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OPERATING INSTRUCTIONS and SPARE PARTS LIST for electric power generator

PMG 10/2 H1 PMG 10/2 E1

430 202 00-ENG-07.03-0.03 Printed in Germany

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Preface
You have acquired a Hatz electric power generator manufactured according to DIN ISO 8528. This operating equipment has been designed and built according to state-of-the-art technology. The electric power generator is exclusively intended for the purpose described in chapter 2. Any utilization exceeding this scope is considered as improper use. Motorenfabrik HATZ cannot be held responsible for any risks and damage resulting from such improper use. The user shall solely bear the risk.

ATTENTION !
This generator may only be started if the operator is familiar with these operating instructions and the operating manual of the engine. Both manuals help to avoid accidents, to operate and service the generator correctly, and thus to remain operative for a long period. The operating instructions are an integral part of the electric power generator; i.e. they have to be attached to the generator at all times (even when sold), and have to be available under all operating conditions.

The worldwide HATZ Service Network is at your disposal to advise you, supply with spare parts and undertake servicing work. You will find the address of your nearest HATZ service station in the enclosed list.

Use only original spare parts from HATZ. Only these parts guarantee a perfect dimensional stability and quality. The reference number is specified in chapter 14.

We reserve the right to make modifications in the course of technical progress.

Contents
1. 2. 3. 4. 5. 6. General safety regulations and rules for the prevention of accidents Agreed application of HATZ electric generators llustration Installation drawing with dimensions Technical specifications and tolerances Instructions before start-up 3 4 5 6 7 8 8 8 8 8 9 10 11 12-15 16 17 18 22

6.1. Installation 6.2. Fuel 6.3. General electro-technical information 6.4. Protective measures 7. 8. 9. Information regarding commissioning and operation of the electric power generator Information regarding closing down of the electric power generator Maintenance and inspection

10. Circuit diagrams 11. Residual risk for electric generating sets 12. Troubleshooting 13. Disassembly and assembly of the generator 14. Spare parts for the generator

This symbol identifies important safety precautions. Please comply with these most carefully in order to avoid any risk of injury to persons or damage to materials. General legal requirements and safety regulations issued by the competent authorities or industrial accident insurers must also be complied with.

1. General safety regulations and rules for the prevention of accidents


The gen sets are constructed in accordance with the applicable standards and regulations. However, danger may arise if they are operated or used incorrectly for an inappropriate application or by untrained personnel. Everybody responsible for commissioning, maintenance, operation or repair must have read these operating instructions and the operating manual for the motor thoroughly and understood the contents; must be familiar with the control and operating elements before starting the electric power generator; must observe all the instruction and warning signs attached to the electric power generator, and keep them in a legible condition. If an adhesive label falls off or becomes difficult to read, please request a replacement at your closest HATZ service centre. On principle the generator has to be checked for proper working order before every application. The electrical devices, supply and extension cables have to be in perfect condition. For safety reasons, only use totally insulated devices. Ensure that children and animals are kept away from the unit. Explosive as well as easily combustible substances must be kept at a distance, as the exhaust of the electric power generator develops very high temperatures during operation. Attention: Do not run in closed or insufficiently ventilated rooms ! Do not inhale the exhaust gases - RISK OF POISONING ! The generator must always be operated on a firm and dry base. The electric power generator must be placed so that it cannot tilt, slip or fall. Protection against contact with live components is only given if all covers on the control panel and terminal box are installed as per the original instructions for the new unit. All control panel, box components e.g. sockets, safety switches and measuring instruments, must have been supplied and installed intact and in correct condition with the new unit. Exhaust system components as well as the surface of the engine will naturally be hot and must not be touched while the engine is running or until it has cooled down after being stopped. Besides the information given in these operating instructions, the generally applicable safety regulations and the regulations for the prevention of accidents laid down by legislators or competent professional associations must also be complied with. Any improper modification made to the electric power generator rules out liability for damage resulting from such modifications. For further safety provisions, please refer to the operating manual of the engine. In case of doubt, please contact the closest HATZ service centre before activating the electric power generator.

