger byelectric shock!Engines that have been turned off have to be secured againstaccidental restarting (e.g. by removing the ignition key andkeeping it safe)!Installation of the generator as well as any maintenance,service and replacement work may only be performed byauthorized and qualified personnel.Never connect the generator to the public electricity supplynetwork or to any other systems for power generation. Risk ofdeath, fire and destruction hazard!Issue date: August 2002 27

Synchronous Generators BG 132 / BG 160Chapter 4: 4.1 Safety precautions for installationDANGERCAUTIONNever connect several generators to each other. Risk of death,fire and destruction hazard!Grounding the neutral conductor of the generator (N, midpointconductor) supersedes the protective measure "protectionseparation" and should therefore be avoided. If the neutralconductor N shall be grounded anyway, this may only beperformed by an electrically qualified person. In this case, acurrent-operated earth-leakage circuit breaker has to beconnected on the load side of the generator output. Theefficiency of the electrical protective measure has to beconfirmed by an appropriate measurement.The generator may only be operated with the protective coversfor the drive mounted as specified. Risk of personal injury!Be sure to completely read and understand the operatinginstructions before installing and using the generator. Thegenerator may only be used for applications described insection "Proper use" and in conformity with the specificationsgiven in this manual.For installation only genuine components or external componentsexpressly approved by the manufacturer may be used.It is not permitted to perform any modifications on the generatoror on individual components or the control box. Any modification,improper repair or use of unsuitable external components willterminate all and any claims under a warranty as well as the typeapproval according to the German Equipment Safety Law and thecertification to EU / EEC directives. In this case the manufacturerwill not assume any liability.28 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.2 Requirements to be met by the place of installation and use4.2 Requirements to be met by the place of installation and useSingle-bearing generators are mounted directly to the engine. These generatorsmay only be mounted to engines which comply with the applicable regulations,rules and requirements.Two-bearing generators are usually installed right next to the engine. Thegenerator has to be firmly and securely mounted on an absolutely flat base witha bearing capacity adequate to the weight class of the generator. When using abelt drive, it is advisable to mount the generator adjustable. For that purposee.g. mounting rails can be used, providing the possibility of adjusting the belttension.All generators are splash-proof according to IP54 specifications and can thusalso be mounted and used outdoor. The generators are not explosion-protectedand thus must no be used in explosive atmospheres. Further regulations on thishave to be observed!When selecting the place of installation and use, the required minimumclearances have to be observed, adequate ventilation has to be ensured at anytime, and the temperature of the cooling air must not exceed 40 °C.The generators and the parts mounted to them must not be sprayed with highpressurecleaners. Therefore, the generators should preferably be installed in away and place which makes it impossible to even inadvertently spray thegenerator with high-pressure cleaners.4.3 General regulations for installationA correct and proper installation of the generator is a prerequisite for a safe,reliable and error-free operation as well as the electrical and mechanical safety.Usually the generators are operated with a counterclockwise direction ofrotation. In this case the output voltage has a "clockwise rotating field".However, the generators can also be operated with a clockwise direction ofrotation. Then the output voltage has a "counterclockwise rotating field".Due to the dynamic processes during the switching of electric loads, the enginemust have adequate power reserves and its governor system must be able to dealwith such processes.The constructional form and design of the generator must not be changed.Mounting surfaces must be precisely flat. Misalignments during installation haveto be avoided.Issue date: August 2002 29

Synchronous Generators BG 132 / BG 160Chapter 4: 4.3 General regulations for installationAfter installation, a test finger according to EN 60034, part 5, or a foreign partwith a diameter greater than 12 mm (e.g. a sphere) must not come in contactwith rotating parts, if a risk could result from this. Especially the protectivecovers of the power transmission have to be constructed stable and mountedfirmly. It must not be possible to remove protective covers without using tools.The cooling air must be supplied and eliminated in a way, that the accumulatingdissipation heat is eliminated definitively. Only harmless amounts of dust andwater may be sucked with the cooling air. Short-circuits of the air have to beavoided.Generators with a second shaft end must not be operated without a machine orprotective cover correctly installed to this end.If the generator is not already equipped ex works with a control box containingelectric protection equipment and sockets, adequate fuse equipment has to beinstalled in an external control cabinet to protect the circuits (sockets) againstovercurrent and short-circuit. Observe that the neutral conductor N has to befused as well. Consult the generator manufacturer GTS for the correct types andnominal currents of the circuit breakers to be used. Further information aboutthis can be found in section 4.8 on page 70.If the generator is not already equipped ex works with a control box containingelectric protection equipment and sockets, the generator, the control cabinetand the complete electric installation have to be checked by visual inspection,testing and measurement according to DIN VDE 0100, part 610, before bringingthe generator into operation for the first time.Observe the specific installation rules and instructions for the individualgenerator types listed in the following sections of this manual. There youcan also find particular installation notes for the different drive types of thegenerators.• Refer to section 4.5 on page 35 for single-bearing generators of the sizeBG 132.• Refer to section 4.6 on page 49 for two-bearing generators of the sizeBG 132.• Refer to section 4.7 on page 62 for two-bearing generators of the sizeBG 160.• Refer to section 4.8 on page 70 for notes and instructions concerning theelectrical connection of the generators.30 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water4.4 Permissible mounting positions and drain holes for cond. water4.4.1 Permissible mounting positions for single-bearinggeneratorsSingle-bearing generators are mounted directly to theengine. Thus, a horizontal mounting position ispredetermined by the engine.When ordering the generator, the position of theterminal box has to be specified (or the position ofthe cable lead-out or the control box, depending onthe version).The following mounting positions are possible:• Terminal box on top• Terminal box turned by 45° or 90° to the left orto the rightNo other mounting positions are permitted!okokokIssue date: August 2002 31

Synchronous Generators BG 132 / BG 160Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water4.4.2 Permissible mounting positions for two-bearing generators(BG 132 and BG 160)The generator has to be mounted on a horizontal flatbase standing on its angle brackets, as shown inthe accompanying figure.When mounted in normal position, the terminal boxis positioned on the top of the generator (or thecable lead-out or the control box, depending on theversion).It is also possible to install the generator turned by45° or 90° to the left or to the right, as shown in theaccompanying figure. For this purpose, the anglebrackets have to be removed and mounted again tothe corresponding mounting profiles.okokokNo other mounting position is permitted!nonono32 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. water4.4.3 Drain holes for condensation water (BG 132 and BG 160)NOTEThis section is only applicable, if drain holes are available in thegenerator housing.The drain holes for condensation water are not available at allgenerators. Depending on the intended field of application of thegenerator, these holes can also be missing. In case of doubt, pleasecheck the generator.Under unfortunate circumstances, possiblycondensation water can occur inside thegenerator. To provide an outlet for thiscondensation water, the generator housingpossibly has several drain holes (4 holeseach on the front and on the rear, 90°spacing).If these drain holes are available in thehousing, the holes at the lowest point inmounting position has always to beopened.All other holes (on both sides and on thetop) have to be closed by screws.NOTE: The holes on the rear side arecovered by the fan impeller shroud. Theholes are only accessible after removingthe shroud.Max. thread length 8 mm!Make sure that the two drain holes locatedon the bottom are opened. If necessary,remove the screws to open thecondensation water drain holes.Issue date: August 2002 33

Synchronous Generators BG 132 / BG 160Chapter 4: 4.4 Permissible mounting positions and drain holes for cond. waterMake sure that the holes on both sides andon the top are closed with screws.If you are installing the generator turnedfrom the mid position, remove the screwsfrom the holes located at the bottom sidein order to open the condensation waterdrain holes and then use these screws toclose the open holes which are nowlocated on the side.34 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4.5 Installation for single-bearing generatorsFor installing the generator proceed according to the descriptions in this section4.5. Prior to installation, read and understand the safety precautions in section4.1 as well as the sections 4.2 to 4.4 and observe the instructions andinformation given there.Optionally, lifting eye bolts are provided on the top or on both sides of thegenerator (45° from the vertical) for attaching lifting equipment. Liftingequipment may only be attached to the generator using these lifting eye bolts.Only appropriate lifting equipment may be used.4.5.1 Scope of delivery (single-bearing generators)The scope of delivery may differ depending on the generator version and theengine type. The type of sealing against the engine depends on the engine/manufacturer. For this reason, the appropriate sealings have to be orderedtogether with the generator.4.5.2 Dimensions (single-bearing generators)The dimensions of the generator can be found in the drawing sheet included inthe annex.No other parts may be mounted to the mountingprofiles of the generator housing.CAUTION4.5.3 Minimum clearances and regulations for cooling (singlebearinggenerators)In order to provide sufficient cooling the generator needs adequate ventilation.The cooling air is sucked on the rear side by the fan impeller and then blown tothe front side through the cooling profiles along the housing. If necessary,adequate openings for cooling air inlet and outlet have to be provided.It is absolutely important to observe the following regulations for minimumclearances and cooling.Issue date: August 2002 35

