Operating Manual -ENGLISH-

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KWG synchronous generators

Size 132,160, 200 and 250

Operating manual –English-

Status December 2012
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Manufacturer address
KW-Generator GmbH & Co.KG
Bänglesäcker 24
73527 Schwäbisch-Gmünd / Lindach
Phone: +49 (0) 7171 104 17 – 0
Fax: +49 (0) 7171 104 17 – 29
www.kw-generator.com
info@kw-generator.com

About this manual

This manual covers generators of series KWG-…. brushless synchronous generators of
sizes 132, 160, 200 and 250. For the technical and type specific data please refer to the
relevant type-related detailed data sheets. The notes on safety and risks as well as the
general data shall be applicable to all KWG generators and shall be complied with in
any case for reasons of liability.
No part of this operating manual shall be copied, published or disclosed – irrespective
of the type and means – unless the express consent of KW-Generator GmbH & Co. KG
has been obtained.
Modifications after printing have not been taken into account. Right to technical
modifications reserved. Status of manual: V21. (page 8- Table of resistors). Oct.2014.

Norms and regulations

The KWG generator systems are in compliance with the regulations according to DIN
EN 60034 / VDE0530 and are in conformity with RoHS.

Application and use of the generators

The generators are components of machines and system intended for industrial and
professional use and thus cannot be treated as retail goods.
The generators shall be used only as defined on the nameplate, the type specific data
sheet or after specific release. Primarily this refers to significant data such as rated
speed, speed range, voltage, output and current as well as the class of protection. The
generator outputs shall be protected by appropriate safeguards against over-current and
short-circuit and shall not be connected to other power distributions or power
generating systems unless the express written approval has been obtained. Single-
bearing generators are intended exclusively for attachment to a combustion engine
which is in compliance with the applicable, norms, directions and regulations.
Two-bearing generators are typically driven via belts, clutches or directly by the drive
unit. It shall be mounted on an absolutely level and suitable surface. When using a belt
drive we recommend mounting the generator, for instance, on rails, to keep it mobile.
The pull of the belt is to be set accordingly. The maximum radial forced as described
below shall not be exceeded. Please do not hesitate to contact KWG-Generator GmbH
& Co. KG for assistance in the design of the drive.
Unless indicated otherwise, the generators and attached components are of class of
protection IP54 and may be operated and stored in the open. Cleaning by means of
high-pressure cleaners is not allowed. The place of installation and use should be
selected such that supply of fresh air to the inlet opening of the ventilator hood is as
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short as possible. The rated output data of the generators apply to intake and generator
ambient temperatures of < 40°C, as well as to installation heights of max. 1000 m. If
the temperatures and/or the installation heights are exceeded, the output de-rating shall
be applicable as described in the following. Operation at temperatures > 60°C shall be
allowed only after specific acceptance and release.

The generators shall be used only for the applications specified here and only in
accordance with this operating manual. Any other use is deemed misuse and thus not
allowed. Improper or unauthorized use of the generators or individual components is
not allowed. No liability will be accepted by KW-Generator GmbH und Co. KG in this
case.

Warranty
Unless specific warranty regulations are defined in writing for type-related applications
and customers, we will grant a warranty according to the general European regulations.

General Safety Instructions

DANGER

Electric machines include dangerous components which are either live or rotate
during machine operation.
Thus:
- Improper use,
- Demounting protective lining, disconnecting safeguards,
- Poor inspection and maintenance,
may cause serious personal and property damage.
The safety officer shall convince himself and ensure that transport, installation,
commissioning, operation, inspection, maintenance and repair of the machine are
carried out by qualified personnel with the following qualifications:
- Specific technical qualification and experience
- Knowledge of technical norms and applicable laws
- Knowledge of the general national and local system-specific safety regulations
- Ability to detect and avoid dangerous situations.
Work at electric machines shall not be carried out without the approval given by
the safety officer; this is applicable to vertical machines where all poles are
separated from the mains and the machine is secured against re-connection
(including auxiliary circuits).
The generator shall not be operated in environments subject to explosion hazards.
The relevant regulations shall be followed!