2. Agreed application of HATZ electric generators


Intended utilization: Back-up electric generation plant within the IT network with protective measure "electrical separation" according to DIN VDE 0100, part 551 & HD 384.5.551 S1: 1997. Insulated system without generator grounding. Depending on the circuit diagram used, a voltage of 230 V or 400 V can be picked off. The frequency is 50 Hz. Electrical consumers may only be connected and operated by HATZ electric power generators if they are suitable for the operation with this generator type and if their total power consumption does not exceed the rated power output of the generator. The electrical data of the consumers, such as voltage and frequency, must correspond to the electric data of the generator. If the wattage is not indicated on one of the consumers, please contact the appropriate manufacturer. If these instructions are not complied with, there is a risk of damaging the electric power generator or the devices connected. Connection into existing electrical systems in buildings is not permitted. Exception: connection into existing systems may only be established by competent electricians and after approval by the appropriate electrical power supply company. Installation of standard Hatz design gen sets is not permitted in vehicles or closed rooms unless appropriate measures have been taken with regard to the supply and removal of cooling air and exhaust gases. The installation will also have to be approved by the manufacturer. The driving motor is set for an operation within the standard reference conditions according to DIN ISO 3046-1, i.e.: Atmospheric pressure: 100 kPa (at an altitude of approx. 100 m above sea level). Intake air temperature: 298K (25C) Relative humidity: 30 % If the conditions at your site of operation differ considerably from the conditions mentioned above and have not been taken into account on ordering the generator, please contact your closest HATZ service centre. Our staff will be able to let you know whether adaptive corrections on the motor are required due to the climate conditions. Important: The use according to the intended purpose also includes the observance of the operating instructions and the specified maintenance and repair instructions. Non-compliance may lead to damage to the electric power generator which may involve danger for persons and other material damage.

3. Illustration
3.1. Generating set conforming to: DIN ISO 8528 3.2. Manufacturer: MOTORENFABRIK HATZ GMBH & CO.KG Ernst-Hatz-Str. 16, 94099 Ruhstorf/Rott. 3.3. Labelling: CE Label 3.4. Illustration:

Model with engine 1D81 Z 3.5. Generator nameplate

Model with enclosed engine 1D81 C

Typ Nr. Please enter the type and number of the generator here. The generator nameplate is located on the generator housing. When making enquiries or placing orders for spare parts, please make sure to specify this data. (List of spare parts for generator, refer to chapter 14). For information on the motor nameplate, please refer to the operating instructions of the engine. 5

4. Installation drawing with dimensions


Type: PMG 10/2 H1 with engine 1D81 Z PMG 10/2 E1

Type: PMG 10/2 H1 with engine 1D81 C PMG 10/2 E1

5. Technical specifications and tolerances


The values indicated in the following table are rated specifications, i.e. specifications based on which the unit has been designed. There are tolerances dependent on material and production, which are included in the construction requirements applicable for the units. These have been kept to. Type Nominal capacity Performance Voltage Amperage Frequency at 3000 rpm Precision of voltage Harmonic content Protection Make of engine Type of operation Series Cooling Cylinder Engine capacity Speed Consumption at 3/4 load Type of start Recommended starter battery Starting temperature no less than -6C Starting temperature no less than -15C Maximum admissible rating Weight (ready for operation) with engine 1D81 S with engine 1D81 C V/Ah V/Ah V/Ah kg, approx. kg, approx. kW r.p.m. l/h approx. Diesel kVA Cos phi 3~V 3~A Hz % % IP PMG 10/2 H1 10 0,9 400 15,2 50 10 6 20,23M HATZ 4-takt 1D81. Luft 1 10,5 3000 2,5 Hand 154 173 PMG 10/2 E1 10 0,9 400 15,2 50 10 6 20,23M HATZ 4-takt 1D81. Luft 1 10,5 3000 2,5 Electric 12/45 12/66 12/88 159 178

6. Instructions before start-up


6.1. Installation
If possible, the electric power generator should be operated outdoors. Thus, cooling air can circulate freely. Do not run the motor in closed or insufficiently ventilated rooms ! Do not inhale the exhaust gases - RISK OF POISONING ! Explosive as well as easily combustible substances must be kept at a distance, as the exhaust of the electric generator develops extremely high temperatures during operation. It is absolutely necessary to make sure that the exhaust muffler or pipe is not directed towards combustible material. Remove covers, such as crates, containers, tarpaulins etc., otherwise damage to the device during operation is inevitable. Moreover, there is an increased risk of fire.

