Milton CAT G200LG4 User 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 and/or property damage.
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 infor-
mation 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 of the unit
as given on the front cover of the Owner’s Manual.
After this heading, read instructions that, if not
strictly complied with, may result in serious personal injury and/or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
Table of Contents
Liquid-cooled Generators
INTRODUCTION ............................................... IFC
SAFETY RULES ....................................................2
Section 1 — GENERAL INFORMATION ............. 4
1.1 Generator Installation ...................................4
1.2 Before Installation .........................................4
1.3 Generator Location .......................................5
1.4 Generator Mounting and Support .................5
1.5 Unpacking .....................................................6
1.6 Lifting the Generator .....................................6
1.7 Fuel Systems .................................................6
1.8 Electrical Connections ...................................8
1.9 Battery Installation ......................................11
Section 2 — INSTALLATION ........................... 11
2.1 Transfer Switch ...........................................11
2.2 Unpacking ...................................................11
2.3 Mounting .....................................................12
Section 3 — OPERATION ................................ 12
3.1 Basic Standby Electric System ....................12
3.2 Standby Circuit Isolation Method ................12
3.3 Total Circuit Isolation Method .....................12
3.4 Connection Diagrams ..................................12
3.5 Wire Recommendations/Sizing ....................14
Section 4 — NOTES ........................................ 16
1
IMPORTANT SAFETY INSTRUCTIONS
Liquid-cooled Generators
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.
The engine exhaust from this product
contains chemicals known to the state
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 Owner’s 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 that
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator unsafe.
WARNING:
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
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 install, 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.
2
GENERAL HAZARDS
• For safety reasons, the manufacturer recommends
that this equipment be installed, serviced and
repaired by an Dealer or other competent, qualified electrician or installation technician who is
familiar with applicable codes, standards and
regulations. The operator also must comply with
all such codes, standards and regulations.
• Installation, operation, servicing and repair of this
(and related) equipment must always 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, operated and serviced in
accordance with the manufacturer’s instructions
and recommendations. Following installation, do
nothing that might render the unit unsafe or in
noncompliance with the aforementioned codes,
standards, laws and regulations.
• The engine exhaust fumes contain carbon monoxide gas, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. For that
reason, adequate ventilation must be provided.
This should be considered prior to installing the
generator. The unit should be positioned to direct
exhaust gasses safely away from any building
where people, animals, etc., will not be harmed.
Any exhaust stacks that ship loose with the unit
must be installed properly per the manufacturer's
instruction, and in strict compliance with applicable codes and standards.
• 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.
• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive
gases and to ensure correct generator operation.
Do not alter the installation or permit even partial
blockage of ventilation provisions, as this can seriously affect safe operation of the generator.
• Keep the area around the generator clean and
uncluttered. Remove any materials that could
become hazardous.
• 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 promptly
repair or replace all worn, damaged or defective
parts using only factory-approved parts.
IMPORTANT SAFETY INSTRUCTIONS
Liquid-cooled Generators
• 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.
ELECTRICAL HAZARDS
• All generators covered by this manual produce
dangerous electrical voltages and can cause fatal
electrical shock. Utility power delivers extremely
high and dangerous voltages to the transfer switch
as well as the standby generator. Avoid contact
with bare wires, terminals, connections, etc., on
the generator as well as the transfer switch, if
applicable. 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.
• If people must stand on metal or concrete while
installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a
dry wooden platform. Work on the equipment only
while standing on such insulative mats.
• The National Electrical Code (NEC), Article 250
requires the frame and external electrically conductive parts of the generator to be connected to
an approved earth ground and/or grounding rods.
This grounding will help prevent dangerous electrical shock that might be caused by a ground fault
condition in the generator set or by static electricity. Never disconnect the ground wire.
• Wire gauge sizes of electrical wiring, cables and
cord sets must be adequate to handle the maximum electrical current (ampacity) to which they
will be subjected.
• Before installing or servicing this (and related)
equipment, make sure that all power voltage
supplies are positively turned off at their source.
Failure to do so will result in hazardous and possibly fatal electrical shock.
• Connecting this unit to an electrical system normally supplied by an electric utility shall be by
means of a transfer switch so as to isolate the
generator electric system from the electric utility
distribution system when the generator is operating. Failure to isolate the two electric system power
sources from each other by such means will result
in damage to the generator and may also result
in injury or death to utility power workers due to
backfeed of electrical energy.
• Generators installed with an automatic transfer
switch 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, disable the generator’s automatic start circuit
(battery cables, etc.) before working on or around
the unit. Then, place a “Do Not Operate” tag on
the generator control panel and on the transfer
switch.
• 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 dry 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
• Keep a fire extinguisher near the generator at all
times. Do NOT use any carbon tetra-chloride type
extinguisher. Its fumes are toxic, and the liquid
can deteriorate wiring insulation. 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.
• This generator may operate using one of several types of fuels. All fuel types are potentially
FLAMMABLE and/or EXPLOSIVE and should be
handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the
unit’s fuel system frequently and correct any leaks
immediately. Fuel supply lines must be properly installed, purged and leak tested according to
applicable fuel-gas codes before placing this equipment into service.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Natural
gas is lighter than air, and LP gas is heavier than
air; install leak detectors accordingly.
3
Section 1 - General Information
Liquid-cooled Generators
1.1 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.
1.2 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 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.
1.2.1 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, LIQEEFIED 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.
1.2.2 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.
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