The generator and its components can be very hot during and after operation.
Danger of burning!
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Earthing of the neutral conductor of the generator (N, neutral) cancels the
protective measure “protective disconnection” and should thus be avoided. If the
neutral conductor N shall be earthed, this shall be carried out only by a qualified
specialized electrician with due consideration given to the relevant regulations.
Efficiency of the electrical protective measure shall be verified by appropriate
measurements. Prior to connecting devices at the generator make sure that the
devices are switched off. Risk of accident! Uncontrolled starting devices may
endanger or injure persons and cause damage or become damaged. Keep children
and animals away from the generator during and after the operation of the latter.
Arrange for the appropriate precautions. Danger to life due to electric shock, risk
of injury and burns!

TRANSPORT AND STORAGE

The generator is delivered ready for installation, screwed on a pallet and sealed by
protective foil against water and pollution. We recommend subjecting it to a careful
inspection for damage on arrival at the destination. Visible damage, if any, shall be
reported directly to the forwarder and KWG. For lifting and moving the generator use
the eyelets provided for this purpose. The eyelets at the generator are suitable only to
lift the generator. They shall not be used for lifting the whole unit. In addition make
sure that suitable lifting tackles are available for the weight of the generator and that all
safety precautions have been arranged for transport. In the event that the generator is
not commissioned immediately, store it at a protected clean, dry and vibration-free
place.
The ball bearings need not be maintained during the period of storage; periodical
turning the shaft will prevent corrosion and hardening of the grease.
Weight (mass): BG 132 approx. 35 - 105 kg
BG160 approx 130 - 210kg
BG200 approx 230 - 270kg
BG250 approx 300 – 500 kg
Admissible temperatures: Transport -25 °C up to +60 °C
Storage -20 °C up to +50 °C
Admissible relative humidity: Transport 95 %, non-condensing
Storage 95 %, non-condensing
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Type code and serial number of generator

Each KWG generator is provided with a unique serial number and a clear type
designation. Both are provided on the nameplate. Provide both numbers for queries, re-
orders, required spare parts and extended data.
The serial number can be as follows: KWG2565
The type number is structured as follows:

design examples of generators

The most common designs are given in the following.

Symbol Construction Explanation

type
Two-bearing design with feet below and one cylindrical shaft
IM B3 end
(B3)

IM B34 Two-bearing design with feet below and flange connection at

(B3/B14) A shield and one cylindrical shaft end

IM 1202 Single-bearing design with SAE clutch disk

SAE J609
Single-bearing design with conical shaft
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Overview of protection classes

Protection against accidental contact and foreign bodies
1. Ident number Designation - explanation
0 Not protected
1 Protected against solid foreign bodies with diameter 50mm and larger:
The object probe (ball 50 mm) shall not penetrate fully
2 Protected against solid foreign bodies with diameter 0.49in and larger:
The object probe (ball 12.5 mm) shall not penetrate fully
Note: Typically the ventilation slots in a PC power pack housing...
3 Protected against solid foreign bodies with a diameter of 2.5 mm:
The object probe (ball 2.5 mm) shall not penetrate
4 Protected against solid foreign bodies 1 mm and larger:
The object probe (ball 1 mm) shall not penetrate
5 Protected from dust:
Penetration of dust cannot be prevented fully; but the amount of penetrating
dust shall not affect the operation of the device or safety.
6 Dust-proof:
No dust penetrates at an under-pressure of 20 mbar in the housing
Protection from water
2. Ident Designation - explanation
number
0 No protection
1 Protected from dripping water:
Vertically falling drips shall not have adverse effects
2 Protected from dripping water if the housing is inclined up to 15°:
Vertically falling drips shall not have adverse effects if the housing is inclined up to
15° at both sides of the vertical
3 Protected from spray water:
Water sprayed at an angle of max. 60! at both sides of the vertical shall not have
adverse effects
4 Protected from splashing water:
Water splashing against the housing from any direction shall not have adverse
effects
5 Protected from jet water:
Water jets against the housing from any direction shall not have adverse effects
Note: Corresponds to approx. 12.5 liters/min (garden hose) Test period approx. 5
minutes. (Subject to correction)
6 Protected from strong jet water:
Strong water jets against the housing from any direction shall not have adverse effects
7 Protected against the effects of temporary submersion in water:
Water shall not penetrate in such amounts that adverse effects are caused if the
housing is submersed in water under standardized pressure and time conditions
8 Protected from the effects of permanent submersion in water:
Water shall not penetrate in such amounts that adverse effects are caused if the
housing is submersed permanently in water under pressure and time conditions as
agreed between manufacturer and owner. However, the conditions must be more
stringent than for basic index 7
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General structure
The generators consist of a main revolving-field machine with salient pole rotor and a
stationary filed exciter to transfer the exciter output. A rotating rectifier set mounted at
the exciter magnet wheel is used to transform the current coming from the exciter
magnet wheel. The housing consists of the stator, the bearing shields, the extrusion
housing and the extrusion feet as well as a hood to cover the fan impeller at the B end.
The terminal box/cable hose can be mounted at 45°. Functional screwing and fastening
ducts are provided at the outer side of the housing.
ATTENTION: The screwing and fastening ducts are provided only for the installation
of the generator feet, the bearing shields and the KWG accessories. The ducts shall not
be used for other attachment parts unless the written release has been obtained. The
encapsulated generator controller is arranged in the cover of the terminal box, however,
can also be mounted as external component.