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generatorsMinimum clearances (single-bearing)The following minimum clearances towardsparts or walls have to be observed forinstallation (see also the accompanyingfigures on the right):• All sides: a = 100 mm• Rear side: b = 170 mmCooling (single-bearing)It is absolutely important to observe thefollowing regulations for cooling. Dangerof overheating!The temperature of the supplied cooling airmust not exceed 40 °C.In the cooling air intake area on the rearside of the generator a maximum partialvacuum of P max =4Pa may arise.Otherwise the fan impeller cannot suckenough cooling air.In the cooling air blow out area on thefront side of the generator a maximumoverpressure of P max = 7 Pa may arise.Otherwise the circulation of the cooling airis not sufficient.Cooling air circulation must not beimpaired by other air flows (e.g.directed from the side or from the frontto the generator).aabP max = 7 PaabP max = 4 Pa36 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4.5.4 Installation to the engine (single-bearing generators)The minimum clearances and regulations for cooling given in the section abovehave to be met for installation.4.5.4.1 Sealing of the generator against the engineDuring installation a sealing has to be attached between the generator and theengine. The type of sealing depends on the used engine. The sealings prescribedfor the different engines are listed in the following table.Engine Type of sealing Installation instructionsB&S 12.5 HP / 14 HP VE1/877 or VE1/977 Press the sealing into theshaft opening in the endshield.Honda GX 390 K1V VE1/871 Bond the sealing into theYamaha MZ 360 Kcorresponding clearance in theend shield.Yanmar L90 / L100 Fluid sealing Apply liquid sealant into thecorresponding clearance in theend shield.Hatz 1D 60CNo sealing required.Issue date: August 2002 37

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4.5.4.2 Installation of brush-type generatorsRemoval prior to installation and removal of the carbon brushes holder1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 7/2) anddetach the sleeve (1).2. Remove both connection cables from the connection lugs of the carbonbrushes holder (4). The connection cables are coded by the width of theconnection lugs and therefore secured against interchanging.3. Unscrew the fastening screw of the carbon brushes holder and detach thecarbon brushes holder (4).4. Pull out the transport locking (wooden chock).5. Remove the fan impeller shroud (3) from the generator.1234Flange representedturned by 45°Figure 7Removal prior to installation of single-bearing brush-typegenerators38 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generatorsInstallationNOTEFor differing installation instructions for shaft fastening by tensionbolt (instead of the grub-screw described here), please refer tosection 4.5.4.4 on page 45.1. Screw the supplied grub-screw (Figure 8/1) into the engine shaft as far as itwill go using an Allen wrench.2. Apply the sealing to the front end shield of the generator as described insection 4.5.4.1 on page 37.3. Align the generator in front of the engine in a way, that the generator shaftlies in one line with the engine shaft. If necessary, support the generatoraccordingly.4. Push the generator against the engine flange and align the threaded hole ofthe generator shaft with the grub-screw screwed into the engine shaft.5. Screw the generator shaft by turning the fan impeller onto the grub-screw inthe engine shaft as far as it will go. This pulls the generator against theengine flange.NOTEWhile screwing the generator shaft onto the grub-screw, alignthe mounting holes in the end shield with the drillings in theengine flange.It is not necessary to tighten the generator shaft on the grubscrew.It is sufficient, if the shaft is screwed onto the grubscrewas far as it will go, since the screw-connection tightensitself when the generator is loaded.For installation instructions for shaft fastening by tension bolt,please refer to section 4.5.4.4 on page 45.6. Fasten the generator's end shield to the engine flange using four fasteningscrews (Figure 8/2).Issue date: August 2002 39

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators1Apply appropriate sealingdepending on the engine24xFigure 8Installation of single-bearing brush-type generators to theengine7. Insert the carbon brushes holder (Figure 9/4) correctly positioned into thegenerator and press it on to the collector rings on the shaft, so that thecarbon brushes are pressed into the carbon brushes holder and the carbonbrushes holder lies on its mounting base.8. Continue to press on the carbon brushes holder and screw in the fasteningscrew, but do not tighten it completely. While screwing in the fasteningscrew, the carbon brushes holder is automatically positioned on themounting base.9. Check the proper seating of the carbon brushes holder and then tighten thefastening screw.10. Plug both connection cables onto the connection lugs of the carbon brushesholder according to the width of the connectors.40 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators11. Remount the sleeve (Figure 9/3) and fasten it by tightening the two screws(2).12. Remount the fan impeller shroud (Figure 9/1).Flange representedturned by 45°1423Figure 9Installing the carbon brushes holderIssue date: August 2002 41

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4.5.4.3 Installation of brushless generatorsRemoval prior to installation1. Remove the fan impeller shroud (Figure 10/1) from the generator.2. Unscrew the four fastening screws (3) at the generator and detach the frontend shield (2).321Figure 10Removal prior to installation of brushless single-bearinggenerators42 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generatorsInstallationNOTEFor additional installation instructions for shaft fastening bytension bolt (instead of the grub-screw described here), pleaserefer to section 4.5.4.4 on page 45.1. Screw the supplied grub-screw (Figure 11/1) into the engine shaft as far as itwill go using an Allen wrench.2. Apply the sealing to the removed front end shield of the generator asdescribed in section 4.5.4.1 on page 37.3. Set the removed front end shield (Figure 11/2) with the sealing applied ontothe engine flange and fasten it using the four screws (Figure 11/3).4. Align the generator in front of the engine in a way, that the generator shaftlies in one line with the engine shaft. If necessary, support the generatoraccordingly.5. Push the generator against the engine and align the threaded hole of thegenerator shaft to the grub-screw screwed into the engine shaft.6. Screw the generator shaft by turning the fan impeller onto the grub-screw inthe engine shaft as far as it will go. This pulls the generator housing againstthe front end shield already mounted on the engine.NOTEWhile screwing the generator shaft onto the grub-screw, alignthe generator with the front end shield mounted on the engine.It is not necessary to tighten the generator shaft on the grubscrew.It is sufficient, if the shaft is screwed onto the grubscrewas far as it will go, since the screw-connection tightensitself when the generator is loaded.For installation instructions for shaft fastening by tension bolt,please refer to section 4.5.4.4 on page 45.7. Fasten the end shield to the generator using four fastening screws (Figure12/2).8. Remount the fan impeller shroud (Figure 12/1).Issue date: August 2002 43

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators1Apply appropriate sealingdepending on the engine234xFigure 11Installation of brushless single-bearing generators to theengine (1)124xFigure 12Installation of brushless single-bearing generators to theengine (2)44 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4.5.4.4 Additional installation instructions for shaft fastening bytension boltInstead of the grub-screw described in the sections 4.5.4.2 and 4.5.4.3,optionally a tension bolt can be used to connect the shafts. In this case thegenerator shaft is drilled hollow.In this case proceed as follows instead of using the particular installationinstructions.When installing single-bearing brush-type generatorsThe following descriptions assume that you have already performed the removalprior to installation and the removal of the carbon brushes holder according tosection 4.5.4.2 on page 38.The steps listed here replace the steps 1. to 6. on page 39.1. Apply the sealing to the front end shield of the generator as described insection 4.5.4.1 on page 37 (see also Figure 13).2. As shown in Figure 13, align the generator in front of the engine in a way,that the generator shaft lies in one line with the engine shaft. If necessary,support the generator accordingly.3. Push the generator against the engine flange, so that the shafts hit eachother.4. Insert the tension bolt (Figure 13/1) from the rear side through the generatorshaft and screw it into the engine shaft, but do not yet tighten it.NOTEWhile screwing in the tension bolt, align the mounting holes inthe end shield of the generator according to the drillings in theengine flange.5. Fasten the end shield of the generator to the engine flange using fourfastening screws (Figure 13/2).6. Secure the engine shaft against twisting and tighten the tension bolt.7. Continue with the further steps described in section 4.5.4.2: Start with step7. on page 40.Issue date: August 2002 45

