installation manual

INSTALLATION

MANUAL

A new standard of reliability

Not intended for use in critical life support applications!

OUTDOOR INSTALLATION ONLY!

This manual should remain with the unit.

INTRODUCTION

Thank you for purchasing this model of the standby generator set.

Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest

Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death.

After this heading, read instructions that, if not strictly complied with, could result in serious personal injury, including death.

After this heading, read instructions that, if not strictly complied with, might result in minor or moderate injury.

NOTE:

After this heading, read instructions that, if not strictly complied with, may result in damage to equipment and/or property.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each indicates is as follows:



This symbol points out important safety information that, if not followed, could endanger personal safety and/or property of others.



This symbol points out potential explosion hazard.



This symbol points out potential fire hazard.



This symbol points out potential electrical shock hazard.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, contact a Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

When contacting a Dealer about parts and service, always supply the complete Model number, Serial number and Type Code (where applicable), of the unit as given on the Data Label affixed to the unit.

Table of Contents

Liquid-cooled Generators

INTRODUCTION ........................Inside Front Cover

Read this Manual Thoroughly .......................................... IFC

How to Obtain Service .................................................... IFC

SAFETY RULES ...................................................... 2

GENERAL INFORMATION ...................................... 4

Generator Installation ............................................................... 4

Before Installation .................................................................... 4

Other Published Standards ................................................. 4

Generator Location ................................................................... 5

Generator Mounting and Support ............................................. 5

Combustible Floor and Roof Protection .............................. 5

Unpacking ................................................................................ 5

Inspection.......................................................................... 5

Lifting the Generator ................................................................ 5

External Muffler or Catalyst Installation ..................................... 6

Muffler Assembly directions............................................... 6

Fuel Systems ........................................................................... 6

Introduction to Gaseous Fuel Systems ............................... 6

Properties of Gaseous Fuels .............................................. 6

The Natural Gas System .................................................... 6

LP Gas Vapor Withdrawal System ...................................... 7

Gaseous Fuel System Piping .............................................. 8

Calculating Volumetric Flow Rate and Pipe Size ........................ 8

Calculating Volumetric Flow Rate ....................................... 8

Calculating Pipe Size ......................................................... 9

Electrical Connections ............................................................ 11

Grouding the Generator .................................................... 11

Battery Charger Connection ............................................. 11

Battery Installation ................................................................. 11

Connection Diagrams ............................................................. 12

R-series Panel Connections ............................................. 12

H-100 Series Panel Connections ...................................... 13

G-series Panel Connections ............................................. 13

Block Heater Connections ................................................ 13

Wire Recommendations/Sizing ............................................... 13

NOTES ................................................................................... 17

1

IMPORTANT SAFETY INSTRUCTIONS




SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.



SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation of the generator and batteries.







WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.





WARNING:

This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.



Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive.

If using a procedure, work method or operating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique that chosen does not render the generator unsafe.



GENERAL HAZARDS



•

•

•

•

•

•

•

For safety reasons, the manufacturer recommends that the installation, initial start-up and maintenance of this equipment is carried out by an Authorized Service Dealer.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally fatigued.

Inspect the generator regularly, and contact the nearest

Authorized Service Dealer immediately for parts needing repair or replacement.

Inspect the generator regularly, and contact the nearest

Authorized Service Dealer immediately for parts needing repair or replacement.

Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

DANGER



Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.



Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.



Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.



Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death.



ENGINE EXHAUST HAZARDS



•

•

•

•

Generator engine exhaust contains DEADLY carbon monoxide, an odorless, colorless poisonous gas. Breathing carbon monoxide can cause: dizziness, throbbing temples, nausea, muscular twitching, headache, vomiting, weakness and sleepiness, inability to think clearly, fainting, unconsciousness or even death. If you experience any carbon monoxide poisoning symptoms, move into fresh air and immediately seek medical attention.

Never operate the generator set with the vehicle inside any garage or other enclosed area.

Adequate, unobstructed flow of cooling and ventilating air is critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compartment and for proper generator operation. Without sufficient cooling airflow, deadly carbon monoxide gas can accumulate and the engine/generator may quickly overheat, causing serious damage to the generator. Do not operate the genset in any confined space.

The exhaust system must be installed in accordance with the genset installation manual. Do not alter the installation or permit even partial blockage of ventilation systems, as this can seriously affect the safe and proper operation of the generator.

