Cummins Onan ES 20 ES generator set Installation Manual

20 ES
GENERATOR SET
Printed in U.S.A.
9280601
595
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by any means, is strictly prohibited.
Table of Contents
SECTION
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii, iv
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3
MOUNTING THE GENERATOR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Access to Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
MECHANICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
4-1
4-1
4-5
4-6
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3-1
3-1
3-2
3-4
3-4
5-1
5-1
5-2
5-3
PRESTART PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
6-1
6-1
6-1
6-1
6-1
6-1
6-1
6-1
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SECTION
7
TITLE
PAGE
INITIAL START AND CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Meters (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Monitor Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
7-1
7-2
7-2
7-2
7-2
7-3
7-3
7-3
7-3
INSTALLATION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Prestart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
8-1
8-1
8-1
8-1
8-2
8-2
8-2
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Safety Precautions
• Be sure battery area has been well-ventilated
Before operating the generator set, read the Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated and maintained. Many accidents are caused
by failure to follow fundamental rules and precautions.
prior to servicing near it. Lead-acid batteries
emit a highly explosive hydrogen gas that can
be ignited by arcing, sparking, smoking, etc..
EXHAUST GASES ARE DEADLY
• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and
audibly inspect the exhaust daily for leaks per
the maintenance schedule. Ensure that exhaust manifolds are secured and not warped.
Do not use exhaust gases to heat a compartment.
• Be sure the unit is well ventilated.
The following symbols, found throughout this
manual, alert you to potentially dangerous conditions to the operator, service personnel, or the
equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
• Engine exhaust and some of its constituents
are known to the state of California to cause
cancer, birth defects, and other reproductive
harm.
CAUTION
This symbol refers to a hazard or unsafe practice which can result in personal injury
or product or property damage.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result from improper practices.
•
• DO NOT fill fuel tanks while engine is running,
unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust
is a potential fire hazard.
•
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
•
• Fuel lines must be adequately secured and
free of leaks. Fuel connection at the engine
should be made with an approved flexible line.
Do not use copper piping on flexible lines as
copper will become brittle if continuously vibrated or repeatedly bent.
•
• Be sure all fuel supplies have a positive shutoff
valve.
from moving parts.
Before starting work on the generator set, disconnect battery charger from its AC source,
then disconnect starting batteries, negative (-)
cable first. This will prevent accidental starting.
Make sure that fasteners on the generator set
are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts,
etc.
Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry
can become caught in moving parts. Jewelry
can short out electrical contacts and cause
shock or burning.
If adjustment must be made while the unit is
running, use extreme caution around hot manifolds, moving parts, etc.
LS-11a
iii
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GENERAL SAFETY PRECAUTIONS
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
•
Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or
heat exchanger pressure cap while the engine
is running. Allow the generator set to cool and
bleed the system pressure first.
•
Benzene and lead, found in some gasoline,
have been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. When checking, draining or adding
gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
•
Used engine oils have been identified by some
state or federal agencies as causing cancer or
reproductive toxicity.
When checking or
changing engine oil, take care not to ingest,
breathe the fumes, or contact used oil.
• DO NOT CONNECT GENERATOR SET DI-
•
RECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from
the generator set into the utility line. This
creates a potential for electrocution or property
damage. Connect only through an approved
isolation switch or an approved paralleling device.
Provide appropriate fire extinguishers and
install them in convenient locations. Consult
the local fire department for the correct type of
extinguisher to use. Do not use foam on electrical fires. Use extinguishers rated ABC by
NFPA.
•
Make sure that rags are not left on or near the
engine.
•
Remove all unnecessary grease and oil from
the unit. Accumulated grease and oil can
cause overheating and engine damage which
present a potential fire hazard.
•
Keep the generator set and the surrounding
area clean and free from obstructions. Remove any debris from the set and keep the floor
clean and dry.
•
Do not work on this equipment when mentally
or physically fatigued, or after consuming any
alcohol or drug that makes the operation of
equipment unsafe.
•
Substances in exhaust gases have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. Take
care not to breath or ingest or come into contact
with exhaust gases.
• Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on
dry wood platforms over floors that are metal or
concrete when around electrical equipment.
Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when
handling electrical equipment.
• Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by a qualified licensed electrician. Tag
and lock open switches to avoid accidental closure.
HIGH VOLTAGE GENERATOR SETS
(1.9kV to 15kV)
• High voltage acts differently than low voltage.
Special equipment and training is required to
work on or around high voltage equipment. Operation and maintenance must be done only by
persons trained and qualified to work on such
devices. Improper use or procedures will result
in severe personal injury or death.
• Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of high
voltage electrical equipment, induced voltage
remains even after the equipment is disconnected from the power source. Plan the time for
maintenance with authorized personnel so that
the equipment can be de-energized and safely
grounded.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
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1. Introduction
your nearest Cummins/Onan dealer or distributor
for assistance.
ABOUT THIS MANUAL
This manual provides installation instructions for
the ES generator set. This includes the following information:
Application and Installation
A standby power system must be carefully planned
and correctly installed for proper operation. This involves two essential elements: application and
installation.