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generatorsApply appropriate sealingdepending on the engine124xFigure 13Installation of single-bearing brush-type generators fastenedwith tension boltWhen installing brushless single-bearing generatorsThe following descriptions assume that you have already performed the removalprior to installation according to section 4.5.4.3 on page 42.The steps listed here replace the steps 1. to 8. on page 43.1. Apply the sealing to the removed front end shield of the generator asdescribed in section 4.5.4.1 on page 37 (see also Figure 14).2. Set the removed front end shield with the sealing applied onto the engineflange and fasten it using the four screws (Figure 14/2).3. As shown in Figure 14, align the generator in front of the engine in a way,that the generator shaft lies in one line with the engine shaft. If necessary,support the generator accordingly.46 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators4. Push the generator against the engine, so that the shafts hit each other.5. Insert the tension bolt (Figure 14/1) from the rear side through the generatorshaft and screw it into the engine shaft, but do not yet tighten it. Byscrewing in the tension bolt, the generator shaft is pushed onto the engineshaft.NOTEWhile screwing in the tension bolt, align the generatoraccording to the front end shield mounted at the engine.6. Fasten the end shield to the generator using four fastening screws (Figure15/2).7. Secure the engine shaft against twisting and tighten the tension bolt. Besure to use the correct torque! Please contact the manufacturer, if you do notknow the correct torque for the tension bolt.8. Remount the fan impeller shroud (Figure 15/1).Apply appropriate sealingdepending on the engine24x1Figure 14Installation of brushless single-bearing generators with tensionbolt (1)Issue date: August 2002 47

Synchronous Generators BG 132 / BG 160Chapter 4: 4.5 Installation for single-bearing generators124xFigure 15Installation of brushless single-bearing generators with tensionbolt (2)48 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6 Installation of two-bearing generators (BG 132)For installing two-bearing generators of the size BG 132 proceed according tothe descriptions in this section 4.6. Prior to installation, read and understandthe safety precautions in section 4.1 as well as the sections 4.2 to 4.4 andobserve the instructions and information given there.CAUTIONOn both sides of the generator, a lifting eye bolt is provided forattaching lifting equipment. Lifting equipment may only beattached to the generator using these lifting eye bolts. Onlyappropriate lifting equipment may be used.4.6.1 Dimensions and mounting (two-bearing type, BG 132)The minimum clearances and regulations for cooling given in the followingsection 4.6.2 have to be met for installation.The dimensions of the generator can be found in the drawing sheet included inthe annex.The generator has to be fastened using fourscrews (min. requirements: M8 orcomparable, quality 8.8). The fastening mustbe durable as well as shock and vibrationresistant. The screws must be securedagainst self-acting unscrewing by suitablemeasures, e.g. a clamp collar according to4 fastening screwsDIN 128.Tightening torque for fastening screws:M = 25 NmIssue date: August 2002 49

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)Permissible load on the shaft:• Standard end shield (shaft ø 28 mm):Fr max = 2000 N (measured at an axialdistance of 50 mm from the shaft outletin the end shield)Fa max = 200 NFa maxFr max• Reinforced end shield (shaft ø 32 mm):Fr max = 3800 N (measured at an axialdistance of 50 mm from the shaft outletin the end shield)Fa max = 380 NNo other parts may be mounted to the mountingprofiles of the generator housing.CAUTION4.6.2 Minimum clearances and regulations for cooling (twobearingtypes, BG 132)In order to provide sufficient cooling the generator needs adequate ventilation.The cooling air is sucked on the rear side by the fan impeller and then blown tothe front side through the cooling profiles along the housing. If necessary,adequate openings for cooling air inlet and outlet have to be provided.It is absolutely important to observe the following regulations for minimumclearances and cooling.50 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)Minimum clearances (BG 132, twobearingtypes)The following minimum clearances towardsparts or walls have to be observed forinstallation (see also the accompanyingfigures on the right):• Both sides and top: a = 100 mm• Front side: b = 200 mm• Rear side: c = 170 mmCooling (BG 132, two-bearing types)It is absolutely important to observe thefollowing regulations for cooling. Dangerof overheating!The temperature of the supplied cooling airmust not exceed 40 °C.In the cooling air intake area on the rearside of the generator a maximum partialvacuum of P max = 4 Pa may arise.Otherwise the fan impeller cannot suckenough cooling air.In the cooling air blow out area on thefront side of the generator a maximumoverpressure of P max = 7 Pa may arise.Otherwise the circulation of the cooling airis not sufficient.Cooling air circulation must not beimpaired by other air flows (e.g.directed from the side or from the frontto the generator).aabbP max = 7 PacaP max = 4 PaIssue date: August 2002 51

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6.3 Installation instructions for belt drive (two-bearingtypes, BG 132)Belt pulleys and belts must be covered by aprotective cover. Never operate the generatorwithout the protective covers correctlymounted. Risk of personal injury!DANGERNever touch a running belt. Risk of personalinjury!Do not knock the belt pulley onto the shaft.Taper bushes must be preferred for fastening.CAUTIONTo prevent the belt pulley against twisting,it is protected on the shaft by a featheredkey. The belt pulley is fastened by a screw tothe front end of the shaft. This screw has tobe protected against accidental looseningusing a suitable lock washer.• Threaded hole in the shaft:M10 x 22 mm• Tightening torque: M = 50 NmThe axis of the driving shaft must beabsolutely parallel to the shaft of thegenerator.The belt pulleys on both shafts must beflush to each other so that the belt runsabsolutely straight.52 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)The belt must not sag loosely.When using slim SPA-type V-belts, thedistance between the shafts must notexceed 600 mm. Permissible shaft distancesfor other belts can be obtained from themanufacturer.Maximum tractive force (tension) of thedrive belt on the shaft:• F max = 2000 N for standard end shield(shaft ø28mm)• F max = 3800 N for reinforced end shield(shaftø32mm)The specified maximum tractive force isapplicable at an axial distance of max. 50mm from the shaft outlet in the end shield.If the belt is to be mounted with a greaterdistance to the end shield, the belt tensionmust be reduced in order to compensate thehigher leverage to the shaft.Type and number of used beltsThe type and number of used belts have tobe adapted to the power of the generator.The maximum belt tension force has to beobserved!F maxl maxIssue date: August 2002 53

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6.4 Installation instructions for flange mounting (two-bearingtypes, BG 132)4.6.4.1 Flange mounting for BG 132 with standard end shieldRemoval prior to installation1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 16/2) anddetach the sleeve (1).2. Unscrew the four screws M12 x 12 (3) and detach them together with thewashers.1234xFigure 16Removal prior to installation for flange mounting (two-bearingtypes, BG 132 with standard end shield)54 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)Installation1. Set the flange (Figure 17/1) onto the generator and fasten it using the fourscrews (4a) with nuts (3a). Underlay the screw head with a blocking disk(4b) and apply threadlocking adhesive to the thread of the screw. Underlaythe nuts with toothed disks (3b).2. Remount the sleeve (Figure 17/2) and fasten it by tightening the two screws.3. Plug the clutch-plate (5) onto the generator shaft and protect it againsttwisting on the shaft by means of a feathered key.4. Fasten the driving side of the clutch (6) to the engine and insert it into theclutch-plate. When inserting, twist the clutch a little bit until the gearinglocks, if necessary.5. Fasten the flange (1) to the engine.14x654a4b23b3a4xFigure 17 Installation for flange mounting (two-bearing types, BG 132with standard end shield)Issue date: August 2002 55

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6.4.2 Flange mounting for BG 132 with reinforced end shieldRemoval prior to installationUnscrew the four headless setscrews M12 x 25 (Figure 18/1).1Figure 18Removal prior to installation for flange mounting (two-bearingtypes, BG 132 with reinforced end shield)56 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)Installation1. Set the flange (Figure 19/1) onto the generator and fasten it using the fourscrews (2a). Underlay the screw head with a toothed disk (2b) and applythreadlocking adhesive to the thread of the screw.2. Plug the clutch-plate (3) onto the generator shaft and protect it againsttwisting on the shaft by means of a feathered key.3. Fasten the driving side of the clutch (4) to the engine and insert it into theclutch-plate. When inserting, twist the clutch a little bit until the gearinglocks, if necessary.4. Fasten the flange (1) to the engine.14x432a2bFigure 19 Installation for flange mounting (two-bearing types, BG 132with reinforced end shield)Issue date: August 2002 57