Brief technical characteristics

The general data of the KWG generators are given in the following.
They shall be applicable unless other data are specified in the type-specific data sheet.

Output range, total 5 to 100 kVA related to the 50 Hz design;

Speed from 1500 (range up to 3500) and 3000 (range up to 4500) min-1 (4/2 poles);
direction of rotation: Two-bearing design anti-clockwise/clockwise rotation; single-
bearing design clockwise rotation only,
Voltages: Preferred values 115, 230, 400V related to 50 Hz;
Frequency: Standard values 50 and 60 Hz.
Any other voltages and frequencies shall be agreed upon;
Power factor: cos φ = 0,8 - 1,0,
Efficiency of 3-phase windings: approx. 90% at a load of 80%
Efficiency of 1-phase windings: approx. 85% at a load of 75%
Coolant temperature: 40 °C; with output reduction usable up to 60 °C;
System of protection: IP 54, higher types of protection on agreement;
Thermal class: F/H class;
Admissible relative humidity: Transport 95 %, non-condensing
Storage 95 %, non-condensing
operating permanent 85% at 25°C
operating short time 100% at max. 35°C
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Resistance of standard alternators 3 phase (1 phase)

Main winding Main winding Main winding Exciter Exciter
Stator Stator Rotor winding winding
L1-N (Phase-N) L1-L2 (Phase- 2F1-2F2 Rotor Stator
phase) (Phase-phase) F1-F2
(Ohm) (Ohm) (Ohm) (Ohm) (Ohm)
KWG-090/2-x10-xxx 0,97 1,94 7,2 1,35 28
KWG-110/2-x10-xxx 0,69 (0,171) 1,39 (0,332) 7,65 1,35 28
KWG-145/2-x10-xxx 0,47 0,94 8,82 1,35 28
KWG-190/2-x10-xxx 0,22 0,57 10,07 1,35 28
KWG-230/2-x10-xxx 0,16 0,32 11,75 1,9 14
KWG-300/2-x10-xxx 0,11 0,22 14,20 1,9 14
KWG-175/4-x10-xxx 0,49 1,0 8,3 1,72 14
KWG-240/4-x10-xxx 0,09 0,3 10,76 1,65 14
KWG-180/2-x20-xxx 0,2 0,24 7,62 0,35 10
KWG-250/2-x20-xxx 0,08 0,15 7,55 0,3 10
KWG-360/2-x20-xxx 0,42 0,82 8,87 0,40 10
KWG-200/4-x20-xxx 0,16 0,31 1,70 0,3 10
KWG-270/4-x20-xxx 0,10 0,20 2,11 0,3 10
KWG-370/4-x20-xxx 0,077 0,15 2,69 0,32 10
KWG-350/4-x40-xxx 0,042 0,081 3,00 0,32 10
KWG-270/4-x31-xxx 0,034 0,065 3,17 0,34 14

Resistance Zu-N is approx. ½ of Resistance L1-N. Also for Zv und Zw the same.