2

IMPORTANT SAFETY INSTRUCTIONS


•

•

Do not operate the generator if the exhaust system is leaking or has been damaged or if you have experienced carbon monoxide poisoning symptoms during use. Shut down the generator and do not operate it until it has been inspected and/or repaired.

Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector.

•

•

•

•

•



ELECTRICAL HAZARDS



The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

During installation onto the vehicle, have the generator properly grounded (bonded) either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped.

DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID

DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.



FIRE HAZARDS



•

•

For fire safety, the generator must be installed and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.

Keep a fire extinguisher in the vehicle at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system. Keep the extinguisher properly charged and be familiar with its use. If there are any questions pertaining to fire extinguishers, consult the local fire department.

•

•

•



EXPLOSION HAZARDS



Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

Gasoline is extremely FLAMMABLE and its vapors are

EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gasoline.

This generator may use liquid propane (LP) gas as a fuel. LP gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion.

3

General Information


GENERATOR INSTALLATION

This equipment is a liquid-cooled, engine-driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor installation only.



If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy.

BEFORE INSTALLATION

Before installing this equipment, check the ratings of both the generator and the transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation Method”.

The generator’s rated wattage/amperage capacity must be adequate to handle all electrical loads that the unit will power. The critical (essential) loads may need to be grouped together and wired into a separate “emergency” distribution panel.

DANGER



Connecting this generator to an electrical system normally supplied by an electric utility shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating.

Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy.



If an open bottom is used, the engine-generator is to be installed over non-combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set.

Only authorized dealers or qualified, competent installation contractors, or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation.



After the system has been installed, do nothing that might render the installation in noncompliance with such codes, standards and regulations.

NFPA STANDARDS

The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection

Association (NFPA), Batterymarch Park, Quincy, MA 02269:

•

•

•

•

•

•

•

•

NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS

TURBINES

NFPA No. 54, NATIONAL FUEL GAS CODE

NFPA No. 58, LIQUEFIED PETROLEUM GAS CODE

NFPA 70, NATIONAL ELECTRIC CODE (NEC)

NFPA 99, STANDARD FOR HEALTH CARE FACILITIES

NFPA 101, LIFE SAFETY CODE

NFPA 110, STANDARD FOR EMERGENCY AND STANDBY

POWER SYSTEMS

NFPA 220, STANDARD TYPES OF BUILDING CONSTRUCTIN

NOTE:

It is essential to use the latest version of any standard to ensure that the generator and its accessories comply with all the applicable standards and local codes.

OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is available:

•

•

•

•

Article X, NATIONAL BUILDING CODE, available from the

American Insurance Association, 85 John Street, New York,

N.Y. 10038.

AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy Council, 909 University Avenue, Columbia, MO,

65201.

ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM

STANDBY ELECTRIC POWER, available from the American

Society of Agricultural Engineers, 2950 Niles Road, St. Joseph,

MI 49085.

A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS,

FIREPLACES AND VENTING SYSTEMS, available from the

American National Standard Institute, 1430 Broadway, New

York, N.Y. 10018.

NOTE:

It is essential to use the latest version of any standard to ensure that the generator and its accessories comply with all the applicable standards and local codes.

The installer must comply with all applicable state and local codes.

4



GENERATOR LOCATION

Install the generator set, in its protective enclosure outdoors, where adequate cooling and ventilating air always is available.

Consider these factors:

•

•

•

•

•

•

•

Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.

Install the generator on high ground where water levels will not rise and endanger it.

This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around.

Allow sufficient room on all sides of the generator for maintenance and servicing. This unit must be installed in accordance with current applicable NFPA 37 and NFPA 70 standards, as well as any other federal, state and local codes for minimum distances from other structures.

Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds.

Install the generator as close as possible to the transfer switch.

This reduces the length of wiring and conduit.

Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT

LAWS OR CODES MAY REGULATE THE DISTANCE.

GENERATOR MOUNTING AND

SUPPORT

A CONCRETE BASE:

When designing a concrete base slab, all federal, state and local codes should be followed. Special attention should be given to the concrete base slab which should exceed the length and width of the generator by a minimum of six (6) inches (0.152 meters) on all sides.

Retain the generator compartment to the concrete slab with masonry bolts.

COMBUSTIBLE FLOOR AND ROOF PROTECTION

If the generator must be installed on any combustible floor or roof, comply with the following rules:

•

•

Place a layer of non-combustible insulation, followed by a layer of sheet metal beneath the unit’s mounting base rails (Figure

1.1).

