Multiquip MQP60GM, MQP45GM, MQP60IV, MQP30GM, MQP30DZ User Manual

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APPLICA TION & INST ALLA TION MANUAL

MQ POWER

Industrial Generator Set

Application & Installation

Manual

Revision #4 (09/07/07)

MQPOWE R

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-883-2551 F AX: 310-632-2656 E-MAIL: mqpower@multiquip.com WWW: www .mqpower.com

PARTS DEPARTMENT:

800-427-1244 F AX: 800-637-3284

SERVICE DEPAR TMENT :

800-835-2551 F AX: 310-638-8046

Page 2

PAGE 2 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 3

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

MUL TIQUIP’S MAIN PHONE NUMBERS

800-421-1244 FAX: 310-537-3927 310-537-3700

PARTS DEP ARTMENT

800-427-1244 FAX: 310-637-3284 310-537-3700

MQ POWER SERVICE DEP ARTMENT

800-835-2551 FAX: 310-638-8046 310-537-3700

TECHNICAL ASSIST ANCE

800-478-1244 FAX: 310-631-5032

WARRANTY DEP ARTMENT

800-421-1244, EXT. 279 FAX: 310-537-1173 310-537-3700, EXT. 279

ON-HAND

WHEN CALLING

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 3

Page 4

T ABLE OF CONTENTS

Proposition 65 California Warning............................. 2

Here's How To Get Help............................................ 3

Table Of Contents ..................................................... 4

Safety Message Alert Symbols.............................. 6-7

Important Safety Instructions............................... 8-13

Introduction ............................................................. 14

Installation Overview.......................................... 15-16

ApplicationApplication

Application

ApplicationApplication

Genset Sizing.....................................................17-21

Determining Load Characteristics ......................22-26

Environmental Consideration — dB(A)..............27-32

Mechanical InstallationMechanical Installation

Mechanical Installation

Mechanical InstallationMechanical Installation

Mounting Foundation ......................................... 33-34

Mounting Genset .................................................... 35

Mounting — Vibration Isolators ............................... 36

Fuel System .......................................................37-45

Exhaust System .................................................46-49

Battery System...................................................50-51

Installing New Battery ........................................52-53

Testing Batter y ...................................................54-55

Charging Battery ................................................ 56-59

entilation and Coolingentilation and Cooling

entilation and Cooling

entilation and Coolingentilation and Cooling

Ventilation and Cooling ...................................... 60-61

Mounted Radiator Cooling ................................. 62-63

Remote Radiator Cooling .................................. 64-65

Hot Well Cooling...................................................... 66

Heat Exchanger Cooling ......................................... 67

Coolant Treatment................................................... 68

Electrical InstallationElectrical Installation

Electrical Installation

Electrical InstallationElectrical Installation

DC Control Wiring ................................................... 69

Control Box Back Panel......................................70-72

AC Electrical Connections.................................. 73-75

System Grounding .............................................76-77

Equipment Grounding............................................. 78

Electrical Distribution System.................................. 79

Pre-Start Preparation ......................................... 80-81

AppendixAppendix

Appendix

AppendixAppendix

Installation Checklist .........................................82

Table 25, Main-Line Circuit Breakers................83-84

Table 26, Generator Specifications...................85-87

Table 27, Engine Specifications ........................88-91

Table 28, Dimension and Weights..................... 92-93

NOTE

PAGE 4 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

All specifications in this manual are subject to change without notice.

Page 5

NOTES PA GE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 5

Page 6

SAFETY MESSA GE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when installing or operating this equipment. Failure to read and understand the Safety Messages and Installation Instructions could result in injury to yourself and others.

This genset Installation Manual has been developed to provide

NOTE

complete instructions for the safe implementation of MQ Power Gensets for field installation. Depending on the power plant you

can be also extremly dangerous if inhaled. They are odorless but a smell has been added to detect any leaks. IMMEDIATELY shut off the gas source if a leak is detected. If in an enclosed area, vacate the premises until the area is ventilated.

have selected, please refer to the engine manufacturers instructions for data relative to its safe operations.

Before installing any MQ Power Genset, ensure that all authorized personnel have read and understands all installation or operating instructions referenced in this manual.

Diesel fuel is extremely flammable, and its vapors

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you about potential hazards that could injure you or others. The Safety Messages specifically address the level of exposure to the operator, and are preceded b y one of three words: DANGER, WARNING, or CAUTION.

You WILL be if you DO NOT follow these directions.

KILLED

SERIOUSLY INJURED

approved containers, in well-ventilated areas and away from sparks and flames. NEVER use fuel as a cleaning agent.

Natural gas and LPG are extremely flammable and will explode and catch fire if exposed to sparks or flame. NEVER smoke in any area where gases are stored or supplied. IMMEDIATELY shut off the gas source if a leak is detected. Be certain that the area is well ventilated before exposing it to any mechanical or electrical device that may emit heat or sparks.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled. NEVER operate this equipment in a confined area or enclosed structure that does not provide ample free flow air. Natural gas and liquid petroelum gas (LPG)

Explosive Fuel

can cause an explosion if ignited. DO NOT start the engine near spilled fuel or combustible fluids. DO NOT fill the fuel tank while the engine is running or hot. DO NOT overfill tank, since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system. Store fuel in

Burn Hazards

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas

You CAN be KILLED or you DO NOT follow these directions.