Mounting Recommendations - Provides instructions for fastening generator set to base
and space requirements for normal operation
and service.
Mechanical Connections - Shows location of
connection points for fuel, exhaust, ventilation,
and cooling.
Electrical Connections – Shows location of
electrical connection points for the control,
generator, and starting system.
Prestart – Provides checklist of items or procedures needed to prepare generator set for operation.
Initial Startup – Describes test complete system to confirm proper installation, satisfactory
performance, and proper operation. Refer to
Operators Manual for troubleshooting information.
Application (as it applies to generator set installations) refers to the design of the complete standby
power system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and
fuel systems. Each component must be correctly
designed so the complete system will function as intended. Application and design is an engineering
function generally done by specifying engineers or
other trained specialists. Specifying engineers are
responsible for the design of the complete standby
system and for selecting the materials and products
required.
Installation refers to the actual set-up and assembly of the standby power system. The installers set
up and connect the various components of the system as specified in the system design plan. The
complexity of the standby system normally requires
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various
segments of the installation. This is necessary so
all components are assembled using standard
methods and practices.
Installation Checklist - Provides reference
checks upon completion of installation.
This manual DOES NOT provide application information for selecting a generator set or designing the
complete installation. If it is necessary to design the
various integrated systems (fuel, exhaust, cooling,
etc.), review standard installation practices, or
specify system materials, additional information is
required. For engineering data specific to the generator set, refer to the specification and product
data sheets. For application information, refer to
Application Manual T-030, ”Liquid Cooled Generator Sets”, available from Onan.
Safety Considerations
The generator set has been carefully designed to
provide safe and efficient service when properly
installed and operated. However, the overall safety
and reliability of the complete system is dependent
on many factors outside the control of the generator
set manufacturer. To avoid possible safety hazards, make all mechanical and electrical connections to the generator set exactly as specified in this
manual. All systems external to the generator (fuel,
exhaust, electrical, etc.) must comply with all applicable codes. Make certain all required inspections
and tests have been completed and all code requirements have been satisfied before certifying
the installation is complete and ready for service.
INSTALLATION OVERVIEW
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations
also cover factory designed options or modifications. However, because of the many variables in
any installation, it is not possible to provide specific
recommendations for every situation. If there are
any questions not answered by this manual, contact
1-1
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1-2
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2. Specifications
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Onan Modified Ford, 4-cylinder, LRG-423
FUEL
Fuel . . . . . . . . . . Natural gas, Propane, Unleaded Gasoline, or a combination of two fuels
Natural Gas Consumption at Full Load
60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 cfh (8.5 m/h)
50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 cfh (7.1 m/h)
Propane (Vapor) Consumption at Full Load
60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 cfh (2.9 m/h)
50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 cfh (2.4 m/h)
Gasoline Consumption at Full Load
60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 US gph (10.2 L/h)
50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 US gph (9.5 L/h)
Maximum Natural Gas or LPG Supply Pressure . . . . 12 inches (305 mm) Water Column
Natural Gas Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 inch NPT
Propane Vapor Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 inch NPT
LPG Liquid Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 inch NPT
Maximum Gasoline Fuel Pump Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 feet (0.9 m)
Gasoline Supply Hose I. D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5/16 inch
BATTERY
Required Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Recommended Battery Rating - Cold Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . 660
OIL AND COOLANT CAPACITY
Engine Oil Capacity (Includes Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 U.S. quarts (4.0 L)
Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 U.S. quarts (11.0 L)
TUNE-UP SPECS
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032 to 0.036 inches (0.8 to 0.9 mm)
IMPORTANT!
DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENERATOR SET. BE SURE TO CONSULT
LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING
YOUR CONSTRUCTION PLANS.
2-1
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2-2
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3. Mounting the Generator Set
•
•
•
•
•
GENERAL
Most generator set installations must be
engineered so the generator set will function
properly under the expected load conditions. Use
these instructions as a general guide only. Follow
the instructions of the consulting engineer when
locating or installing any components.
The
complete installation must comply with all local and
state building codes, fire ordinances, and other
applicable regulations.
Electrical connections
Accessibility for operation and servicing
Noise levels
Vibration isolation
LOCATION
Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and
exhaust. The set should be located as near as
possible to the main power fuse box.
Requirements to be considered prior to installation:
•
•
•
•
Discharge of exhaust gases
Level mounting surface
Adequate cooling air
Provide a location away from extreme ambient
temperatures and protect the generator set from
adverse weather conditions. An optional housing is
available for outside operation.
Adequate fresh induction air
Discharge of circulated air
3-1
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MOUNTING
FLAT WASHER
Generator sets are mounted on a steel skid that
provides proper support. The engine-generator
assembly is isolated from the skid frame by rubber
mounts that provide adequate vibration isolation for
normal installations. For critical installations, install
vibration isolators between the skid base and
foundation.
HEX NUT
SKID
Mount the genset on a substantial and level base
such as a concrete pad.
Use 3/4-inch diameter, anchored mounting bolts to
secure the generator set skid to the floor to prevent
movement. Secure the skid using a flat washer and
a hex nut for each bolt (Figure 3-1).