Both the layer of insulation and the sheet metal must extend beyond the generator base to a distance of at least 12 inches

(30.5 cm) on all sides.

For rooftop or building structure mounting, it is recommended that spring isolators be installed between the engine frame and the mounting system. A minimum of six (6) isolators are required and must be located at the front and rear cross members and the center of the frame.

Figure 1.1 — Combustible Floor and Roof Protection

Since the entire bottom of the genset is now exposed, it should be covered with a metal plate to keep out small animals and protect the integrity of the internal parts of the genset. Genset movement is more intense with spring isolation, so flexible connections for the fuel and the electrcal conduits are also required.

NOTE:

Consult the local building codes which may vary.

UNPACKING

UNPACKING PRECAUTIONS

Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton.

INSPECTION

After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consignor’s memo of loss or damage.

LIFTING THE GENERATOR



When lifting or hoisting equipment is used, be careful not to touch overhead power lines. The generators weight of more than 900 pounds requires proper tools, equipment, and qualified personnel to be used in all phases of handling and unpacking.

5



EXTERNAL MUFFLER OR CATALYST

INSTALLATION

If the generator requires an external catalyst (shipped loose in a kit), follow the instructions provided with the Catalyst Kit or

Owner's Manual. If the generator requires an external muffler

(shipped loose in a kit), follow these installation instructions.

MUFFLER ASSEMBLY DIRECTIONS

1. Slip item 3 over the exhaust pipe which extends though the exhaust duct and secure with clamp (item 2) (see Figure

1.2).

2. Assemble item 5A to item 5B using six (6) screws (item 4).

3. Secure the item 5 assembly to the generator using four (4) screws (item 4).

4. Secure item 6 to the item 5 assembly using four (4) screws

(item 4).

5. Slip item 1 over item 3 and tighten.

Figure 1.2 — Muffler Extension Installation

FUEL SYSTEMS

6

INTRODUCTION TO GASEOUS FUEL SYSTEMS

DANGER



Gaseous fuels, such as LP and natural gas, are highly volatile and their vapors are explosive.

LP gas is heavier than air and will settle in low areas. Natural gas is lighter than air and will settle in high areas. Even the slightest spark can ignite these fuels and cause an explosion.

For safety, all codes, standards and regulations pertaining to the installation and use of gaseous fuels must be strictly complied with.

Local fuel gas codes may vary widely. For that reason, it is recommended that a local gas distributor or installer be consulted when installing a gaseous fuel supply system.

In the absence of local fuel gas codes and regulations, booklets published by the National Fire Protection Association (NFPA) may be used as sources of information.

PROPERTIES OF GASEOUS FUELS

Natural Gas

Natural gas is lighter than air. It is found in the gaseous state at normal ambient temperatures and pressures. It is highly explosive and can be ignited at the slightest spark. For that reason, fuel lines must be free of leaks and adequate ventilation is absolutely essential.

Local fuel/gas codes usually dictate the maximum pressure at which natural gas can enter a structure. In order to reduce the gas pressure to that required by law, a PRIMARY REGULATOR is required.

LP Gas

Liquefied petroleum (LP) gas is heavier than air. The gas vapors are explosive and, like natural gas, can be ignited by the slightest spark.

LP tank pressure is dependent on the ambient temperature and can be as high as 200 psi. A primary regulator is required at the tank to reduce the pressure to the required five to 14 inches of water column for units less than 70kW, or 11 to 14 inches of water column for units 70kW and larger.

THE NATURAL GAS SYSTEM

A typical natural gas system is shown in Figure 1.2, below. The maximum pressure at which the gas can enter a building is established by code and may vary from area to area. A primary regulator is required to reduce gas supply pressures to the required safe level before the gas enters a structure.

The primary regulator may or may not be provided by the gas supplier. The gas distribution company will usually provide piping from the main distribution line to the generator site. It is the responsibility of the gas supplier to ensure that sufficient gas pressure is available to operate the primary regulator.

From the primary regulator, gas flows to the generator connection.

A flexible length of gas line is required between rigid piping and the gas connection at the generator. The generator fuel system consists of an electrical fuel shutoff valve/regulator assembly and a gas actuator.

The secondary regulator reduces gas pressure to about five inches of water column before the gas Is delivered to the actuator.

NOTE:

Gas pressure from the primary regulator (supplied by the installing contractor) to the generator's fuel shutoff valve should not exceed 14 inches of water column.