Balance quality of rotor: Class 2.5 according to IEC 34-12 / for 2-bearing generators
balanced with half fitting key
Ventilation: Self surface-ventilated by rotating fan at B end
Exciter unit: with electronic controller, self-excited,
Set value setting: ± 2.5 % of UN, with internal trimmer;
Static voltage tolerance: < ± 1 % of UN and a speed drop of 5 % of nN;
Dynamic voltage variation: < 25 % at mains connection/disconnection;
Recovery time: 0.1 to 0.5 s depending on application and generator type;
Permanent short-circuit current: > 3 x IN three-phase; > 6 x IN single-phase for 3 to 5 s;
Load unbalance: For load unbalance capacity refer to type-specific generator data sheet;
Damper rods in rotor: serienmäßig;
Total harmonic distortion: < 5 % U-N for standard windings and <3% U-N for
increased requirements;
Short-term overload capacity: 50 % for 2 min,
Permanent overload capacity: Between rated load and 50% overload, back regulation
occurs automatically depending on the ambient conditions,

Over-temperature in generator: Depending on the type, the temperature is measured by

a sensor integrated in the generator and/or the temperature is determined at the
resistance of the winding.
If a temperature threshold is exceeded, the output power is automatically reduced
variably.
Over-temperature in generator controller: Each KWG controller measures the controller
temperature by a sensor integrated in the controller. If a temperature threshold is
exceeded, the exciter output is automatically reduced invariably.
Under-speeds: Possible without limitation;
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Storage: Grooved ball bearing at drive end as fixed bearing and floating bearing at the
fan end, permanently lubricated bearings in non-leaking C3 design, max. lifetime cycle
of bearings: 20000h hours when meeting the ambient conditions, max. radial shaft load
at the center of the shaft end:
BG132 2pole max. 3500N
BG132 4pole max. 4000N
BG160 2/4pole max. 6500N
BG200 4pole max. 8500N
BG250 4pole max. 11000N

Terminal box
Typically, the terminal box is arranged at the rear of the housing and contains the
connections of the stator winding and all additional terminals required for generator
operation and monitoring. For customer’s connections, waterproof (IP54 to IP67) cable
glands are provided, the number and dimensions of which should be agreed. The top
terminal box can be turned by 180°. The terminal box may include up to 4 metric or PG
threads.
An M32x1.5 thread is standard at the B end. The standard design of the stator winding
is sufficiently dimensioned in star connection with led out star point – with due
consideration given to the load unbalance.

Sense of rotation and rotary field

For clockwise sense of rotation of the drive (clockwise seen to the shaft end) the time
sequence of the phases corresponds to the terminals U-V-W according to DIN EN
60034-8. The phase sequence changes in case of reversal. Anti-clockwise sense of
rotation of drive with phase sequence U-V-W is possible.

Behavior in case of under-speed

Under-speeds at the generator will not cause problems. The generator controller limits
the exciter current to the maximum admissible current and, at the same time, monitors
the temperature at several points. Depending on the ambient conditions, the rated output
is presented yet up to 5 % under-speed. For set applications, additional output control is
integrated as protection from motor torque overload.

Behavior in case of over-speed

The max. admissible speed shall not be exceeded. Otherwise the rotor may be damaged
mechanically due to the high centrifugal forces. The rotor may contact the stator and
destroy the generator completely. In addition, the generator controller cannot keep the
specified step response times at over-speed. The result would be that the remanence
voltage of the generator exceeds the rated voltage and damage the generator or the
devices connected to it
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INSTALLATION AND COMMISSIONING