6.3. General electro-technical information


As extension cables, only use rubber-coated cables which correspond to the designs H 07 RN-F or A 07-RN-F according to DIN VDE 0282-4 or IEC 245-4 (rubber-insulated cables with rated voltages up to 400 V) or ones exceeding these quality standards. Extension cables must be selected according to the expected mechanical, electrical and thermal loads; they must be laid according to the specifications. Fuses providing protection by cut-out are unacceptable in electric power generators of this power range !

6.4. Protective measures


The manufacturer has provided and installed the protective measure "electrical separation with equipotential bonding". This protective measure corresponds to DIN VDE 0100-551, HD 384.5.551S1: 1997 and HD 384.4.41S2: 1996. It must be ensured that components providing protection are maintained in their original condition. This applies especially to equipotential bonding conductors (marked in green and yellow), plug-and-socket connectors, extension cables, fuse cut-outs and switches. The active components of the 400V/231 V system must not be connected to other current circuits or to the ground. It is absolutely necessary that the cables are perfectly insulated. All electro-conductive elements of a connected consumer must be connected to the non-grounded equipotential bonding conductor.

6.2. Fuel
Only diesel fuel as specified in the operating instructions of the engine must be used. Stop the engine before refilling the fuel tank. Never refuel near a naked flame or sparks which could start a fire. Don't smoke. Use only pure fuel and clean filling equipment. Take care not to spill fuel.

All sockets must feature a ground contact, which has to be connected to the equipotential bonding system. All flexible connecting cables (except safety class II) and extension cables must comprise a protective conductor. If one piece of electrical equipment is used, the following max. lengths of extension cables are admissible: 60 m in case of 1.5 mm 100 m in case of 2.5 mm 150 m in case of 4.0 mm If two or more pieces of electrical equipment are connected to the electric power generator, the admissible cable lengths are halved. If 2 or more pieces of electrical equipment are supplied and if an insulation failure occurs in 2 of these, a protective device must effect a power supply cut-off within 0.2 seconds. Please note: The two insulation failures must concern 2 active conductors of different polarity (e.g. device 1, insulation phase L1 faulty; device 2, insulation PEN conductor faulty) -> every branch (sub-distribution) must be protected by fuses on all poles.

The number of pieces of electrical equipment and their location must be arranged in a way that the operator can easily monitor and control them. The enlargement of the plant to be supplied is limited. (In case of doubt, please consult a specialist electrician before starting the generator.) The user must pay special attention to the correct laying of cables, and have control over devices critical for safety (e.g. safety switches) at all times. It must be ensured on all accounts that the ground-fault loop resistance (total resistance) does not exceed 1.5 Ohm. The installation of other protective measures, which must all correspond to the applicable standards, may only be performed by authorized specialists.

7. Information regarding commissioning and operation of the electric power generator


Check whether the entire electrical equipment is in proper working order. Special attention must be paid to the insulation before start the generator. The engine must be started according to its operating instructions. Note: The speed-setting device is set to maximum motor speed. Individual speed setting is not possible; therefore a speed-setting lever has not been installed. Check whether the generator is producing voltage (voltmeter). If necessary, engage the circuit-breaker. Start up the consumers one by one, and check them for proper working order. Avoid extended no-load operation periods.

8. Information regarding closing down of the electric power generator


Close down or switch off all consumers according to their specifications/instructions. Electrical equipment Battery charging pilot lamp "2" and oil pressure lamp "3" light up after motor has come to a standstill. Turn the starter key to position 0 and remove it; all pilot lamps must go out.

1 2 3
Stop lever of engine 1D81 S

4 5
Note: Engines equipped with a "solenoid for closing down the motor" are switched off by turning the starter key back to position 0.