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6.5 Installation instructions for hydraulic drive (two-bearingtypes, BG 132)4.6.5.1 Hydraulic drive for BG 132 with standard end shieldRemoval prior to installationAt the generator perform the removal prior to installation as described on page54 (see Figure 16).Installation1. Set the flange (Figure 20/2) onto the generator and fasten it using the fourscrews (4a) with nuts (3a). Underlay the screws with a blocking disk (4b) andapply threadlocking adhesive to the thread of the screws. Underlay the nutswith a toothed disk (3b).2. Remount the sleeve (1) and fasten it by tightening the two screws.3. Plug the first part of the clutch (5) onto the generator shaft and protect itagainst twisting on the shaft by means of a feathered key.4. Mount the disc (6) to the hydraulic motor (8).5. Set the second part of the clutch (5) onto the hydraulic motor.6. Set the hydraulic motor (8) together with the disc (6) and the second part ofthe clutch onto the generator. When inserting, twist the clutch a little bituntil the gearing locks, if necessary.7. Underlay the eight screws (7a) with a blocking disc (7b) and use them tofasten the disc (6) to the flange (2).8. Place the sleeve (9) to the clutch assembly and fasten it by tightening thetwo screws.58 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)2x98x187a7b 2652x4x4a4b3b3a4xFigure 20Installation of the flange mounting for hydraulic drive (twobearingtypes, BG 132 with standard end shield)Issue date: August 2002 59

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)4.6.5.2 Hydraulic drive for BG 132 with reinforced end shieldRemoval prior to installationAt the generator perform the removal prior to installation as described on page56 (see Figure 18).Installation1. Set the flange (Figure 21/1) onto the generator and fasten it using the fourscrews (2a). Underlay the screws with a blocking disk (2b) and applythreadlocking adhesive to the thread of the screws.2. Plug the first part of the clutch (3) onto the generator shaft and protect itagainst twisting on the shaft by means of a feathered key.3. Mount the disc (4) to the hydraulic motor (6).4. Set the second part of the clutch (3) onto the hydraulic motor.5. Set the hydraulic motor (6) together with the disc (4) and the second part ofthe clutch onto the generator. When inserting, twist the clutch a little bituntil the gearing locks, if necessary.6. Underlay the eight screws (5a) with a blocking disc (5b) and use them tofasten the disc (4) to the flange (1).7. Place the sleeve (7) to the clutch assembly and fasten it by tightening thetwo screws.60 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.6 Installation of two-bearing generators (BG 132)2x768x5a5b432a2b4x1Figure 21Installation of the flange mounting for hydraulic drive (twobearingtypes, BG 132 with reinforced end shield)Issue date: August 2002 61

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)4.7 Installation of two-bearing generators (BG 160)For installing generators of the size BG 160 proceed according to thedescriptions in this section 4.7. Prior to installation, read and understand thesafety precautions in section 4.1 as well as the sections 4.2 to 4.4 and observethe instructions and information given there.CAUTIONOn both sides of the generator, a lifting eye bolt is provided forattaching lifting equipment. Lifting equipment may only beattached to the generator using these lifting eye bolts. Onlyappropriate lifting equipment may be used.4.7.1 Dimensions and mounting (BG 160)The minimum clearances and regulations for cooling given in section 4.7.2 mustbe met for installation. The dimensions of the generator can be found in thedrawing sheet included in the annex.The generator has to be fastened usingfour screws (min. requirements: M12 orcomparable, quality 8.8). The fasteningmust be durable as well as shock andvibration resistant. The screws must besecured against self-acting unscrewing bysuitable measures, e.g. a clamp collaraccording to DIN 128.4 fastening screws• Tightening torque for fastening screws:M = 87 NmFr max• Permissible load on the shaft:Fa maxFr max = 5000 N (measured at an axialdistance of 60 mm from the shaftoutlet in the end shield)Fa max = 500 NNo other parts may be mounted to the mountingprofiles of the generator housing.CAUTION62 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)4.7.2 Minimum clearances and regulations for cooling (BG 160)In order to provide sufficient cooling the generator needs adequate ventilation.The cooling air is sucked on the rear side by the fan impeller and then blown tothe front side through the cooling profiles along the housing. If necessary,adequate openings for cooling air inlet and outlet have to be provided.It is absolutely important to observe the following regulations for minimumclearances and cooling.Minimum clearances (BG 160)The following minimum clearances towardsparts or walls have to be observed forainstallation (see also the accompanyingaafigures on the right):b• Both sides and top: a = 100 mm• Front side: b = 300 mm• Rear side: c = 200 mmCooling (BG 160)It is absolutely important to observe thebfollowing regulations for cooling. Dangerof overheating!P max = 4 PaThe temperature of the supplied cooling airmust not exceed 40 °C.In the cooling air intake area on the rearP max = 7 Paside of the generator a maximum partialvacuum of P max = 4 Pa may arise.cOtherwise the fan impeller cannot suckenough cooling air.In the cooling air blow out area on thefront side of the generator a maximumoverpressure of P max = 7 Pa may arise.Otherwise the circulation of the cooling airis not sufficient.Cooling air circulation must not beimpaired by other air flows (e.g.directed from the side or from the frontto the generator).Issue date: August 2002 63

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)4.7.3 Installation instructions for belt drive (BG 160)Belt pulleys and belts must be covered by aprotective cover. Never operate the generatorwithout the protective covers correctlymounted. Risk of personal injury!DANGERNever touch a running belt. Risk of personalinjury!Do not knock the belt pulley onto the shaft.Taper bushes must be preferred for fastening.CAUTIONTo prevent the belt pulley against twisting,it is protected on the shaft by a featheredkey. The belt pulley is fastened by a screw tothe front end of the shaft. This screw has tobe protected against accidental looseningusing a suitable lock washer.• Threaded hole in the shaft:M16 x 36 mm• Tightening torque: M = 200 NmThe axis of the driving shaft must beabsolutely parallel to the shaft of thegenerator.The belt pulleys on both shafts must beflush to each other so that the belt runsabsolutely straight.64 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)The belt must not sag loosely.When using slim SPA-type V-belts, thedistance between the shafts must notexceed 800 mm. Permissible shaft distancesfor other belts can be obtained from themanufacturer.Maximum tractive force (tension) of thedrive belt on the shaft:F max. = 5000 N at an axial distance of max.60 mm from the shaft outlet in the endshield. If the belt is to be mounted with agreater distance to the end shield, the belttension must be reduced in order tocompensate the higher leverage to theshaft.F maxl maxType and number of used beltsThe type and number of used belts have tobe adapted to the power of the generator.The maximum belt tension force has to beobserved!Issue date: August 2002 65

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)4.7.4 Installation instructions for flange mounting (BG 160)Removal prior to installationUnscrew the four headless setscrews M12 x 25 (Figure 22/1).1Figure 22 Removal prior to installation for flange mounting (BG 160)66 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)Installation1. Set the flange (Figure 23/1) onto the generator and fasten it using the fourscrews (2a). Underlay the screw head with a toothed disk (2b) and applythreadlocking adhesive to the thread of the screw.2. Plug the clutch-plate (3) onto the generator shaft and protect it againsttwisting on the shaft by means of a feathered key.3. Fasten the driving side of the clutch (4) to the engine and insert it into theclutch-plate. When inserting, twist the clutch a little bit until the gearinglocks, if necessary.4. Fasten the flange (1) to the engine.14x432a2bFigure 23 Installation of the flange mounting (BG 160)Issue date: August 2002 67

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)4.7.5 Installation instructions for hydraulic drive (BG 160)Removal prior to installationAt the generator perform the removal prior to installation as described on page66 (see Figure 22).Installation1. Set the flange (Figure 24/1) onto the generator and fasten it using the fourscrews (2a). Underlay the screws with a blocking disk (2b) and applythreadlocking adhesive to the thread of the screws.2. Plug the first part of the clutch (3) onto the generator shaft and protect itagainst twisting on the shaft by means of a feathered key.3. Mount the disc (4) to the hydraulic motor (6).4. Set the second part of the clutch (3) onto the hydraulic motor.5. Set the hydraulic motor (6) together with the disc (4) and the second part ofthe clutch onto the generator. When inserting, twist the clutch a little bituntil the gearing locks, if necessary.6. Underlay the eight screws (5a) with a blocking disc (5b) and use them tofasten the disc (4) to the flange (1).7. Place the sleeve (7) to the clutch assembly and fasten it by tightening thetwo screws.68 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.7 Installation of two-bearing generators (BG 160)2x768x5a5b434x2a2b1Figure 24 Installation of the flange mounting for hydraulic drive (BG 160)Issue date: August 2002 69