Prior to installation
- check whether the data given on the nameplate of the generator meet the system data;
- remove the protective foils and transport guards
- check whether all screws and nuts at the generator are tightened for installation of the
system,
- check whether mechanical assembly is correct,
- check whether sufficient cooling air is present and whether it is ensured that
the generator does not take in hot air and no hot air is blown to the sides of the
generator by other unit ventilators. In addition ensure sufficient space for inspection
work (refer to chapter “Care and maintenance”). KWG offers technical assistance for
the installation situation.
- for single-bearing generators, check whether the tightening torque of the clutch disk is
correct and/or the cone is compressed,
- check whether the system is secured against unauthorized access
- check whether the system is provided with the necessary safeguards according to legal
regulations,
- check whether the connections at the terminal board have been made properly,
- check whether the connections have not been confused and no short-circuits exist
between generator and external switches,
- start the generator only if it is ensured that the system is disconnected at the main
switch or other switch-off devices Risk of accident due to automatically starting
machines,
- for connection of system wait until the units reached its rated speed.
In total, the lengths of all connected extension cables shall not exceed the following
values:
• max. 250 m at a line cross-section of 2.5 mm²
• max. 109.36 yd at a line cross-section of 1.5 mm²
To ensure safe operation of three-phase generators, the current tapped for consumers
should be distributed as uniformly to the three external wires as possible. Make sure not
to exceed the maximum current indicated for each socket.
Both bearing shields are provided with a water drain hole which may be closed by a
sealing plug by the manufacturer. If the water drain hole is required, check whether it is
provided at the bottom side of the generator. Attention: If the generator is installed in
inclined position, the water drain hole must always be at the bottom side so that any
condensation water or penetrated water can flow off. If necessary, turn the bearing
shields towards the housing. Wrong position of the water drain holes will cause
penetration of water and failure of the generator.

Alignment
Carefully align the generator and the drive motor.
Incorrect alignment may result in vibration, bearing damage, damage to drive unit,
damage to adapter unit (clutch) and unnecessary noise emission.
When using single-bearing generators check the dimensions of connection
housing/connection flange and flywheel/shaft cone of drive motor In addition, check
the dimensions of the flange and clutch disk/shaft cone of the generator.
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Fastening torques
Please keep the following tightening torques in Nm
Application Thread size
M5 M6 M8 M10 M12 M16
Terminal board and electric 5 6 12 30 36 -
connections
Fastening for minor loading
Fastening for normal loading 5 8 14 24 39 -
(Terminal box cover,…)
Fastening for high loading 6,5 11 25 45 75 120
(Feet, flanges, ..)

Insulation test
The generator is checked for insulation at high voltage during the final KWG test
according to norms. Prior to starting the system and, above all, after longer periods of
storage, check the generator for correct insulation at 500 V using an insulation tester.
The insulation value of the winding against earth should not exceed 5 M_ohms. If this
value is not OK, please contact the KWG after-sales service department or KWG
directly.

Electric connection and terminal board

Generators with connection at terminal board

Make sure to connect the cable eyelets as shown in the picture. Improper connection
may result in over-heating and fire due to too high a contact resistance.

Assignment of terminal board as shown

The bolt size at the terminal boards depends on the types used
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Max. current load and fastening torque at KWG-terminal board

The design of the terminal board depends to the particular type of the generator. The
following table shows the max. current laod of each pin of the terminal board. This
must not be exceeded.

Terminal Max. current load Tightening torque

board (A) movement
(Nm)
M4 16 1,5
M5 25 3
M6 63 5
M8 100 9
M10 160 20
M12 250 25

Generators without connection to terminal board

In most cases, cable design with strand in flexible corrugated conduit Separation of
corrugated conduit and strand from generator is possible only in the premises of KWG
connection of the system is customer-specific, but in most cases by means of cable ring
lugs.
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Generator controller connection
Generator with three-phase voltage winding and DVR controller

Generator with three-phase voltage winding and SCB controller

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Generator with single-phase winding and DVR controller

Generator with single-phase winding SCB controller

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Plug assignment of generator controller

DVR controller
Generator-Interface
1= F1
2=F2
3=ZU
4=ZV
5=ZW
6=ZN (nc)
CAN-Interface
1= LOW
2=HIGH
3=GND
4=+9 to +30V
5=+5V
RMS
1= PE
2= Sense N
3= Sense U
Relais-Interface
1= Rel1
2=Rel2
3=Mag-
4=Mag+
Sensor
1= NTC
2=NTC

Additional interface I/O

1= +10V ref. out max.20mA
2= GND
3= analog in
4= nc
5= digital in +
6= digital in -
7= digital out -
8= digital out +

SCB controller
Generator-Interface
1= F1
2=F2
3=ZU
4=ZV
5=ZW
6= (ZN) nc
INPUT
1= Sensor wire
2= Sensor wire
Relais-Interface
1= Rel1
2=Rel2
3=Mag-
4=Mag+
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Description of functions of generator controller