Figure 1.2 — Typical Natural Gas System

Primary Regulator

(Supplied by

Installing

Contractor)

Generator Base Gas Actuator

Flex Fuel Line

(Supplied with Unit)

Fuel Shutoff/Regulator

Assembly

11 - 14” Water Column

Recommended (> = 70kW)

5 - 14" Water Column

Recommended (< 70kW)

Manual Shutoff

Valve

Follow the local codes on selecting the required AGA approved, and UL listed, for NG application flexible portion of the fuel line

(supplied by the installing contractor).

LP GAS VAPOR WITHDRAWAL SYSTEM

This type of system utilizes the vapors formed above the liquid fuel in the supply tank (see Figure 1.3). Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. Gas pressure requirements for an LP vapor system at the frame of the generator are the same as those listed for natural gas in "The Natural Gas System". See Table 1 for information regarding the vapor capacity of LP tanks. The installer should be aware of the following:

•

•

•

When ambient temperatures are low and engine fuel consumption is high, the vapor withdrawal system may not function efficiently.

Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume.

In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect.

Figure 1.3 — Typical LP Gas Vapor Withdrawal System

Manual Shutoff Valves

Generator Base

Fuel

Tank

Primary Regulator

(Supplied by

Installing

Contractor)

Flex Fuel Line

(Supplied with Unit)

Gas Actuator

Fuel Shutoff/Regulator

Assembly

11 - 14” Water Column

Recommended (> = 70kW)

5 - 14" Water Column

Recommended (< 70kW)

7



GASEOUS FUEL SYSTEM PIPING

NOTE:

The information below is to assist in planning gaseous fuel installation. In NO WAY should this information be interpreted to conflict with applicable fuel gas codes. Contact the local jurisdiction if questions arise.

The following general rules apply to piping used in gaseous fuel systems:

•

•

The piping should be of black iron, rigidly mounted and protected against vibration.

Install the supplied length of flexible hose between the generator connection point and rigid piping.



The supplied flexible hose is not to be installed underground or in contact with ground. The flexible hose is for in-line installation only. Bends, kinks or off-center in-line installation of flexible hose is NOT allowed.

•

•

•

Piping must be of the correct size to maintain the required supply pressures and volume flow under varying conditions (see

Calculating Volumetric Flow Rate and Pipe Size).

Installed piping must be properly purged and leak-tested, in accordance with applicable codes and standards.

Use an approved pipe sealant or joint compound on all threaded fittings, to reduce the possibility of leakage.

NOTE:

In the absence of local purging and leak test standards, NFPA

No. 54 may be used as a guide.

CALCULATING VOLUMETRIC FLOW

RATE AND PIPE SIZE

If the Owner's Manual identifies the fuel consumption requirements by a volumetric flow rate (units of ft

3

/hr), skip the next section and go on to the section, Calculating Pipe Size. If the Fuel Consumption requirements are given in units of lb/hr, follow the next section,

Calculating Volumetric Flow Rate.

CALCULATING VOLUMETRIC FLOW RATE

Since the fuel consumption requirements (from the owners manual) are given as a mass flow (units of lb/hr), the volumetric flow rate (ft

3

/hr) must be identified before the appropriate pipe size can be selected. The relationship between the mass flow rate

(lb/hr), density (lb/ft

3

), and volumetric flow rate (ft

3

/hr) can be described by Equation 1. According to Equation 1, the volumetric flow rate can be calculated by dividing the mass flow rate by the density. You may need to contact your fuel vendor to identify the density or specific gravity for your fuel. If your vendor provides the specific gravity (relative to air) Table 1 can be used to identify the appropriate density. Since the density of natural gas and LP is temperature dependant, the maximum temperature of the fuel (at the fuel shutoff/regulator assembly) should be measured so the fuel consumption requirements can be more accurately identified for the generator. A sample calculation (Example 1) is included in this section.

Equation 1:

ν •

=

Where:

ν = Volumetric Flow Rate (ft

3

/hr) ṁ = Mass Flow Rate (lb/hr)

p = Density from Table 1 -

—

C

TABLE 1

Specific

Gravity(1)

0.5

0.55

0.6

0.65

0.7

Multiplier

1.1

1.04

1

0.962

0.926

Density lb/ft

0.0383

0.0421

0.0459

0.0497

0.0536

0.8

0.9

0.867

0.817

0.0612

0.0689

Note 1: Relative to air at 30 inches Hg, 60°F

3

8

Specific

Gravity(1)

1

1.2

1.4

1.5

1.7

1.9

2.1

Multiplier

0.775

0.707

0.655

0.633

0.594

0.565

0.535

Density lb/ft

3

Pressure Drop

0.0765

0.0918

0.1072

0.1148

0.1301

0.1454

0.1607

0.1

0.2

0.3

0.5

1

2

5

Multiplier

0.577

0.815

1

1.29

1.83

2.58

4.08



C = 11111 (for Natural Gas) or 3333 (for LP)

T = Temperature of the fuel into the fuel shut-off/regulator

Example 1: Determine the volumetric flow rate for a generator that requires 91.34 lb/hr of natural gas at 100% load.