12 INCH
(305 mm)
MOUNTING BOLT
M1627
FIGURE 3-1. BOLT DIAGRAM
3-2
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THE MUFFLER IS SUPPORTED
INDEPENDENTLY OF THE ENGINE
AN EXHAUST THIMBLE IS USED
TO PASS THE EXHAUST PIPE
THROUGH A COMBUSTIBLE WALL
TRANSFER
SWITCH
FLEXIBLE
EXHAUST
TUBE
RADIATOR
DISCHARGE
AIR DUCT
CONTROL
PANEL
MANUAL GAS
SUPPLY SHUTOFF
VALVE
LINE
CIRCUIT
BREAKER
GAS
FILTER
FRESH
AIR FLOW
CRANKING
BATTERY
FLEXIBLE
GAS SUPPLY
HOSE
POWER SUPPLY AND
CONTROL WIRING ARE
ROUTED SEPARATELY
M-1896s
FIGURE 3-2. TYPICAL INSTALLATION
3-3
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4. Once the genset is in position, the isolators
may require adjusting so that the set is level.
The isolators are adjusted by inserting the
leveling bolt through the skid and into the
isolator (the leveling bolt’s locking nut should
be threaded up towards the bolt head).
ACCESS TO SET
Plan for access to the genset for servicing and
provide adequate lighting around the unit. For
convenience in general servicing such as the
radiator, fan belt and changing the crankcase oil,
the surface of the mounting base should be at least
6 inches (152 mm) above the floor.
The leveling bolt will adjust the clearance
between the top plate and the isolator base. A
nominal clearance of 0.25 inch (6 mm) or
greater is desired. This will provide sufficient
clearance for the rocking that occurs during
startup and shutdown. If the 0.25 inch (6 mm)
clearance is not present, turn the leveling bolt
until the desired clearance is achieved.
VIBRATION ISOLATORS
Installation and Adjustment Procedure
1. Place the vibration isolators (Figure 3-3) on the
genset support structure. The isolators should
be shimmed or grouted to ensure that all of the
isolator bases are within 0.25 inch (6 mm)
elevation of each other. The surface that the
isolator bases rest on must also be flat.
2. Loosen the side snubber lock nuts so that the
top plate of the isolator is free to move vertically
and horizontally. Be sure that the top plate is
correctly aligned with the base and springs.
3. Place the genset onto the isolators while
aligning the skid’s mounting with the threaded
isolator hole. The top plates will move down
and approach the base of the isolator as load is
applied.
5. The genset may not be level yet; therefore,
adjust the leveling bolts until the set is level and
sufficient clearance still remains. Once all
isolators have been set, lock the leveling bolt in
place with the lock nut.
6. The snubber nuts may remain loose and
therefore provide better isolation between the
genset and support structure.
GENSET SKID
LEVELING BOLT
LOCK NUT
0.25 INCH (6 mm)
CLEARANCE
SNUBBER
BASE
M1828-1s
M1828-1s
FIGURE 3-3. VIBRATION ISOLATORS
3-4
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4. Mechanical Connections
• Install a manual fuel shut-off valve at the outlet
GENERAL
of an above-ground fuel tank to facilitate service.
• For a combination gas/gasoline set, provide a
manual shut-off valve in each fuel line. Plug
unused fuel inlet. The air/fuel ratio will be upset
if both fuels are available at the same time or if
air enters an unused fuel inlet, resulting in poor
performance.
• Do not use galvanized piping, fittings or tanks.
The zinc coating reacts with elements in the
fuel, resulting in contamination of the fuel.
The generator set mechanical system installation
includes connecting the fuel, exhaust, ventilation
and cooling systems. Before starting any type of
fuel installation, all pertinent state and local codes
must be complied with and the installation must be
inspected before the unit is put in service.
FUEL SYSTEM
Sets can be equipped to operate on gasoline only,
LPG (propane), gasoline/natural gas, gasoline/
LPG and LPG/natural gas combinations. Figures
4-1 and 4-2 illustrate the fuel system components
for various generator set configurations. A fuel selector switch may be provided for fuel changeover.
(The position of the switch determines which fuel
valve will open when the set is operated.)
Gasoline Fuel
WARNING Fuel presents the hazard of fire or
explosion which can result in severe personal
injury or death. Do not smoke or allow any
flame, spark, pilot light, arc–producing equipment, or switch, or other ignition sources
around fuel or fuel components, or in the installation area or areas with shared ventilation.
Keep a type ABC fire extinguisher nearby.
The following items should be considered when
installing a fuel supply system:
• Install an approved flexible fuel line at the fuel
The gasoline-carbureted fuel system delivers a
mixture of fuel and air to the combustion chamber.
The system draws fuel from a tank, delivers it
through a filter and fuel pump, to the carburetor float
chamber. Air passing through the carburetor venturi
draws fuel from the the float chamber.
inlet to allow the set to rock on its mounts. Do
not use copper tubing as a flexible fuel line - it
will crack and spill gasoline.
• The highest fuel level in the fuel tank must be
lower than the inlet of the fuel pump to prevent
spillage of fuel if a leak occurs (because of a
faulty connection, ruptured pump diaphragm,
etc.).