Stop lever of engine 1D81 C Turn stop lever "1" in "STOP" direction, and hold it tight until the engine has come to a standstill (see illustrations above). Having stopped the engine, release stop lever "1", and make sure that it returns to "START" position.

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9. Maintenance and inspection


General For performance of maintenance, inspection and repair, the engine must be switched off and secured against unauthorised starting.

9.2. Generator
After the electric power generator has been operating for a period of time corresponding to its field of application (approx. 1 year), specialists or well-trained persons must perform the following inspections: The generator and all necessary covers are in perfect condition and in place. All the generator's screw fastenings must be checked for proper condition and tight fit. The front plates with operating elements are mechanically and electrically in order. Inspection of the protective conductor and its terminals. Connection of the protective conductor terminal in the switch box to the individual sockets, to the switch box housing, to the generator case, to the frame and to the earth terminal must be low-resistance, i.e. resistance must be lower than 0.3 ohms. This value must be verified. The protective conductor wire rating must be the same as the wire rating of the external conductor and the flexible conductor.

Remarks
To carry out maintenance, inspection and repair, appropriate workshop equipment is absolutely necessary. It is not allowed to clean the units with water or jet steam (high-pressure cleaner).

9.1. Engine
See engine operating instructions. Battery Maintenance: The battery surface must always be kept dry and clean, otherwise leak currents may develop which can discharge the battery. Every 250 service hours, check the battery and the cable connections for perfect fit and good condition of the contact areas. Use battery grease to protect the terminal heads and the terminals against corrosion. Additional maintenance work for batteries with inspection plugs Check battery fluid level at regular intervals. If the level is too low, top up battery with distilled water only (by no means acid). Batteries generate explosive gases. Keep them away from naked flame and sparks which could cause them to ignite; smoking is prohibited ! The liquid electrolyte is dangerous for the skin and especially for the eyes. Rinse off splashes of acid immediately and thoroughly. If necessary, consult a doctor. When handling liquid electrolyte, use gloves and protective goggles. Do not place tools on the battery.

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Armaturenkasten Instrument box Boitier de bord

10. Circuit diagrams

10.1. Electrical components on the engine

Display board 05092100

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STARTEINRICHTUNG BERWACHUNG UND ANZEIGE MOTORABSTELLUNG

STROMVERSORGUNG / LADEEINRICHTUNG

POWER SUPPLY / Charging device Alimentation electr. / Chargeur

Starting device Dispo. de demarr.

Monitoring + display Surveillance + temain

Engine shut-down Arret du moteur


Hinweis: Jede nderung der Verdrahtung erfordert eine Rcksprache mit dem Werk! Intruction: Any change in wiring requires a consultation with the factory! Remarque: Avant de modifier le cablage, contacter lusine!

Smtliche Leitungen ohne Querschnittsangabe sind 1 mm2 All wires without conductors cross section data are 1 mm2 Tout les cables sans indication de section sont de 1 mm2

Key for the electrical components on the engine


CODE G1 G3 M1 K9 R5 S1 S6 S7 S8 X1 Y4 BEZEICHNUNG Batterie Ladeeinrichtung im Generator Startermotor im Generator Start-Hochstromrelais Vorwiderstand mit Thermozeitschalt. Glhstartschalter Temperaturschalter fr Motortemperatur ldruckschalter Druckschalter fr Luftfilter Klemmleiste fr Armaturenkasten Kraftstoffabsperrventil DISIGNATION Battery Charger part of the alternator Starter motor integratet in the alternator High-current start relais Series resistor with thermostat. Glow starting switch Temperature Switch for engine temperature Oil pressure switch Pressure switch for airfilter Terminal strip at instrument box Fuel shut off valve DESIGNATION Batterie Chargeur dans l'alternateur Demarreur electrique dans l'alternateur Relais de dmarrage pour cournat fort Switch Pre-resistance avec interr. Thermo. Contact a cle avec prechauff. Interrupteur de temprature culasse Transmetteur de pression dhuile Interrupteur de colmatage du filtre a air Bornier au tableau de bord Electro-vanne darret du carburant

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10.2. Circuit diagram of electric power generator - three-phase current with 400 V (380 V) (for inductive load)