Solution:

Specific gravity according to the local vendor: 0.5

Density of Natural Gas from Table 1: 0.0383 lb/ft3

Maximum Temperature of the fuel going into the generator: 90°F

C=11111 (for Natural Gas) from Equation 1

ν

=

Thus:

•

ν

=

And:

and

ν

•

= 2566 ft

3

/hr

ṁ = 91.34 lb/hr

p = 0.0383 -

(90-60)

—

11111

p = 0.0356 lb/ft

3

CALCULATING PIPE SIZE

Now that the volumetric flow rate has been identified, the minimum pipe size can be determined by using Table 2. This table is based on a specific gravity of 1.00 (specific gravity of air). For that reason, a correction is required when the fuel used has a different specific gravity. The fuel’s specific gravity can be obtained from the fuel supplier. The table is also based on a pressure drop of

0.3, which allows for a nominal amount of restrictions from bends, fittings, etc. Example 2 illustrates how to calculate the pipe size for the generator.

Example 2: Determine the iron pipe size for a generator that requires 2566 ft

3

/hr of Natural Gas. The unit is located 75 feet from the fuel source.

Solution:

Specific gravity of natural gas according to the local vendor: 0.5

Multiplier for the given specific gravity from Table 1: 1.1

According to Table 2, a 2-1/2 inch pipe will deliver 1750 ft^3/hr of air if it is located 75 feet from the fuel source. To determine the volumetric flow rate of natural gas, multiply the given flow rate by the multiplier (from Table 1).

Natural gas flow rate = air flow rate (ft

3

/hr) * Multiplier

= 1750 ft

3

/hr * 1.10

Natural gas flow rate = 1925 ft

3

/hr

Since the flow rate through a 2-1/2 inch iron pipe is less than the flow rate required by the generator (2430 ft

3

/hr), we must evaluate the next larger pipe (3 inches) by the same method.

TABLE 2

Length of Pipe

(In Feet)

120

150

180

210

240

270

300

450

600

60

75

90

105

15

30

45

1/2”

76

52

43

38 86

77

70

65

3/4”

172

120

99

120

109

100

92

173

155

141

131

1”

345

241

199

270

242

225

205

190

178

170

140

119

1-1/4”

750

535

435

380

345

310

285

320

300

285

270

226

192

Iron Pipe Size (IPS Inches)

1-1/2”

1220

850

700

2”

2480

1780

1475

2-1/2”

3850

2750

2300

610

545

490

450

420

380

350

1290

1120

1000

920

860

780

720

2000

1750

1560

1430

1340

1220

1120

660

620

580

545

450

390

1030

970

910

860

710

600

2300

2090

1950

1780

1680

1580

1490

1230

1030

3”

6500

4700

3900

3450

3000

2700

2450

13680

12240

11160

10330

9600

9000

8500

7000

6000

6”

38700

27370

23350

19330

17310

15800

14620

4800

4350

4000

3700

3490

3250

3000

2500

2130

4”

13880

9700

7900

6800

6000

5500

5100

27920

25000

22800

21100

19740

18610

17660

14420

12480

8”

79000

55850

45600

39500

35300

32250

29850

9



TABLE 3 — VAPOR CAPACITY OF PROPANE STORAGE TANKS

To Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature (40º, 20º or 0º F) that the generator would be operating in. The third column (tank capacity) will give the required tank size to continually produce the given fuel flow.