See Specifications section for gasoline inlet size.
Fuel lift should not exceed 3 feet (0.9 m). The recommendations in Onan publication T030, the Application Manual for Liquid-Cooled Generator Sets,
should be followed in regard to fuel supply system
pipe sizes and manual shutoff valves.
• Provide a separate fuel line for each set served
by the same fuel tank to prevent either set from
being starved for fuel.
4-1
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See Specifications section for natural gas/LPG fuel
inlet size. The recommendations in Onan publication T030, the Application Manual for Liquid-Cooled
Generator Sets, should be followed in regard to fuel
supply system pipe sizes,manual shutoff valves,
fuel filters and gas pressure regulators.
Natural Gas/LPG Vapor/LPG Liquid Fuel
System
WARNING Natural gas and LPG vapor are
highly flammable. LPG vapor is heavier than air.
Do not bleed lines so fumes can collect in low
areas. Do not smoke or allow any flame, spark,
arcing switch or equipment, pilot light, or other
source of ignition around fuel lines.
Gas Pressure: The fuel regulators in each line provide constant gas pressure at the gas mixer under
varying load conditions (approximately 5 inches
WC for natural gas and –1.5 inches WC for LPG).
There is a pressure test port on the supply side of
the gas mixer for measuring fuel inlet pressure.
A combination gasoline-gaseous fuel carburetor or
straight gaseous fuel carburetors are available for
use with gaseous fuels. A gaseous fuel system
uses a fuel regulator to control the flow of gas from
the lines to the carburetor. At the carburetor, the
gaseous fuel is mixed with the incoming air.
The maximum permissible fuel supply pressure
is 20 inches WC (water column) and the minimum is 10 inches WC. This applies to LPG as well
as to natural gas. The minimum pressure refers to
supply pressure under rated load (maximum gas
flow). There is a pressure test port on the supply
side of each fuel regulator for measuring fuel supply
pressure.
Gaseous-fuel supply system design, materials,
components, fabrication, assembly, installation,
testing, inspection, operation and maintenance
must comply with the applicable codes. See MFPA
Standards No. 37, No. 54 and No. 58.
4-2
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GAS MIXER
LPG FLOW
ADJUSTMENT
COCK
NATURAL GAS
FUEL REGULATOR
NATURAL GAS
FUEL VALVE
PRESSURE
SWITCH
LPG FUEL
REGULATOR
LPG FUEL
VALVE
FUEL
SELECTION
SWITCH
PLUG IN
NATURAL GAS
SUPPLY INLET
PLUG IN LPG
SUPPLY INLET
CARBURETOR
GASOLINE FUEL
FILTER
FUEL PUMP
GASOLINE
SUPPLY INLET
FIGURE 4-1. GASOLINE/NATURAL GAS/LPG VAPOR FUEL SYSTEM
4-3
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NATURAL GAS
FUEL REGULATOR
LPG FLOW
ADJUSTMENT
COCK
NATURAL GAS
FUEL VALVE
GAS MIXER
PRESSURE
SWITCH
LPG LIQUID
CONVERTOR
FUEL
SELECTION
SWITCH
PLUG IN
NATURAL GAS
SUPPLY INLET
GASOLINE FUEL
FILTER
CARBURETOR
PLUG IN LPG
SUPPLY INLET
FUEL PUMP
GASOLINE
SUPPLY INLET
FIGURE 4-2. GASOLINE/NATURAL GAS/LPG LIQUID FUEL SYSTEM
4-4
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CAUTION Weight applied to the engine manifold can result in turbocharger damage. Support the muffler and exhaust piping so no
weight or stress is applied to engine exhaust elbow.
EXHAUST SYSTEM
Pipe exhaust gases to the outside of any enclosure.
Locate the exhaust outlets away from any air inlets
to avoid gases re-entering the enclosure. Exhaust
installations are subject to various detrimental conditions such as extreme heat, infrequent operation
and light loads. Regularly inspect the exhaust system both visually and audibly to see that the entire
system remains fume tight and safe for operation.
DRIP CAP
RAIN CAP
HOLES IN
END OF
INNER SLEEVE
WARNING Inhalation of exhaust gases can result in severe personal injury or death. Use extreme care during installation to provide a tight
exhaust system. Terminate exhaust pipe away
from enclosed areas, windows, doors and
vents.
9 INCH MIN
(230 mm)
VERTICAL
ROOF
9 INCH MIN
(230 mm)
Use an approved thimble (Figure 4-3) where exhaust pipes pass through wall or partitions. Refer to
NFPA 37, Section 6-3. ”Stationary Combustion Engines and Gas Turbines” for accepted design practices. Build according to the code requirements in
effect at the installation site.
HORIZONTAL
WARNING Inhalation of exhaust gases can result in severe personal injury or death. Do not
use exhaust heat to warm a room, compartment
or storage area.
WALL OR PARTITION
EXS1036
Rain caps are available for the discharge end of vertical exhaust pipes. The rain cap clamps onto the
end of the pipe and opens due to exhaust discharge
force from the generator set. When the generator
set is stopped, the rain cap automatically closes,
protecting the exhaust system from rain, snow, etc.