400 V, 15.2 A

400 V, 15.2 A

400 V, 15.2 A

10.3. Circuit diagram of electric power generator - 3 x single-phase current with 231 V (for inductive or ohmic load)

231 V, 15.2 A 231 V, 15.2 A 231 V, 15.2 A

10.4. Circuit diagram of electric power generator - single-phase current with 231 V (for ohmic load)

U / V / W = induction coils in generator L / L1 / L2 / L3 = outer conductors to consumers N = neutral (PEN conductor) PE = equipotential bonding conductor

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10.5. Circuit diagram 400 V / 231 V - fittings

10.6. Circuit diagram - starter


Starter Battery charger

n<350 rpm

n<350 rpm

n<350 rpm

L1 - L3 = Starter windings D1 - D3 = Free wheeling diodes S1 - S6 = Magnetically actuated switches at n<350 rpm: sequence S1, S2, S3, S4, S5, S6, S1, S2,

n<350 rpm

n<350 rpm

n<350 rpm

L4 = Charging current winding D4 = Charging diode

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11. Residual risk for electric generating sets


Despite all quality control on raw materials, production and final build using the most up-to-date quality control methods there still remain residual risks in the operation of a gen set. After analysing the possible dangers the following could still be a risk or danger in operation. Interruption of the protective conductor Interruption of protective conductors within the switch box or an extension circuit may become dangerous for the operator of electric generating sets and consumers under unfavourable conditions. This is the case if two faults occur at any one time. In this connection faulty voltage of up to 400 V may occur. Reducing the residual risk in the electrical system The residual risk can be reduced by installing a ground-fault circuit interrupter or an insulation monitoring device. Dangers of injury due to heated or hot parts of the unit In the area where the exhaust gas is ventilated i.e. the muffler / exhaust temperatures of up to 300 C may occur depending on the load. Attention: The unit must be switched off before any work is carried out. Any internal work required on the generator unit must be carried out by an electrical specialist.

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12. Troubleshooting
Error: 100% unit capacity not reached Possible cause: Height above sea level > 300m Ambient temperature > 30 C Air humidity > 60% Extension cable too long or wire rating too small Motor is running at 3000 rpm but no voltage at the consumer No voltage at the socket Defective plug connection Defective connections Safety switch has been triggered Check and replace if necessary Push reset button (Reset). Determine and eliminate reason for tripping Consult electric specialist Consult electric specialist Solution:

Reduction of consumer capacity Shorter wires or larger wire rating

Defective wiring inside the generator Defective components inside the generator Voltage during idling too high or too low Correct voltage during idling but too low if loaded Incorrect engine speed

Check the speed, if required have it readjusted Reduce the load Check the speed, if required have it readjusted Check external connections See operating instructions of the engine See operating instructions of the engine Fix loose wires

Load too high Reduced speed for load

Voltage fluctuations

Improper contacts Fuel supply impaired Irregular rotation

Noise at the generator

Loose wiring

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13. Disassembly and assembly of the generator


The generator as such does not include any wearing parts. Should disassembly of the generator nevertheless become necessary, e.g. in conjunction with a repair to the motor, it is essential that the necessary work is performed according to the following illustrated description !

Disassembly and assembly may only be performed by specialists !

13.1. Disassembly

9x

641 520 00

M10x180

2x
M10x180

8x

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High magnetic forces are generated when the stator is separated from the rotor. Non-observance increases the risk of injury !

10

11

12

13
6x

14

19

13.2. Assembly

15

16

115 Nm 6x

17

18

19

20

21

46 Nm 2x

22

23

23 Nm

8x 46 Nm
!
High magnetic forces are generated when the stator is connected to the rotor. Non-observance increases the risk of injury !

20

24

25

26

27

28
DIESEL

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14. Spare parts for the generator


Tabl. No. 01

Starke magnetische Krfte knnen schwere Verletzungen verursachen! High magnetic force may cause serious injury! Force magntique leve peut causer de graves blessures!

!
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Fig.No.

HATZ Ident-No.