To safely operate the KWG generator use the KWG-GR-xxx generator
controller. The voltage controller has been adapted to the safe and stable
operation of the relevant type of generator. The system is stable in all operating
positions and meets the regulations and requirements of the application.
Adaptation is possible only in the premises of KWG because all parameters
have been saved in digital form in the generator software.
Modes of operation such as over-load, under-speed, idling, single-phase load
and loads at cos phi < 1 are detected automatically - and responded
accordingly - by the generator controller.
ATTENTION! Avoid operating the generator at under-speed because this mode
of operation will require more exciter output – due to the principle – and the
exciter system and the whole generator will heat up unnecessarily.
The generator controller is connected with the generator by AMP-MATE-N-LOK
plug connectors.
Use of potentiometers
The generator controller can compensate the output voltage in the range +/-
2.5% (type-specific) by means of TR1. Turning clockwise increases the output
voltage, turning anti-clockwise reduces it. KWG generator controllers control the
output voltage to averaging (AVG), but they can also control the output voltage
to the real effective value (TRUE-RMS). For this reason it is important to
measure the generator voltage during compensation using a TRUE-RMS / AVG
measuring instrument.
Thermal protection
All KWG generators are thermally protected. The temperature is measured in
the generator controller. The threshold value here is 85 °C. If the temperature
exceeds this threshold, the output is reduced until a temperature of max. 85 °C
is restored.
Interface options
The KWG generator controller is provided with quite a number of I/O interfaces.
In addition to the standard CAN bus in DVR, there are the following options:
- Current sensor,
- Relay output 1 as normally open or normally closed contact
- Direct possibility of voltage supply for 24 V actuator
- Analog voltage input 0-10V DC
- Digital voltage input 12/24V DC
- Digital output via opto coupler
- Interface to KWG insulation monitor
Contact KWG directly for these standard options and other specific options.
Inductive/capacitive load
The standard KWG generator systems are designed both for inductive and
capacitive loads of 0.8 – 1.
For non-Ohm loads beyond these values please contact KWG for the de-rating
tables.
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Interface to KWG insulation monitor

In addition to the independent mode, the KWG insulation monitor offers the
feature of communication with the KWG generator controller. The insulation
value is put out via the CAN-BUS. At the same time, the insulation value can be
processed further in the KWG generator controller and, for instance, control
relays.

Operation with insulation monitor

Make sure that the insulation monitor is operational and functional. The DIN EN
61557-8 must be observed. The effectiveness of the test equipment (insulation
monitor) must be checked by an internal or external test button for proper
operation and compliance. Typically, the effectiveness of the test equipment
(insulation monitor) must be checked every working day.

Instructions for demounting from drive unit

Prior to demounting the machine, make sure that the unit cannot be
started automatically or manually. In addition, the system must be
disconnected and dead.
Provide suitable lifting tackles and transport means. Have all safety
precautions arranged for transport.

Disconnect the connection power cables and other cables to the generator
terminal box. Prior to loosening the bolts from the machine foot, secure the
generator against sliding or falling down. For demounting generators with SAE
flange and disk, SAE flange and clutch as well as single-bearing generators
with conical shaft please obtain the necessary instructions from KWG.

Maintenance and care

Maintenance work shall be carried out regular and in due time in order to
ensure reliable operation of the generator.
In principle, all components of the generator are maintenance-free. Damage to
and defects in the generator must be eliminated immediately by authorized and
qualified specialists, irrespective of the maintenance intervals. Do not start the
generator unless the defects have been eliminated. Repair work shall be
carried out by qualified specialists only. Check the generator for undue pollution
at regular intervals, clean it, if necessary.
ATTENTION! Cleaning by means of high-pressure cleaners is not allowed!
Inspections at the drive system should be carried out according to the
specifications and provisions of the relevant drive/system manufacturer.
This includes also mounted protective covers.
Please follow the maintenance instructions of the drive or system manufacturer.
The generator shall be opened only by the manufacturer or authorized persons.
It does not contain components which can be replaced or repaired by the
operator.