Check the rain cap periodically for proper operation
(cap is not stuck closed).
FIGURE 4-3. MOUNTING EXHAUST THIMBLE
Use a section of flexible exhaust pipe between the
engine and remainder of exhaust system. Support
exhaust system to eliminate weight applied to engine exhaust outlet elbow/turbocharger connection.
4-5
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Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD to allow any moisture condensation
to drain away from the engine. If an exhaust pipe
must be turned upward, install a condensation trap
at the point where the rise begins (Figure 4-4).
IF EXHAUST LINE MUST BE
PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID
SHARP
BENDS
Shield or insulate exhaust lines if there is danger of
personal contact. Allow at least 12 inches (305 mm)
of clearance if the pipes pass close to a combustible
wall or partition.
DRAIN CONDENSATION
TRAP PERIODICALLY
WARNING
Exhaust pipes are very hot and they
can cause severe personal injury or death from
direct contact or from fire hazard. Shield or insulate exhaust pipes if there is danger of personal contact or when routed through walls or
near other combustible materials.
EXS1046s
FIGURE 4-4. CONDENSATION TRAP
VENTILATION AND COOLING
Generator sets create considerable heat that must
be removed by proper ventilation. Outdoor installations rely on natural air circulation but indoor installations need properly sized and positioned vents for
required airflow.
Vents and Ducts
For indoor installations, locate vents so incoming air
passes through the immediate area of the installation before exhausting. Install the air outlet higher
than the air inlet to allow for convection air movement.
Size the vents and ducts so they are large enough to
allow the required flow rate of air. The ”free area” of
ducts must be as large as the exposed area of the
radiator. Refer to the ES series Product Data
Sheets for the airflow requirements.
CS1366
FIGURE 4-5. WIND BARRIER
Wind will restrict free airflow if it blows directly into
the air outlet vent. Locate the outlet vent so the effects of wind are eliminated. See Figure 4-5.
4-6
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Standard Radiator Cooling uses a set mounted
radiator and engine pusher fan to cool engine water
jacket. Air travels from the generator end of the set,
across the engine and out through the radiator. An
integral discharge duct adapter flange surrounds
the radiator grille.
Dampers
Dampers or louvres protect the genset and equipment room from the outside environment. Their operation of opening and closing should be controlled
by operation of the genset.
Set Mounted Heat Exchanger Cooling uses a liquid-to-liquid heat exchanger that requires a connection to a supply of pressurized cold water and to a
drain to discharge the water when it has passed
through the heat exchanger. The engine coolant
pump pumps coolant through the closed, pressurized loop between the engine and heat exchanger.
In cooler climates movable or discharge dampers
are used. These dampers allow the air to be recirculated back to the equipment room. This enables the
equipment room to be heated by the generator set
when operating.
The cold water supply line should have a manual
shutoff valve, water strainer and 12 VDC water solenoid valve to shut off the water supply when the engine is not running. A thermostatic water flow valve
is also recommended. See Application Manual
T-030 for more information.
Radiator Set Requirements
Radiator set cooling air is drawn past the rear of the
set by a pusher fan that blows air through the radiator (Figure 4-6). Locate the air inlet to the rear of the
set. Make the inlet vent opening 1-1/2 times larger
than the radiator area. It is important that the inlet
and outlet (louvers) do not restrict the cooling
air flow beyond the capability of the engine
cooling fan. If this capability is exceeded, engine will overheat.
A powered ceiling vent will probable be required for
ventilating the generator room.
Remote Radiator Cooling (Optional) substitutes
a remote mounted radiator and an electrically driven fan for the set mounted components. Removal of
the radiator and the fan from the set reduces noise
levels without forcing dependence on a continuous
cooling water supply. The remote radiator installation must be completely protected against freezing.
Locate the cooling air outlet directly in front of the radiator and as close as possible. The outlet opening
must be at least as large as the radiator area.
Length and shape of the air outlet duct should offer
minimum restriction to airflow.
Remote radiator plumbing will vary with installation.
Follow recommendations given in Application
Manual T-030. See product data sheet for friction
head and static head limits.
The radiator has an air discharge duct adapter
flange. Attach a canvas or sheet metal duct to the
flange and the air outlet opening using screws and
nuts so duct can be removed for maintenance purposes. The duct prevents recirculation of heated air.
Before installing the duct, remove the radiator core
guard.
Before filling cooling system, check all hardware for
security. This includes hose clamps, capscrews, fittings and connections. Use flexible coolant lines
with heat exchanger, standpipe or remote mounted
radiator.
4-7
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THERMOSTATIC
AIR RECIRCULATING
DAMPER*
WIND/
NOISE
BARRIER
INLET
AIR
DAMPER
HOT
AIR
COOL
AIR
D
DISTANCE SHOULD NOT
BE LESS THAN HEIGHT
OF RADIATOR
FLEXIBLE
DUCT
CONNECTOR
RADIATOR
* Louvers should close when
room ambient is above 60° F
(16° C)
FIGURE 4-6. TYPICAL RADIATOR SET INSTALLATION
4-8
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5. Electrical Connections
GENERAL
The genset electrical system includes connecting
the load, installing the control wiring and connecting
the batteries. Connect the batteries last to avoid accidental starting of the unit during installation.