Stck Qty. PMG 10/2 H1 PMG 10/2 E1 1 1 1 1 1 7

Bemerkungen Notes

1 2 3 4 5 5 6

04221400 05262800 05233000 05259600 01729110 01744710 05233100

1 1 1 1 1 7

M10x200 with bore-hole for lead seal 165 mm

M 10 x 200

A3C

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Tabl. No. 02

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Fig.No.

HATZ Ident-No.

Stck Qty. PMG 10/2 H1 PMG 10/2 E1 1 8 8 16 5 1 1 7 2 2 7 3 1 3 2 0...1 0...2 1 2 1 1 1 1 2 1 0...2 0...2 1

Bemerkungen Notes

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 D

01729202 01744801 ------------50145900 50145800 50208500 50175900 50526400 50526300 50135400 03414100 50029900 50135600 50149900 05234411 50145900 50540300 50190310 50170900 50462900 50540500 ------------------50485300 05234320 05234500 50533000 05244400 05245700 50052900 50533100 05251100 50094300 50002600 05251200

1 8 8 13 6 1 1 7 2 2 7 3 1 3 2 2 2 2 0...1 0...2 1 2 1 0...2 0...2 1

(Pos. 9-10, 13-27, 33-34) (Pos. 9-10, 13-24, 33-39, 44-91)

10,5 M10 8 M 8 x 30 M 20 x 1,5 M 20 x 1,5 M 8 x 20 11 x 18 x 44 M 10 x 55 10 M 10 x 30 10,5 M 10 x 180 21/15 6 M 6 x 20

DIN DIN DIN DIN

125 -St. A3C 934-8 A3C 128 - A3C 912-8.8 A3C

DIN 933 - 8.8 A3C DIN 931-8.8 A3C DIN 128 - A3C DIN 933-8.8 A3C DIN 125-St A3C DIN 933-8.8 A3C DIN 128-A3C DIN 6912-8.8 A3C

M 5 x 16

DIN 912-8.8 A3C

8,2 x 13 x 30 M 8 x 60 DIN 912-8.8

M5 5

DIN 934-8 A3C DIN 128-A3C

50223300 = Sealant Loctite 221, 50 ml

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Tabl. No. 03

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Fig.No.

HATZ Ident-No.

Stck Qty. PMG 10/2 H1 PMG 10/2 E1 3 9 3 9 3 6 3 3 3 3 3 3 3 3 3 6 6 3 6 6 6 1 2 3 1 2 1

Bemerkungen Notes

44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

50023200 50170900 50170700 50144500 05244900 05244800 05244600 50092100 05245500 50213200 50129500 05245400 05245200 05245300 05244700 05244500 50148100 50533700 01745100 ------------------------------------------------05246800 ------50328300 50361800 50135600 50145900 05245100 05235000 05245000

BM 8 6 M 6 x 16 6,4 M 6 x 25,5 6,2 x 17 x 2 6,2 x 8 x 8 M 6 x 25 M 6 x 45 M8 8,2 x 17 x 8

DIN DIN DIN DIN

439-5 A3C 128 - A3C 912-8.8 A3C 125-St. A3C

DIN 933-8.8 A3C DIN 912-8.8 A3C DIN 985-8 A3C

M 8 x 16 8,2 x 17 x 2 8,4 M 8 x 65 (Pos. 63-73)

DIN 125-St A3C DIN 933-8.8

VM 6 M 10 x 50 10 10,5

DIN DIN DIN DIN

980-8 A3C 912-8.8 A3C 128-A3C 125-St A3C

10,2 x 12 x 9

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Tabl. No. 03

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Fig.No.

HATZ Ident-No.

Stck Qty. PMG 10/2 H1 PMG 10/2 E1 2 1 2 4 6 9 4 2 6 3 6 3

Bemerkungen Notes

80 81 82 83 84 85 86 87 88 89 90 91

50145800 50023800 50532800 50208500 50148000 50148100 05244500 03814200 03814200 50532900 05245600 50208500

M 10 BM 10 M 8 x 50 8 M8 8,4 8,2 x 17 x 2

DIN DIN DIN DIN DIN DIN

934-8 A3C 439-A3C 933-8.8 A3C 128-A3C 934-8 A3C 125-St A3C

DIN 128-A3C

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