Disposal hints
For the proper disposal of the materials used please read the type-specific data
sheet.
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Troubleshooting
KWG generators are permitted only for operation with a KWG controller. The
system has been tested and documented by the manufacturer. Thus please
record the serial number of the generator, the type of generator, the serial
number of the controller and the type of controller in case of requests to KWG.
If unexpected failure occurs at the generator system, a specialized electrician
may carry out the following checks in advance.

Fault Possible cause Remedy

Output voltage not correct - Trimmer not adapted to Setting of trimmer and controller
controller and measuring the output voltage
- Measuring instrument using a correct measuring
used not suitable for that instrument
purpose
Output voltage varies - Controller not matching Replacing the controller by a
the generator type correct one
- Drive system extremely Stabilizing the drive system
instable
No output voltage - Connected fuse Replacing and/or activating the fuse
disconnected Eliminating the output short-circuit
- 3-phase short-circuit of Determining - by external
output phases excitation of generator – whether
- Generator or controller generator is functioning properly
defective Refer to KWG instruction “external
excitation”
If generator is OK, the controller
might be defective
Generator becomes too - Too hot generator Checking ambient conditions and
hot environment air intake
- Intake air too hot Measuring the temperature at the
- Generator intake reduced generator and/or reading out the
by foreign bodies generator temperature by means of
- Generator is in normal the diagnosis unit and contacting
operating state KWG
- Generator is overloaded Cleaning the generator
- Generator is extremely
polluted
Generator too noisy - Foreign bodies in fan hood Remove foreign matter,
- Ball bearings defective Have ball bearing checked by a
- Single-phase over-load specialist
- Drive unit not correct Measuring the phase currents using
an ammeter, eliminate overload, if
necessary
Replace Vee belt and/or set it to
correct tensile force Checking the
drive for running noise
Mechanical damage to - Damage to generator Please contact KWG and submit
generator found during maintenance photograph, if any, showing the
work damage. Shut down generator until
clarification in order to avoid
consequential damage
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Advanced Troubleshooting

Error: No or low output voltage

1) Is a to heavy load connected? In any case, there should be no load connected at
this troubleshooting routine.

2) Check that the generator is rotating at rated speed. Most controllers are provided
with a f/U characteristic. E.g. at a frequency less than 48 Hz, the voltage begins to
decrease in a defined ramp down.

3) Check that the generator or the generator controller is not too hot. If necessary.
cool down and check the output voltage. Should have been the cause of the increased
heat, then possibly overload, single-phase overload, dirty excessive contamination of
the generator inlet of the ventilation hood or not free or external influence is as
exhaust or exhaust manifold near the alternator or the regulator.

4) If the output voltage is less than about 4 V (UN) as the generator loose the
RETENTION. This can happen when the generator with motor load slowly comes to a
standstill. The case that the RETENTION is lost, is very rare.
To eliminate the problem, see "external excitation".

5) If the output voltage is about 4V - 50V (UN), then either the regulator or the
generator cause damage.
Remove the AVR from the generator. Disconnect the AVR. Are any damage visible?
With unpluged AVR check the resistance value of the windings. (See table).

6) The Winding tap or the exciterwinding at single phase generators Zu-Zv-Zw are
connect on the 6pol.AMP connector with wires in yellow or orange.

The primary winding is placed usually on a terminal board.

Also can be compare the symmetry of the resistance values with each other.

7) Insulation measurement with a special measuring device (DC500V).

Warning: an electrician is needed.

8) Seems the generator in all the steps described above, it is to test with the machine
running. Start the engine, the output voltage must be measured. To the 6-pin AMP
connector red and gray wires increase slowly the voltage (red = +), observe the output
voltage. For an output voltage of about 230 V (UN), an exciting current of
approximately 0.4-0.7 A DC is required. The voltage required for this purpose can be
calculated. FOR EXAMPLE U = R * I, 28.5 * 0.4 A = 11.4 V. E.g. in most cases you
can supply with a 12V or 9V battery.

9) If all ok after testing the generator, and yet it does not provide correct output
voltage, a further test with a replacement controller is necessary.

10) For insiders: check the generator resistance and also the rotationg diodes on the
exciter rotor.