LOAD
NORMAL
SOURCE
CAUTION To prevent arcing, always disconnect a battery charger from its AC source before
disconnecting the battery cables. Otherwise,
disconnecting the cables can result in voltage
spikes high enough to damage the DC control
circuits of the set.
GENSET
NOTE: SHOWN WITH LINE
CONNECTED TO LOAD
WARNING Accidental starting of the generator
set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables
(negative [–] first).
FIGURE 5-1. TYPICAL LOAD TRANSFER SWITCH
Arcing can ignite the explosive hydrogen gas
given off by batteries, causing severe personal
injury. Arcing can occur if the negative (–) battery cable is connected and a tool being used to
connect or disconnect the positive (+) battery
cable accidentally touches the frame or other
grounded metal part of the set. To prevent arcing, always remove the negative (–) cable first,
and reconnect it last.
Most local regulations require that wiring connections be made by a licensed electrician and the
installation be inspected and approved before operation. All connections, wire sizes, etc. must conform to the requirements of all electrical codes in effect at the installation site.
WARNING
Improper wiring can cause a fire or
electrocution, resulting in severe personal injury or death and/or property and equipment damage.
TRANSFER SWITCH
If the installation is for standby service, a transfer
switch is required for switching the load from the
normal power source to the generator set (Figure
5-1). Either a manual or automatic switch can be
used. Follow the installation instructions provided
with the transfer switch when connecting the load
and control wiring.
5-1
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connection Diagram to identify the output leads that
must be routed through each current transformer,
and also appropriate transformer post selection for
meter sensing leads.
AC WIRING
Generator Voltage Connections
The generator output voltage and maximum current
rating are specified on the generator set nameplate.
Line-to-neutral voltage is always the lower voltage
shown and line-to-line voltage is the higher rating.
Load Balancing
When connecting loads to the generator set, balance the loads so the current flow from each line terminal (L1, L2 and L3) is about the same. This is especially important if both single phase and three
phase loads are connected. Any combination of
single phase and three phase loading can be used
as long as each line current is within 10 percent of
median value and no line current exceeds the
nameplate rating of the generator. Check the current flow from each line by observing the control
panel ammeter.
These generators can be configured for the voltages shown in the Reconnection Diagram. Most of
these voltages must be reconnected by the installer
to give the voltage required by the installation. Before shipping, the factory tests the generator set
output by connecting the generator to produce a
particular test voltage. The generator may be connected at the factory to produce a specified voltage
per customer order. The installer must always
check the stator lead terminal connections and perform any necessary reconnect to obtain the voltage
desired. Note that some voltages are available only
on certain specific generators.
Grounding
Grounding involves making a conducting connection between the metal parts of the generator set or
one of its electrical circuits and the earth. The design and installation of a grounding system is affected by many factors such as the use of multiple
transformers, ground fault protection requirements
and physical location of the generator. Follow the
recommendations of the consulting engineer when
installing the grounding system.
Refer to Reconnection Diagram when reviewing the
voltage connection information and use the electrical schematic supplied with your generator set
when actually performing load connections.
CAUTION Reconnecting factory connected
generator sets to lower voltages can reduce set
ratings, and also render line circuit breakers too
small. Consult with your distributor before performing reconnection for a different voltage.
WARNING
Contact with electrical equipment
can result in severe personal injury or death. It
is extremely important that bonding and equipment grounding be properly done. All metallic
parts that could become energized under abnormal conditions must be properly grounded.
Load Connections
Flexible conduit and stranded conductors must be
used for connections to take up movement of the
set.
Typical requirements for bonding and grounding
are given in the National Electrical Code, Article
250. All connections, wire sizes, etc. must conform
to the requirements of the electrical codes in effect
at the installation site.
When installing sets with AC meters, the generator
output leads must be routed through current transformers for proper meter operation. The transformers are labeled CT21, CT22 and CT23. Refer to Re-
5-2
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gauge stranded copper wire. If the distance is 1000
to 2000 feet (305 to 610 m), use 16 gauge stranded
copper wire. Always run control circuit wiring in a
separate conduit from the AC power cables to avoid
inducing currents that could cause problems within
the control.
DC WIRING
Remote Control Connections
Provisions are made inside the control box for adding optional remote starting stations, alarms and remote monitoring of genset. Refer to DC wiring diagram shipped with genset for remote connections.
CAUTION Do not install DC control wiring in
the same conduit as the AC power. AC voltage
induced currents can create operational problems with electronic solid-state devices.
If the distance between the generator set and remote stations is less than 1000 feet (305 m), use 18
B+
REM
START
REMOTE
SWITCH
RUN
PRE
HET
PRE
LOP
LET
HET
REMOTE
LIGHTS
(OPTIONAL)
OS
OC
LOP
FAULT
ALARM
GND
5A
COMMON
COMMON GROUND
ALARM
FIGURE 5-1. CONNECTIONS FOR REMOTE CONTROL AND ANNUNCIATION
5-3
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Battery Connections
rate trickle charger. Onan automatic transfer
switches include such a battery charging circuit.