Max kW

Vapor

30

Minimum

Temp

40

Operating

Hours @

Max kW

24

Tank Capacity

(Gallons)

Length

Inches

Dia

Inches

Overall

Ht. Inches

20 20 35 120 57 24 33

10 0

40 35

67

26

25 20 36 150 68 24 33

12

60

0

40

72

26

40 20 38 250 94 30 39

20

80

0

40

74

26

50 20 40 325 119 30 39

25

100

0

40

77

31

60 20 51 500 119 37 46

30

150

100

50

170

120

60

0

40

20

0

40

20

0

100

35

53

105

36

51

103

850

1000

165

192

41

41

50

50

Propane storage tanks can provide either a liquid or a vapor supply to the generator. The above chart is for vapor withdrawal only and provides the kW output or amount of vapor that can be withdrawn at a given temperature while keeping the temperature of the liquid above the boiling point. If the withdrawal rate is too high, the LP temperature goes below the boiling point, the pressure drops to zero and no vapor can be withdrawn. A primary regulator is also required at the tank to reduce the line pressure to the generator to 5-14 inches of water column.

Propane Conversions: 36.38 ft

3

= 90,500 btu = 1 gal • 1lb = 21,500 btu = 8.56 ft

3

Figure 1.6 — Propane Storage Tank

10



Natural gas flow rate = air flow rate (ft

3

/hr) * Multiplier

= 3000 ft

3

/hr * 1.10

Natural gas flow rate = 3300 ft

3

/hr

A 3 inch pipe is required at the given distance of 75 feet. Pressure drop does not have to be considered unless an unusual number of fittings, bends or other restrictions are used. In such unusual cases, the fuel supplier will usually specify which multiplier is applicable.

NOTE:

The installed piping system shall be capable of providing the

Fuel Consumption requirements as identified in the specifications section of the Owners Manual.

ELECTRICAL CONNECTIONS

GROUNDING THE GENERATOR

A GROUNDING LUG is provided on the generator mounting base for the purpose of grounding the frame and the external electrically conductive parts of this equipment to an approved earth ground and/or grounding rods where required by the National Electrical

Code (Figure 1.4). Consult a qualified electrician for grounding requirements in the area. Grounding procedures must meet local regulations.

DANGER



Do not connect the ground wire to any pipe that carries a flammable or explosive substance –

FIRE or an EXPLOSION may result.

Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices.

Figure 1.4 – Generator Grounding Lug (typical)

GROUNDING

LUG

BATTERY CHARGER CONNECTION

The generator has been equipped with a battery charger installed in the control panel. Power leads for the charger have been run to the connection box (Figure 1.5). On units equipped with 2.5L engines, this connection is found in the control panel. The terminals will

need to be supplied from a 120VAC, 15 Amp circuit.

Refer to the Connection Diagrams section in this manual.

Figure 1.5 — Battery Charger Connection

Customer to provide

120 VAC

15 Amp

} {

Factory provided connection to battery charger in control panel.

BATTERY INSTALLATION

DANGER



Standby generators installed with automatic transfer switches will crank and start automatically when NORMAL (UTILITY) source voltage is removed or is below an acceptable preset level.

To prevent such automatic start-up and possible injury to personnel, do not connect battery cables until certain that normal source voltage at the transfer switch is correct and the system is ready to be placed into operation.



Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks or any spark producing tools or equipment near the battery.



Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protective goggles, protective clothing and gloves when handling a battery. If fluid is spilled, flush the affected area immediately with clear water.

11





Do not dispose of the battery in a fire. The battery is capable of exploding.



Do not open or mutilate the battery. Released electrolyte can be toxic and harmful to the skin and eyes.



The battery represents a risk of high short circuit current. When working on the battery, always remove watches, rings or other metal objects, and only use tools that have insulated handles.

VENTED BATTERIES



The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

•

•

•

•

Wear full eye protection and protective clothing,

Where electrolyte contacts the skin, wash it off immediately with water,

Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and

Spilled electrolyte is to be washed down with an acidneutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon

(4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased.

The resulting liquid is to be flushed with water and the area dried.



Lead acid batteries present a risk of fire because they generate hydrogen gas. The following procedure are to be followed:

•

•

•

DO NOT SMOKE when near batteries,

DO NOT cause flame or spark in battery area, and

Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

For recommended batteries, see the “Specifications” section in the Owner’s Manual. All batteries must be at 100 percent state-ofcharge before they are installed on the generator.

When using maintenance-free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in the “Maintenance” section in the Owner’s Manual. A negative ground system is used.

Battery connections are shown on the wiring diagrams. Make sure all batteries are correctly connected and terminals are tight.

Observe battery polarity when connecting batteries to the generator set.

12

NOTE:

Damage will result if the battery connections are made in reverse.

CONNECTION DIAGRAMS

All wiring in the standby electric power system must be in strict compliance with applicable codes, standards and regulations.

Such wiring must be properly supported, routed, and connected.