Synchronous Generators BG 132 / BG 160Chapter 4: 4.8 Electrical connection of the generators4.8 Electrical connection of the generatorsPrior to installation, read and understand the safety precautions in section 4.1as well as the connection notes in this section 4.8 and observe the instructionsand information given there.This section is only applicable for generators which are not equipped with acontrol box ex works.Work on electrical installations and equipment may only beperformed by adequately trained qualified personnel and inconformity with the applicable national rules and regulations(in Germany: VDE regulations, among others).DANGERWork on electrical installations and equipment may only beperformed in the off and de-energized state. Mortal danger byelectric shock!Engines that have been turned off must be secured againstaccidental restarting (e.g. by removing the ignition key andkeeping it safe)!Grounding the neutral conductor of the generator (N, midpointconductor) supersedes the protective measure "protectionseparation" and should therefore be avoided. If the neutralconductor N shall be grounded anyway, this may only beperformed by an electrically qualified person. In this case, acurrent-operated earth-leakage circuit breaker has to beconnected on the load side of the generator output. Theefficiency of the electrical protective measure has to beconfirmed by an appropriate measurement.4.8.1 GeneralIf the generator is not equipped with a control box ex works, adequate fuseequipment has to be installed in an external control cabinet to protect theconnected circuits (sockets):• Short-circuit tripping: characteristic "B"• Protection against overcurrent: according to nominal current• The neutral conductor has also to be fused.70 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 4: 4.8 Electrical connection of the generators4.8.2 Version with terminal boxObserve the following connection notes when connecting generators equippedwith a terminal box:• When opening the terminal box, be careful not to tear-off or damage theconnecting wires of the generator governor installed in the cover.• After opening the terminal box, remove the plug-and-socket connector to thegenerator governor installed in the terminal box cover. The plug-and-socketconnector is mechanically coded and thus can not be plugged-in twisted.Plug-in the connector only immediately before closing the cover.• For leading cables into the terminal box only use appropriate waterproofIP54 cable glands.• Lay the connecting wires inside the terminal box with utmost care.• When closing the cover, be careful not to catch or squeeze any connectingwires.Figure 25Pin assignment of the connection terminal plate in the terminalboxIssue date: August 2002 71

Synchronous Generators BG 132 / BG 160Chapter 4: 4.8 Electrical connection of the generators4.8.3 Version without terminal box, cables are lead out in a hoseOptionally the generator can also be delivered without a terminal box equipped.In this case, the connecting cables are lead out of the generator in a hose.This is a customized version. For this reason, the connection of the cables has tobe discussed with the generator manufacturer.72 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5 OperationThis chapter provides information about operating the generator. The operationcan differ depending on the generator version and equipment. Where applicable,such differences are mentioned in the concerning texts.Prior to operating the generator, read and understand the safety precautionslisted in section 5.1 as well as the sections 5.2 through 5.6 below and observethe instructions and information given there.5.1 Safety information for operationThis section summarizes all relevant safety precautions for operating thegenerator.DANGERDo not operate the generator in explosive environments.Further regulations on this have to be observed!Never connect the generator to the public electricity supplynetwork or to any other systems for power generation. Risk ofdeath, fire and destruction hazard!Never connect several generators to each other. Risk of death,fire and destruction hazard!The generator supplies highly dangerous voltages duringoperation! Never touch the generator or the devices connectedto the generator with wet hands during operation. Mortaldanger by electric shock!Generator components may be very hot, not just during but alsoafter operation. Burning hazard!The generator may only be operated with the protective coversfor the drive mounted as specified. Risk of personal injury!Grounding the neutral conductor of the generator (N, midpointconductor) supersedes the protective measure "protectionseparation" and should therefore be avoided. If the neutralconductor N shall be grounded anyway, this may only beperformed by an electrically qualified person. In this case, acurrent-operated earth-leakage circuit breaker has to beconnected on the load side of the generator output. Theefficiency of the electrical protective measure has to beconfirmed by an appropriate measurement.Issue date: August 2002 73

Synchronous Generators BG 132 / BG 160Chapter 5, OperationIf the generator shall be connected to an existing powerdistribution network (e.g. a house wiring), it has to beensured, that the system is completely and reliablydisconnected from the public electricity supply network of theDANGERenergy supply company. Reverse feeding into the publicelectricity supply network or network interconnection is notallowed. Reverse feeding involves mortal danger by electricshock for persons possibly working at the de-energized publicelectricity supply network. Due to network interconnectionwith the public electricity supply network, the generator can bedamaged, burn or cause fire in electrical cables of the system.Be sure to completely read and understand these operatinginstructions before using the generator. The generator may onlybe used for applications described in section "Proper use" andin conformity with the specifications given in this manual.Before connecting devices to the generator, ensure that thedevices are switched off. Accident hazard! Unsupervisedstarting devices can endanger or injure persons as well as causedamages or damage themselves.Infants and animals must have no admittance to the generator,not just during but also after operation. Make appropriateprecautions. Mortal danger by electric shock, injury andburning hazard!The generator or its components must never beexposed to the jet of high-pressure cleaners.Mortal danger by electric shock anddestruction hazard!CAUTIONBe sure to observe the operating conditions given in section 5.2.The generator may only be operated in conformity with theoperating conditions and data specified there. This especiallyapplies to the ambient and cooling conditions and the permissiblecurrent load.74 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5.2 Permissible operating conditionsThe generator may only be used, if the operation conditions listed below arekept.Only those devices may be connected, the voltage and frequency specificationsof which meet the specifications given on the type plate of the generator. Thegenerator may not be overloaded. The total power consumption of all connecteddevices must not exceed the output power specified for the generator.The generator must have a free cooling air supply as well as an unimpededcooling air dissipation. The cooling air temperature must not exceed 40 °C. Ifthe cooling conditions can not be met, the generator must not be loaded withits full rated output power.In case of inadequate cooling of the generator or under conditions other thanpermissible operation conditions, the generator output voltage is automaticallyreduced. In this case, the load connected to the generator has to be reduced toavoid damage of the connected devices.5.3 Electric protection equipment, protective measures andgrounding5.3.1 Electric protection and grounding/equipotential bondingIf the generator is not equipped with the option "Insulation monitoring withswitching-off", it fulfills the protective measure "Protection separation withequipotential bonding" according to VDE 0100, part 728.If the generator is equipped with the option "Insulation monitoring withswitching-off", it fulfills the better protective measure "Protection separationwith insulation monitoring" according to VDE 0100, part 728.For a proper function of the mentioned electrical protective measures, it is notrequired to ground the generator (e.g. using a grounding rod). If this is desiredanyway or required for some special cases, a defined grounding of the generatorhousing can be performed or the generator housing can be included into anequipotential bonding with other devices. For this purpose, only theIssue date: August 2002 75

Synchronous Generators BG 132 / BG 160Chapter 5, Operationcorresponding earth connection points marked with the earth symbolbe used.mayDANGERGrounding the neutral conductor of the generator (N, midpointconductor) supersedes the protective measure "protectionseparation" and should therefore be avoided. If the neutralconductor N shall be grounded anyway, this may only beperformed by an electrically qualified person. In this case, acurrent-operated earth-leakage circuit breaker has to beconnected on the load side of the generator output. Theefficiency of the electrical protective measure has to beconfirmed by an appropriate measurement.5.3.2 Protection against overcurrentIf the generator is equipped with a control box ex works, the sockets of thecontrol box mounted on the generator are protected against overcurrent andshort-circuit conditions using automatic circuit breakers. See Figure 26.Circuit breaker block(protection: 3P + N)Figure 26Circuit breaker in control box (only applicable for 8 kVA and13 kVA generators)76 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, OperationIf the generator is not equipped with a control box ex works, adequate fuseequipment has to be installed in an external control cabinet to protect theconnected circuits (sockets):• Short-circuit tripping: characteristic "B"• Protection against overcurrent: according to nominal current• The neutral conductor has also to be fused.5.4 Connection to an existing power distribution network (e.g.house wiring)The connection of generators to an existing power distribution network (e.g.house wiring) may only be performed by a qualified electrically skilled personand only after permission of the energy supply company. Observe all relevantDIN and VDE regulations, especially DIN VDE 0100, part 728.6, as well aspossibly existing additional technical connection regulations of the energysupply company.For this purpose, considerable changes at the generator can be necessary whichmay only be performed by a qualified electrically skilled person and afterconsultation of the generator system manufacturer.If the generator shall be connected to an existing powerdistribution network (e.g. a house wiring), it has to beensured, that the system is completely and reliablydisconnected from the public electricity supply network of theDANGERenergy supply company. Reverse feeding into the publicelectricity supply network or network interconnection is notallowed. Reverse feeding involves mortal danger by electricshock for persons possibly working at the de-energized publicelectricity supply network. Due to network interconnectionwith the public electricity supply network, the generator can bedamaged, burn or cause fire in electrical cables of the system.Issue date: August 2002 77