Starting the unit requires 12 volt battery current.
Necessary battery cables and rack are on the unit.
Service batteries as necessary. Infrequent use (as
in emergency standby service), may allow battery
to self-discharge to the point where it cannot start
the unit. If installing an automatic transfer switch
that has no built-in charge circuit, connect a sepa-
WARNING Ignition of explosive battery gases
can cause severe personal injury. Always connect battery negative (-) last to prevent arcing.
WARNING Do not smoke while servicing the
batteries. Explosive gases are emitted from batteries in operation. Ignition of these gases can
cause severe personal injury.
5-4
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6. Prestart Preparations
GENERAL
VENTILATION
Verify all air vents and ducts are open and free from
any obstructions.
Before attempting the initial start of the generator
set, be sure it is serviced and ready for operation.
Refer to the Maintenance section of the Operator’s
Manual for the recommended procedures for adding oil, coolant or fuel.
EXHAUST SYSTEM
Gensets are shipped with oil and coolant added. Be
sure to check these systems to make sure they are at
proper operating levels before starting.
Check the exhaust system for proper installation.
Verify there is at least 12 inches (305 mm) clearance between exhaust pipes and combustible materials. Check for leaks. If any are suspected, do not
start set until fixed.
LUBRICATION
ELECTRICAL SYSTEM
Before starting, check engine dipstick and if required, fill the crankcase with the recommended oil.
Verify all electrical connections are secure and all
wiring is complete and inspected. Replace and secure any access panels that may have been removed during installation.
COOLANT
Battery Connections
Before starting, check the coolant level in the radiator and if required, fill the radiator with the recommended coolant.
The battery is connected for a negative (–) ground
system. Connect positive (+) battery cable before
connecting negative (–) battery cable to prevent
arcing. Verify that battery connections are secure
FUEL
Service the battery as necessary.
Open all manual shutoff valves. Be sure manual
changeover switch is moved to desired fuel. Check
for leaks. If any are suspected, do not start set until
fixed.
MECHANICAL CHECKS
Check the generator set for loose or damaged components and repair or replace as required.
6-1
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6-2
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7. Initial Start and Checks
The engine control automatically disconnects the
starter when the engine gets to about 500 RPM.
Before putting the generator set under load conditions, verify the set will perform correctly by checking the following areas.
Cranking continues if the engine does not start right
away. Cranking periods of 15 seconds are alternated with rest periods of 15 seconds until the engine starts. The engine control will shut down the
set in approximately 75 seconds if the engine does
not start. This is indicated by the fault lamp on the
control panel. See Troubleshooting charts in the
Operator’s Manual.
STARTING
Press the panel Start/Stop/Remote switch to the
Run position. The starter should crank the engine
and the engine should start within a few seconds.
RESET / LAMP
TEST SWITCH
OUTPUT VOLTAGE
TRIMMER
START / STOP /
REMOTE
SWITCH
AC OUTPUT
METERS
SCALE INDICATOR
LAMPS
INDICATOR
LAMPS
PHASE SELECTOR
SWITCH
HOUR
METER
CIRCUIT
BREAKERS
DC VOLTMETER
OIL PRESSURE
GAUGE
COOLANT
TEMPERATURE GAUGE
SC1635c
FIGURE 7-1. CONTROL PANEL
7-1
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single phase sets; L1-L2, L2-L3 and L3-L1 on three
phase sets). Read the AC voltmeter using the upper
or lower scale as indicated by the scale indicator
light. At no load, the line-to-line voltage should be
the same as the set nameplate rating.
ENGINE GAUGES
Check the following while the genset is operating:
Oil Pressure Gauge
The oil pressure should be in the range of 40 to 65
psi (275 to 448 kPa) when the engine is at operating
temperature.
AC Ammeter
Turn the phase selector switch to each phase selection shown on the amperes scale (L1and L2 on
single phase sets; L1, L2 and L3 on three phase
sets). Read the ammeter using the upper or lower
scale as indicated by the scale indicator light. At no
load, the current readings should be zero. With a
load applied, each line current should be approximately the same and no line current should exceed
the set nameplate reading
Water Temperature Gauge
The water temperature should be in the range of
180° to 195°F (83° to 91°C) depending on the load
and ambient temperature.
DC Ammeter/DC Voltmeter
The maximum charge rate for the set mounted battery charging alternator is 65 amperes. Charge rate
should taper to zero following start-up as battery becomes charged. The DC voltmeter should read between 12 and 14 volts.
EXHAUST SYSTEM
With the genset operating, inspect the entire exhaust system including the exhaust manifold, muffler and exhaust pipe. Visually and audibly check for
leaks at all connections, welds, gaskets and joints.
Make sure exhaust pipes are not heating surrounding areas excessively. If any leaks are detected,
have them corrected immediately.
AC METERS (IF EQUIPPED)
Note the AC instruments on the control panel. The
frequency meter and voltmeter should indicate
rated nameplate frequency and voltage at no load.