In addition, wiring must be properly sized to carry the maximum load current to which is will be subjected.

The connections between the generator and transfer switch will vary depending on the equipment ordered. In each case there are two types of interconnections, load wiring and control wiring.

NOTE:

Control wiring must always be run in a separate conduit from the load wiring.

DANGER



Make sure to turn OFF both the NORMAL

(UTILITY) and STANDBY (EMERGENCY) power supplies before trying to connect power source and load lines to the transfer switch. Supply voltages are extremely high and dangerous.

Contact with such high voltage power supply lines causes extremely hazardous, possibly lethal, electrical shock.



Be sure to maintain proper electrical clearances between live electrical parts and grounded metal. Allow at least one-half inch of clearance circuits up to 400 amps.

DANGER



Extremely high and potentially lethal supply voltages are present at the transfer switch when verifying phase rotation. This operation should only be performed by a trained electrician.

R-SERIES PANEL CONNECTIONS

The R-series generator consists of an AUTO/OFF/ MANUAL switch, a SET EXERCISE switch, and several fault indicator LEDs. See

Figure 1.7 on page 13 for an interconnection diagram. On units equipped with 2.5L engines, the control connections and main circuit breaker are found in the control panel. In this configuration the control wires consist of Utility 1 and Utility 2 (N1 and N2), and

23 and 194. See "Control Wiring" for control wire sizing recommendations.



DANGER



Make sure to turn OFF the NORMAL (UTILITY) power supply before trying to connect the Utility

1 and Utility 2 control wires. Supply voltages are extremely high and dangerous. Contact with such high voltage power supply lines causes extremely hazardous, possibly lethal, electrical shock.



Terminals 178 and 183 in the generator AC connection box are not used in this application.

Connection of any wires to these terminals may result in unwarrantable damage to the control board.

The load wires consist of wires run between the generator main circuit breaker and the transfer mechanism, and a neutral wire. See

"Wire Recommendations/Sizing" for load wire sizing information.

H-100 SERIES PANEL CONNECTIONS

An H-100 controlled generator is identified from the front of the control panel, which consists of a control panel with integrated dual LCD display and tactile keypad. See Figure 1.8 on page 15 for an interconnection diagram. In this configuration the control wires consist of RS485 + and RS485 - communication wires run in a shielded cable. See "Wire Recommendations/Sizing" for communication wire sizing and type recommendations.

NOTE:

RS485 communication wiring MUST consist of a 2 wire, twisted pair cable with overall screen.

NOTE:

The shield wire of the RS485 communication cable MUST be connected on one end only.



Terminals 0 and 183 in the generator AC connection box are not used in this application.

Connection of any wires to these terminals may result in unwarrantable damage to the control board.

The load wires consist of wires run between the generator main circuit breaker and the transfer mechanism, and a neutral wire. See

"Wire Recommendations/Sizing" for load wire sizing information.

G SERIES PANEL CONNECTIONS

A G Series (or PowerManager Digital Controller Platform™) controlled generator is identified from the front of the control panel, which consists of a touch screen. Contact an Authorized Dealer for interconnection diagrams.

BLOCK HEATER CONNECTIONS

Industrial generator models are equipped with a block heater and an AC outlet (Figure 1.9). The block heater will not function unless it is plugged into the AC outlet and the outlet is properly wired to an AC power supply (by the installer).

Block heater kits can be purchased at the authorized dealer if the generator is not already equipped.

Figure 1.9 — AC Outlet for Block Heater and

Battery Charger (to be wired by installer)

WIRE RECOMMENDATIONS/SIZING

(SEE TABLE 4 ON PAGE 16)

CONTROL WIRING

Control system interconnections on an R-series controlled generator consist of N1 and N2, and leads 23 and 194. Control system interconnection leads must be run in a conduit that is separate from the AC power leads. Recommended wire gauge size depends on the length of the wire:

Max. Cable Length

460 feet (140m)

461 to 730 feet (223m)

731 to 1,160 feet (354m)

1,161 to 1850 feet (565m)

Recommended Wire Size

No. 18 AWG.

No. 16 AWG.

No. 14 AWG.

No. 12 AWG.

LOAD WIRING

Power source and load line conductors must be properly supported, of approved insulative qualities, and of the correct wire gauge size.

When connecting power, source, and load lines remove surface oxides from stripped ends of conductors with a wire brush. Apply joint compound to stripped ends of conductors. Tighten terminals to the specified torque value, as given in the owner's manual for the transfer switch.