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5.5 Operating information for safe working with electric devicesObserve the following operating information for a safeoperation and handling of electric devices.Please also observe the safety precautions for operation givenDANGER in section 5.1 on page 73.• Devices that caused the insulation monitoring unit to switch-off and toindicate a "FAULTY INSULATION" must also not be operated at othergenerators without insulation monitoring or in the public electricity supplynetwork. Devices with defective insulation have to be immediately taken outof operation and replaced or repaired by the device manufacturer or anauthorized electric company.• Only connect devices that are in a faultless and safe condition. The devicesand connectors have to be clean and dry.• Before connecting devices to the generator, ensure that the devices areswitched off. Accident hazard! Unsupervised starting devices can endanger orinjure persons as well as cause damages or damage themselves.• Depending on the field of operating and application, regulations,prescriptions, requirements or recommendations of the professionalassociations and trade associations have to be observed when working withgenerators. Additionally, the Gerätesicherheitsgesetz (GSG, GermanEquipmant Safety Law), the relevant regulations for preventing accidents aswell as the mine regulations of the countries have also to be considered.When using generators outside the scope of requirements of the FederalRepublic of Germany, the suitability of the generator has to be proofed underconsideration of the individual national requirements. If you have anyquestions, please contact the system manufacturer.• The generator may only be operated under the permissible operatingconditions given in section 5.2 on page 75.• Many portable electric tools comply with protection class II (protectiveinsulation, identification ). It is recommended to use such devices as faras possible. If devices of protection class I are used (i.e. with metal housingparts which are not insulation protected), these must be equipped with aconnection cable and a connector with PE conductor.• When working in "conductive areas with limited freedom of movement", i.e.in areas within the scope of DIN VDE 0100 part 706 (e.g. in metal tanks),only one single device may be connected to the generator if it is a "hand-78 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, Operationheld electric tool or a mobile measuring instrument". Otherwise for eachdevice a separate isolating transformer or an isolating transformer withseveral separate secondary windings must be used. Hand-held luminaires inconductive areas with limited freedom of movement may only be operated viaan isolated transformer with protection low voltage (SELV).• Cables for distribution (e.g. extension cords and cord sets) must beextensively selected, laid and maintained. Electric cables have to be checkedin regular intervals. Defective cables and cords have to be exchanged. Whenconnecting extension cords, observe the following section 5.6.2 on page 81.Issue date: August 2002 79

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5.6 Operation of the generatorCAUTIONOnly take the generator into operation after you have completelyread and understood all sections of this chapter 5, particularly thesafety precautions given in section 5.1 on page 73.If your generator is equipped with the option "Insulationmonitoring with switching-off", the correct function of theinsulation monitoring unit has to be checked every working day.The generator may only be taken into operation, if the correctfunction of the insulation monitoring unit has been confirmed.5.6.1 Control elements in the control box (if available)Figure 27 shows all possible control elements and indicators in the control boxoptionally mounted on the generator (insulation monitoring unit and hour meterare also optional).Insulation monitoring unitwith switch and signal lamp(optional)Circuit breaker block(protection: 3P + N)Hour meter(optional)Socket 400 V3 sockets 230 VFigure 27Control elements and indicators in the control box (optional)80 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5.6.2 Current distribution and connection of devicesDANGERCAUTIONNOTEThe generator must not be used for the supply of assembliesfor construction sites.Generators which are equipped with an insulation monitoringunit must not be connected to further insulation monitoringunits since the insulation monitoring units can mutuallyinteract.The generator may not be overloaded. The total power consumptionof all connected devices must not exceed the output powerspecified for the generator.Only those devices may be connected the voltage and frequencyspecifications of which meet the specifications listed on the typeplate of the generator.If your generator is equipped with a control box:• Do not use the circuit breakers in the control box for switchingthe connected devices on and off. When using several devicesconnected to the single-phase AC voltage sockets at the sametime (especially when using devices with different powerconsumptions), short-term over- or undervoltages may arise dueto a turn-on delay of the neutral conductor.• The cover of the control box and the hinged lids of unusedsockets have always to be kept correctly closed in order toguarantee IP54 protection (tighten the locking screws byhand).Current-operated earth-leakage circuit breakers are not functionalin ungrounded networks (IT systems, as supplied by the generator),because there is no grounding. However, since the generatorsupplies the protective measure "protection separation", additionalprotection by means of current-operated earth-leakage circuitbreakers is not necessary.Issue date: August 2002 81

Synchronous Generators BG 132 / BG 160Chapter 5, OperationProceed as follows to take the generator into operation and to connect theloads:1. If necessary, perform the daily check of the insulation monitoring unit. Seesection 5.6.3 on page 84.2. Make sure that no devices are connected to the generator.3. Switch off all devices which are to be connected later (switch in position"OFF" or "0"). Accident hazard by unsupervised starting devices!4. Start the engine. Wait until the engine has reached its rated speed.5. If necessary, switch on the circuit breakers in the control box (if equipped,see Figure 27) or in the control cabinet (position "ON" or "I").6. Connect (or switch on) the devices one after the other. First switch on thepowerful devices with high current consumptions or high starting currentsand then the less powerful devices.NOTEThe total length of all connected extension cables may notexceed the following values:• 250 m max. at a conductor cross section of 2.5 mm 2• 100 m max. at a conductor cross section of 1.5 mm 2Devices driven by electric motors possibly require startingcurrents that are many times higher than the specifiedoperating currents. In case of doubt, please contact themanufacturer.To ensure a safe operation of three-phase generators, the loadcurrents should be distributed to all three phases as equal aspossible.Take care that the maximum currents specified for each socketare not exceeded.82 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 5, Operation7. When switching off the connected devices, switch off the devices one afterthe other and unplug their mains plugs. If possible, first switch off the lesspowerful devices and finally the powerful devices with high currentconsumptions.NOTEEnsure that the hinged lids of the sockets are correctly closedagain after unplugging the mains plugs.Issue date: August 2002 83

Synchronous Generators BG 132 / BG 160Chapter 5, Operation5.6.3 Checking the insulation monitoring unit (if available)CAUTIONIf your generator is equipped with the option "Insulationmonitoring with switching-off", the correct function of theinsulation monitoring unit has to be checked every working day.The generator may only be taken into operation, if the correctfunction of the insulation monitoring unit has been confirmed.Proceed as follows to check the insulation monitoring unit (refer to Figure 27 forthe location of the control elements and indicators):1. Unplug all devices and cables connected to the generator.2. Start the engine. The check must be performed while the generator isrunning.3. Open the cover of the control box and switch on the insulation monitoringunit (position "ON" or "I").4. Push the red test push-button which is at the same time used as an indicator.Now the insulation monitoring unit must trip.5. Check whether the insulation monitoring unit has tripped and the redindicator "FAULTY INSULATION" is on.NOTEIf the insulation monitoring unit does not trip or if the "FAULTYINSULATION" indicator does not light, the generator must notbe used any longer. In this case, mark the generator asdefective and have it repaired (refer to section 7 on page 92).6. Stop the engine to reset the insulation monitoring unit.7. Switch on the insulation monitoring unit again (position "ON" or "I") andcorrectly close the cover of the control box (tighten the locking screws byhand).8. If the check was successful the generator is now ready for operation.84 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance6 MaintenanceAll components of the generator are maintenance-free in principle (exception:changing the carbon brushes holder for brush-type generators, see section 6.4.1on page 89). Nevertheless, the maintenance operations listed in section 6.1have to be performed regularly and on time to ensure reliable operation of thegenerator.CAUTIONIn addition to the work described in this chapter, the drivingsystem/engine possibly has to be checked according to theguidelines and regulations of the driving system/enginemanufacturer. This also includes the correct attachment ofprotective covers. Be sure to observe the maintenance instructionsof the driving system/engine manufacturer.Do not open or disassemble the housing of thegenerator or the control box! The generator mayonly be opened by the manufacturer or an agencyauthorized by the manufacturer. It does notcontain any components which can be replaced orrepaired by the user. It is not allowed to performany work or operations not described in thismanual.Any damages and defects found on the generator have to be repairedimmediately by authorized and qualified personnel independent of themaintenance intervals. The generator must not be taken into operation until anydefects have been removed. Any repair work must only be carried out byadequately trained qualified personnel.Issue date: August 2002 85