Turn the control panel Output Voltage Trimmer (if
equipped) for nameplate voltage. Use the Phase
Selector Switch to read each of the line-to-line voltages.
WARNING Inhalation of exhaust gases can result in severe injury or death. Inspect exhaust
system visually and audibly for leaks daily. Shut
down generator set and repair any leaks immediately.
Frequency Meter
ENGINE MONITOR INDICATOR LAMPS
The generator frequency should be stable and the
reading should be the same as the nameplate rating.
Move the Run/Stop/Remote switch on the engine
panel to the Stop position. Hold the Reset/Lamp
Test switch in the Test position. All indicator lamps
should light. Verify all the lamps are on and then release the switch. Contact your authorized service
center if any lamps require replacement.
AC Voltmeter
Turn the phase selector switch to each line-to-line
phase selection shown on the volts scale (L1-L2 on
7-2
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WARNING Ignition of explosive gases can
cause severe personal injury. Do not smoke
while servicing the batteries.
FUEL SYSTEM
With the genset operating, inspect the fuel supply
lines, filters and fittings for leaks. Check any flexible
sections for cuts, cracks and abrasions and make
sure they are not rubbing against any sharp, abrasive or hot surface.
COOLING SYSTEM
With the generator stopped, check for loose belts
and fittings, leaking gaskets and hoses, or any
signs of mechanical damage. Before removing any
fan guards or safety guards, turn off the battery
charger (if equipped) and remove battery cables to
prevent accidental startup. If any problems or coolant leaks are found, have them corrected immediately.
WARNING Leaking fuel creates a fire hazard
that can result in severe personal injury or
death. Shut off set and repair any leaks immediately.
With the set running, listen for any unusual noises
that can indicate mechanical problems. Refer to
Operator’s or Service Manual for required adjustments.
DC ELECTRICAL SYSTEM
With the generator set off, check the terminals on
the battery for clean and tight connections. Loose or
corroded connections create resistance that can
hinder starting. Turn off the battery charger before
removing battery cables. Clean and reconnect the
battery cables if loose. Always connect the negative
battery cable last.
LUBRICATION SYSTEM
Open access doors and inspect entire engine for oil
leaks. When engine has been stopped for at least
10 minutes, check the oil level.
7-3
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7-4
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8. Installation Checklist
GENERAL
GenSet wattage capacity is sufficient to handle maximum anticipated load.
At least 3 feet of clearance is provided around entire genset for servicing and ventilation.
GenSet is located in an area not subject to flooding.
All operating personnel have read and are familiar with Operator’s Manual.
All operators have been thoroughly briefed on correct operation and exercise procedures.
All operators have been thoroughly briefed on preventive maintenance procedures.
All operators have read and understand all Safety Precautions in Operator’s Manual.
GENSET SUPPORT
Floor, roof or earth on which the genset rests is strong enough and will not allow shifting
or movement. Observe local codes on soil bearing capacity due to freezing and thawing.
GenSet is properly supported and retained to approved base which is separate and independent
of the surface on which it sits. Vibration isolators are installed between base and set.
Supporting base is large enough - extends 12-inches all around set.
COOLING AIR FLOW
GenSet air inlet is faced into direction of strongest, prevailing winds.
Air inlet openings are unrestricted and at least 1-1/2 times larger than air outlet area.
Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
FUEL SYSTEM
Fuel tanks meet or exceed all Local, State or National codes.
Fuel lines are properly installed, supported and protected against damage.
Flexible fuel line is installed between main fuel supply line and genset to protect against
vibration, expansion and contraction.
Fuel line shutoff valves are installed to prevent fuel flow in case of leaks.
External fuel pumps are connected and operated to be turned On when genset is started
and turned Off when genset is shut down.
No fuel leaks are found in supply line or engine fuel system.
8-1
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EXHAUST SYSTEM
Operators are thoroughly briefed on the dangers of carbon monoxide gas, preventing
the buildup of this gas in inhabited areas.
Areas around set are well ventilated. No possibility of exhaust fumes entering building
doors, windows, or intake fans.
Exhaust gases are piped safely outside and away from building.
The correct length of approved rigid pipe is connected to the genset flexible pipe using
approved securing methods with no weight resting on engine exhaust components.
There are no bends in flex section.
Condensation drain is provided in lowest section of exhaust piping.
Exhaust piping is insulated to guard against burns to personnel.
Exhaust piping passing through walls or ceilings have approved fire-proof materials and
are in compliance with all codes.
Exhaust piping is large enough in diameter to prevent back pressure on engine.
AC AND DC WIRING
Wire sizes, insulation, conduits and connection methods all meet applicable codes.
AC and DC wires are separated in their own conduit to prevent electrical induction.
All load, line and generator connections are proper and correct.
GENSET PRESTART
GenSet engine is properly serviced with oil and coolant.
Batteries are properly installed, serviced and charged.
Battery charger and engine coolant heater are connected and operational.
All genset covers and safety shields are installed properly.
All fuel and coolant shutoff valves are operational.
Fuel system is primed.
8-2
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