Recommended wire gauge size depends on the current rating of the generator main circuit breaker.

13



Figure 1.7 — R-series Panel Connections

QUIET TEST SERIES ENGINE

GENERATOR CONNECTION PANEL

BATTERY CHARGER

CONNECTIONS

LINE

NEU

GND 3 PHASE

ON

SINGLE PHASE

N1

N2

23

194

TB1

1

N1

UTILITY

2

N2

UTILITY

3

TRNS SW

WIRE 23

4

TRNS SW

WIRE 194

5

RM STRT

WIRE 183

6

RM STRT

WIRE 178

7

8

CUSTOMER

CONNECTION

E1 E2 (E3)

E1 E2

NEUTRAL BLOCK

TO 120VAC,

15 AMP CIRCUIT

NOTE:

178 AND 183

CONNECTIONS ARE

NOT USED IN THIS

APPLICATION

NOTE: E3, N3 AND T3 WIRES ARE ONLY

USED ON 3 PHASE SYSTEMS

POWER LEADS

TRANSFER SWITCH

LEADS

14



Figure 3.3 — H-100 Series Panel Connection

15



TABLE 4 — ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS RATED 0-2000 VOLTS, 60° TO 90° C (140° TO 194°

F). NOT MORE THAN THREE CONDUCTORS IN RACEWAY OR CABLE OR EARTH (DIRECTLY BURIED), BASED

ON AMBIENT TEMPERATURE OF 30° C (86° F) (REFERENCE NEC TABLE 310-16)

60° C

(140° F)

TYPES

TW¥, UF¥

24

260

280

320

355

385

400

410

435

455

495

520

545

560

—

—

20¥

25¥

30

40

55

70

85

95

110

125

145

165

195

215

14

12

10

8

6

4

3

2

1

1/0

2/0

3/0

4/0

250

300

350

SIZE

AWG

kcmil

18

16

400

500

600

700

750

800

900

1000

1250

1500

1750

2000

TEMPERATURE RATING OF CONDUCTOR

75° C

(167° F)

TYPES

FEPW¥

RH¥, RHW¥

THHW¥

THW¥

THWN¥

XHHW¥

90° C

(194° F)

TYPES

TA, TBS, SA

SIS, FEP¥

FEPB¥

RHH¥, RHW2

THHN¥, THHW¥

THW2, THWN2

USE2, XHH

XHHW¥

XHHW2, ZW2

60° C

(140° F)

TYPES

TW¥

42

460

475

490

520

545

590

625

650

665

175

200

230

255

285

310

335

380

USE¥, ZW¥

COPPER

—

—

20¥

25¥

35¥

50

65

85

100

115

160

150

14

18

25¥

30¥

40¥

55

75

95

110

130

150

170

195

225

260

290

320

350

380

430

475

520

535

555

585

615

665

705

735

750

UF¥

75° C

(167° F)

TYPES

RH¥, RHW¥

THHW¥

THW¥

THWN¥

XHHW¥

SIZE

90° C

(194° F)

TYPES

TA, TBS

SA, SIS,

THHN¥

THHW¥

USE¥

THW2, THWN2

RHH¥, RHW2

USE2

XHH, XHHW

XHHW2, ZW2

ALUMINUM OR COPPER CLAD ALUMINUM

—

—

—

20¥

25

30

40

55

65

75

85

100

115

130

150

170

190

210

225

260

285

310

320

330

355

375

405

435

455

470

230

250

270

310

340

375

385

395

425

445

485

520

545

560

—

—

—

20¥

30¥

40

50

65

75

90

100

120

135

155

180

205

255

280

305

350

385

420

435

450

480

500

545

585

615

630

—

—

—

25¥

35¥

45

60

75

85

100

115

135

150

175

205

230

AWG

900

1000

1250

1500

1750

2000

300

350

400

500

600

700

750

800

3

2

1

1/0

2/0

3/0

4/0

250

10

8

6

4

—

—

—

12

¥ Unless otherwise specifically permitted in the NEC, the overcurrent protection for conductor types marked with an ¥ shall not exceed 15 amperes for No.

14, 20 amperes for No. 12, and 30 amperes for No. 10 copper; or 15 amperes for No. 12 and 25 amperes for No. 10 aluminum and copper-clad aluminum after any correction factors for ambient temperature and number of conductors have been applied.

16

Notes

17

Part No. 0H2649 Revision B (08/14/09) Printed in U.S.A.

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