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance6.1 Maintenance overviewInterval Maintenance operation To be performed byEveryworking dayMonthlyEvery 1.000hours ofoperationEvery 5.000hours ofoperationEvery 20.000hours ofoperationCheck the correct function of the insulationmonitoring unit (if available).See section 5.6.3 on page 84.At the generator:• Visual inspection for contamination ordamages. Cleaning if necessary.• If necessary, clean the plates and labelsor replace them.• Check the cooling air openings forcontamination or blocking and cleanthem, if necessary.See section 6.3 on page 88.At the control box (if mounted):• Visual inspection for contamination ordamages. Cleaning if necessary.• Check the cover and the socket lids forwaterproof locking.See section 6.3 on page 88.Only for brush-type generators:Check the carbon brushesSee section 6.4.1 on page 89.Check the ball bearings by "listening".Replace, if necessary (rough noises at thebearings).UserUserUserQualifiedelectrically skilledpersonQualifiedskilled personReplace the ball bearingsManufacturerThe standard maintenance interval forreplacing the ball bearings is 20.000 hours.If necessary (see check every 5.000 hours),the ball bearings have to be replaced earlier.See section 6.4.2 on page 91.86 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance6.2 Safety precautionsThis section summarizes the safety precautions relevant for maintenanceoperations.Work on electrical installations and equipment may only beperformed by adequately trained qualified personnel and inconformity with the applicable national rules and regulations(in Germany: e.g. VDE regulations).DANGERWork on electrical installations and equipment may only beperformed in the off and de-energized state. Mortal danger byelectric shock!Engines that have been turned off must be secured againstaccidental restarting (e.g. by removing the ignition key andkeeping it safe)!Any maintenance, service and replacement operations on thegenerator may only be performed by authorized and qualifiedpersonnel.Generator components may be very hot, not just during but alsoafter operation. Burning hazard!Do not perform any visual inspections for maintenancepurposes and cleaning work on the generator during operation.Always turn off the engine first and make sure that it cannot berestarted accidentally (e.g. by removing the ignition key andkeeping it safe). Mortal danger by electric shock!The generator or its components must never beexposed to the jet of high-pressure cleaners.Mortal danger by electric shock anddestruction hazard!For repair and replacement operations, only genuine components orexternal components expressly approved by the manufacturer maybe used.CAUTIONIssue date: August 2002 87

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance6.3 Visual inspections and cleaning to be performed by the userIn addition to the safety precautions provided below, read and observe thesafety precautions listed in section 6.2 above.Do not perform any visual inspections for maintenancepurposes and cleaning work on the generator during operation.Always turn off the engine first and make sure that it cannot berestarted accidentally (e.g. by removing the ignition key andDANGERkeeping it safe). Mortal danger by electric shock!Generator components may be very hot, not just during but alsoafter operation. Burning hazard!The following operations have to be performed by the user in monthly intervals.1. Check the generator housing for damages visible on the outside as well as forexcessive contamination which could impair cooling. If necessary, use a wetcloth to clean the generator.2. If the generator is equipped with a control box, check the housing of thecontrol box and the installed sockets for damages and contamination visibleon the outside. If necessary, use a wet cloth to clean the control box. Checkthe transparent cover of the control box and the hinged lids of the socketsfor damages and waterproof locking.3. Check whether the safety and warning label and the type plate attached tothe generator are readable. If necessary, clean the plates and labels orreplace them.4. Check the cooling air openings on the rear side of the generator forcontamination which could obstruct the cooling air flow and use a wet clothto clean the openings, if necessary.88 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance6.4 Maintenance to be performed by authorized qualifiedpersonnelAny maintenance, service and replacement operations on thegenerator may only be performed by authorized and qualifiedpersonnel.DANGERIn addition to the safety precautions listed below, read and observe the safetyprecautions given in section 6.2.6.4.1 Checking and/or replacing the carbon brushes (only brushtypegenerators)The carbon brushes of brush-type generators have to be removed and checkedevery 1.000 hours of operation by qualified personnel as described below. If thecarbon brushes are used up more than half, the complete carbon holder must bereplaced. It is not possible to replace only one single carbon brush.Removing the carbon brushes holder1. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 28/2) anddetach the sleeve (1).2. Remove both connection cables from the connection lugs of the carbonbrushes holder (Figure 28/3). The connection cables are coded by the widthof the connection lugs and therefore protected against interchanging (seeFigure 29).3. Unscrew the fastening screw of the carbon brushes holder and detach thecarbon brushes holder (Figure 28/3).123Figure 28Removing the carbon brushes holderIssue date: August 2002 89

Synchronous Generators BG 132 / BG 160Chapter 6, MaintenanceChecking the carbon brushesThe carbon brushes holder has to be replaced, if the carbon brushes are used upmore than half, i.e. if they jut out of the carbon brushes holder less than 6 mm(see Figure 29).redgray6 mm min.Figure 29Checking/Replacing the carbon brushesInstalling the carbon brushes holder1. Insert the carbon brushes holder (Figure 30/3) correctly positioned into thegenerator and press it onto the collector rings on the shaft, so that thecarbon brushes are pressed into the carbon brushes holder and the carbonbrushes holder lies on its mounting base.2. Continue to press on the carbon brushes holder and screw in the fasteningscrew, but do not tighten it completely. While screwing in the fasteningscrew, the carbon brushes holder is automatically positioned on themounting base.3. Check the proper seating of the carbon brushes holder and then tighten thefastening screw.4. Plug both connection cables onto the connection lugs of the carbon brushesholder according to the width of the connectors (see Figure 30).5. Remount the sleeve (Figure 30/1) and fasten it by tightening the two screws(2).90 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 6, Maintenance12red gray3Figure 30Installing the carbon brushes holder6.4.2 Replacing the ball bearingsThe ball bearings of the generator have to be replaced at least every 20.000hours of operation. However, if rough noises are detected at the ball bearingsduring the check prescribed every 5.000 hours of operation, the ball bearingshave to be replaced earlier.We strongly recommend for these operations to remove the generator and tosend it to the manufacturer or to an agency authorized by the manufacturer.Removing the generator is described in chapter 8 on page 93.Issue date: August 2002 91

Synchronous Generators BG 132 / BG 160Chapter 7, Reconditioning7 ReconditioningAside from the work described for maintenance in chapter 6, no otherreconditioning operations can be carried out for the generators outside themanufacturer plant.If repair work is necessary, we recommend to remove the generator and to sendit to the manufacturer or to an agency authorized by the manufacturer.Removing the generator is described in chapter 8 on page 93.92 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 8, Removal8 RemovalTo remove the generator, proceed according to the descriptions given in thischapter.8.1 Safety precautionsDANGERRemoving of the generator may only be performed byauthorized and qualified personnel.Generator components may be very hot, not just during but alsoafter operation. Burning hazard!For removing the generator make sure that the switched-offengine cannot be restarted accidentally (e.g. by removing theignition key and keeping it safe). Mortal danger by electricshock, risk of personal injury!8.2 Removal of two-bearing generators (BG132 and BG160)The removal of two-bearing generators has to be performed in accordance withthe descriptions in chapter 4.8.3 Removal of single-bearing generatorsNOTEFor the removal of single-bearing generators the following specialtools are required:• Special tool of the engine manufacturer to hold the engineshaft.• For shaft fastening by grub-screw:Special hexagon nut for turning the generator shaft using aspanner as well as special sawing ring pliers for removing andmounting the sawing ring which secures the fan impeller on theshaft.• For shaft fastening by tension bolt:Pushing rod and pushing screw.• Additionally for brush-type generators:Special wooden chock serving as transport locking for the rotor.Issue date: August 2002 93

Synchronous Generators BG 132 / BG 160Chapter 8, Removal8.3.1 Removal of single-bearing brush-type generatorsWork prior to removal and removal of the carbon brushes holder1. Disconnect the electric connection cables of the generator as described insection 4.8 on page 70.2. Unscrew the two screws M8 x 45, spanner size 10 mm, (Figure 31/2) anddetach the sleeve (1).3. Remove both connection cables from the connection lugs of the carbonbrushes holder (Figure 31/5). The connection cables are coded by the widthof the connection lugs and therefore secured against interchanging.4. Unscrew the fastening screw of the carbon brushes holder and detach thecarbon brushes holder (Figure 31/5).5. Refer to the following descriptions to continue the removal:- For shaft fastening by grub-screw continue on page 95.- For shaft fastening by tension bolt continue on page 97.1 2345Figure 31Work prior to removal of single-bearing brush-type generators94 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 8, RemovalRemoval for shaft fastening by grub-screw1. Remove the fan impeller shroud (Figure 31/4) and the fan impeller (Figure31/3) from the generator. The fan impeller is secured against twisting on theshaft by means of a feathered key and a sawing ring.2. Attach the special hexagon nut (Figure 32/2) onto the generator shaftinstead of the fan impeller and secure it against twisting by means of thefeathered key (1).3. Hold the engine shaft using the special tool of the engine manufacturer.4. Attach the spanner to the special hexagon nut and undo the grub-screwconnection between engine and generator shaft.5. Support the generator if necessary and unscrew the four end shield fasteningscrews (Figure 32/3) at the engine flange.6. Unscrew the generator shaft from the grub-screw screwed into the engineshaft and detach the generator.7. Unscrew the grub-screw (Figure 32/4) from the engine shaft using an Allenwrench.1423Figure 32 Removal of single-bearing brush-type generators (1)Issue date: August 2002 95

Synchronous Generators BG 132 / BG 160Chapter 8, Removal8. Detach the special hexagon nut (Figure 33/1) from the generator shaft.9. Remount the carbon brushes holder (Figure 33/4) according to thedescriptions on page 90 (section 6.4.1) into the generator and reconnect theconnection cables.10. Insert the special wooden chock serving as transport locking for the rotor.11. Remount the sleeve (Figure 33/6) and fasten it by tightening the twoscrews (5).12. Remount the fan impeller (Figure 33/2) and secure it on the generator shaftby means of the feathered key (against twisting) and the sawing ring.13. Remount the fan impeller shroud (Figure 33/4).651234Figure 33 Removal of single-bearing brush-type generators (2)96 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 8, RemovalRemoval for shaft fastening by tension bolt1. Detach the cap (Figure 34/2) at the fan impeller shroud.2. Hold the engine shaft using the special tool of the engine manufacturer.3. Undo the tension bolt (Figure 34/1) and pull it out of the generator shaft.4. Support the generator if necessary and unscrew the four end shield fasteningscrews (Figure 34/3) at the engine flange.5. Insert the pushing rod (Figure 34/4) into the generator shaft instead of thetension bolt and screw the pushing screw (5) into the generator shaft. Byscrewing in the pushing screw, the generator shaft is detached from theengine shaft.6. Detach the generator from the engine.7. Remove the pushing screw and the pushing rod from the generator shaft.Remount the cap onto the fan impeller shroud.8. Remount the carbon brushes holder (Figure 33/5) according to thedescriptions on page 90 (section 6.4.1) into the generator and reconnect theconnection cables.9. Insert the special wooden chock serving as transport locking for the rotor.10. Remount the sleeve (Figure 33/7) and fasten it by tightening the twoscrews (6).12453Figure 34Removal of single-bearing brush-type generators with tensionboltIssue date: August 2002 97

Synchronous Generators BG 132 / BG 160Chapter 8, Removal8.3.2 Removal of brushless single-bearing generatorsWork prior to removal1. Disconnect the electric connection cables of the generator as described insection 4.8 on page 70.2. Refer to the following descriptions to continue the removal:- For shaft fastening by grub-screw continue with the following section onthis side.- For shaft fastening by tension bolt continue on page 101.Removal for shaft fastening by grub-screw1. Remove the fan impeller shroud (Figure 35/3) and the fan impeller (Figure35/2) from the generator. The fan impeller is secured against twisting on theshaft by means of a feathered key and a sawing ring.2. Support the generator if necessary and unscrew the four end shield fasteningscrews (Figure 35/4) at the generator.3. Attach the special hexagon nut (Figure 36/2) onto the generator shaftinstead of the fan impeller and secure it against twisting by means of thefeathered key (Figure 36/1).4. Hold the engine shaft using the special tool of the engine manufacturer.5. Attach the spanner to the special hexagon nut and undo the grub-screwconnection between engine and generator shaft.6. Unscrew the generator shaft from the grub-screw screwed into the engineshaft and detach the generator.7. Remove the front end shield of the generator which is still mounted on theengine. For this purpose, unscrew the four screws (Figure 36/3) and detachthe end shield (Figure 36/4).8. Remount the front end shield (Figure 36/4) to the generator.98 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 8, Removal9. Unscrew the grub-screw (Figure 37/1) from the engine shaft using an Allenwrench.10. Detach the special hexagon nut (Figure 37/2).11. Remount the fan impeller (Figure 37/3) and the fan impeller shroud (Figure37/4). Secure the fan impeller on the generator shaft by means of thefeathered key (against twisting) and the sawing ring.1423Figure 35 Removal of brushless single-bearing generators (1)1423Figure 36 Removal of brushless single-bearing generators (2)Issue date: August 2002 99

Synchronous Generators BG 132 / BG 160Chapter 8, Removal1234Figure 37 Removal of brushless single-bearing generators (3)100 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 8, RemovalRemoval for shaft fastening by tension bolt1. Detach the cap (Figure 38/2) from the fan impeller shroud.2. Detach the front end shield from the generator. For this purpose, unscrew thefour fastening screws (Figure 38/5) of the front end shield at the generator.3. Hold the engine shaft using the special tool of the engine manufacturer.4. Undo the tension bolt (Figure 38/1) and pull it out of the generator shaft.5. Insert the pushing rod (Figure 38/3) into the generator shaft instead of thetension bolt and then screw the pushing screw (Figure 38/4) into thegenerator shaft. By screwing in the pushing screw, the generator shaft isdetached from the engine shaft.6. Detach the generator from the engine.7. Remove the pushing rod (Figure 38/3) and the pushing screw (Figure 38/4)from the generator shaft. Remount the cap (Figure 38/2) onto the fanimpeller shroud.8. Remove the front end shield (Figure 39/1) of the generator which is stillmounted to the engine. For this purpose, unscrew the four screws (Figure 39/2) and detach the end shield.9. Remount the front end shield to the generator.51234Figure 38Removal of brushless single-bearing generators with tension bolt(1)Issue date: August 2002 101

Synchronous Generators BG 132 / BG 160Chapter 8, Removal12Figure 39Removal of brushless single-bearing generators with tension bolt(2)102 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 9, Transport and storage9 Transport and storageThe generators are bolted onto a transport pallet and packed accordingly forprotection against damages and penetrating humidity when leaving the factory.Single-bearing generators achieve IP54 protection only when they are mountedto the engine.The generators have to be transported and stored dry and protectedagainst water. Transport and storage may only be performed indelivery state with the packaging and protective devices mounted.CAUTIONOn both sides of the generator, a lifting eye bolt is provided for attaching liftingequipment. Lifting equipment may only be attached to the generator using theselifting eye bolts. Only appropriate lifting equipment may be used.If no lifting eye bolts are provided at the generator ex works, these must bemounted later for lifting the generator.Generators BG 132 Generators BG 160Weight (mass) approx. 40 - 80 kg approx. 140 -180 kgPermissible temperatures:transportstoragePermissible rel. humidity:transportstorage-25 °C to +60 °C-20 °C to +50 °C95%, non-condensing95%, non-condensingIssue date: August 2002 103

Synchronous Generators BG 132 / BG 160Chapter 10, Putting out of operation, storage after dismantling, disposal10 Putting out of operation, storage after dismantling,disposalDismantling the generators and putting the generators out of operation have tobe performed according to the descriptions in chapter 8.Generators which are still functional have to be packed and stored as describedin chapter 9.Generators which are no longer functional have to be labeled accordingly anddisposed or supplied for recycling in accordance with the legal requirements. Formore detailed information refer to the relevant environmental protectionauthority or to the manufacturer.10.1 Waste disposal informationGenerator housingFan impeller shroudFan impellerRotor and shaftWindingsElectronic componentsAluminumIron/steelPolypropyleneIron/steelCopper, impregnated by modified Ester-Imide (THEIC)Electronics scrap104 Issue date: August 2002

Synchronous Generators BG 132 / BG 160Chapter 11, Spare parts11 Spare partsCompanies authorized for repair and replacement work are asked to contact themanufacturer for the service manual.Issue date: August 2002 105

Synchronous Generators BG 132 / BG 160Chapter 11, Spare parts106 Issue date: August 2002