SERIOUSLY INJURED

while the engine is running or immediately after operation. NEVER operate the engine with heat shields or heat guards removed.

Rotating Parts

You CAN be these directions.

Potential hazards associated with MQ Power Gensets field installation will be referenced with Hazard Symbols which appear throughout this manual, and will be referenced in conjunction with Safety Message Alert Symbols.

PAGE 6 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

INJURED

if you DO NOT f ollo w

NEVER operate equipment with covers or

guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

Page 7

SAFETY MESSA GE ALERT SYMBOLS

Accidental Starting

ALWAYS place the ignition switch or genset

starting device in the OFF position, remove key and/or disconnect the battery before servicing the engine or equipment.

Over Speed Conditions

NEVER tamper with the factory settings of the

engine governor or settings. Personal injury and damage to the engine or equipment can result if operating in speed ranges above maximum allowable.

Guards and Covers In Place

NEVER operate the genset without guards and

covers in place.

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual to help prevent damage to your genset, other property, or the surrounding environment.

THIS MQ POWER GENSET, OTHER PROPER TY, OR THE SURROUNDING

EQUIPMENT COULD BE DAMA GED IF Y OU DO NOT FOLLOW INSTRUCTIONS

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 7

Page 8

IMPORTANT SAFETY INSTRUCTIONS

■

SAVE THESE INSTRUCTIONS — This manual contains important safety instructions for MQ Power Industrial generators that should be followed during installation, operation, and maintenance of the engine-generator set.

F ailure to follow instructions in this manual may lead to serious injury or even death! This equipment is to be operated by trained and qualified personnel only! This equipment is for industrial use only.

GENERAL SAFETY

■

DO NOT install, operate , or service this equipment before reading this entire manual along with the operation manual.

High Temperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with burns.

■

The engine of this generator requires an adequate free flow of cooling air. Never operate the generator in any enclosed or narrow area where free flow of the air is restricted. If the air flow is restricted it will cause serious damage to the generator or engine and may cause injury to people. The generator engine giv es off DEADLY carbon monoxide gas.

NEVER operate the genset in a restricted air flow environment!

hot

components can cause serious

■

NEVER operate this equipment without proper protective clothing, shatterproof glasses, steel-toed boots and other protective devices required by the job.

■

NEVER operate this equipment when not feeling well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the influence of drugs or alcohol.

■

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or generator .

■

DO ALWAYS refuel in a well-ventilated area, away from sparks and open flames. Fire or explosion could result from fuel vapors, causing severe bodily harm — even

death!

DO NOT smoke around or near the

machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine, causing severe bodily harm — even

ALWAYS use extreme caution when working with flammable liquids. When refueling, stop the engine and allow it to cool.

NEVER operate the generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe

Topping-off to filler por t is dangerous, as it tends to spill fuel.

death!

bodily harm or even death!

PAGE 8 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 9

IMPORT ANT SAFETY INSTR UCTIONS

GENERAL SAFETY

■

NEVER touch output terminals during operation. This is extremely dangerous. Always stop the machine and disconnect the battery when contact with the output terminals is necessar y.

RADIAT OR

■

1. Radiator Cap - Removing the radiator cap while the

DO NOT touch or open an y of the components mentioned

below while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

engine is hot will result in high pressurized, boiling water or coolant to gush out of the radiator, causing severe scalding to any persons in the general area of the generator .

■

NEVER connect the generator to house wiring. This is illegal and very dangerous. Electrical shock could occur causing damage to the generator and bodily harm — even

2. Coolant Drain Plug - Removing the coolant drain plug

death!

3. Engine Oil Drain Plug - Removing the engine oil drain

■

NEVER use damaged or worn cables when connecting power tools or equipment to the generator. Make sure power connecting cables are securely connected to the generator’ s output terminals, insufficient tightening of the terminal connections may cause arcing and damage the generator . Touching worn or frayed electrical cables may cause electrical shock, which could result in severe bodily harm or even

death!

while the engine is hot will result in hot coolant to drain out of the coolant drain plug, and could cause severe scalding to any persons in the general area of the generator .

plug while the engine is hot will result in hot oil to drain out of the oil drain plug, and could cause severe scalding to any persons in the general area of the generator .

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 9

Page 10

IMPORTANT SAFETY INSTRUCTIONS

Operation Safety

■

ALWAYS be sure the operator is familiar with proper saf ety

■

precautions and operations techniques before using generator .

■

DO NOT allo w unauthorized people near equipment.

■

ALWAYS wear ear protection when working in

a loud environment.

■

NEVER run engine without air filter. Engine damage will occur.

■

DO NOT leave the generator running in the MANUAL mode unattended.

■

NEVER use accessories or attachments which are not recommended by MQ P ower for this equipment. Damage

Maintenance Safety

When performing maintenance on MQ Po wer generator sets, it is important to prevent automatic start-up of the unit by a remote contact closure by disconnecting the engine battery before servicing.

to the equipment and/or injury to user may result.

■

Manufacturer does not assume responsibility for any accident due to equipment modifications.

■

ALWAYS check the machine for loosened par ts or bolts

before starting.

Always disconnect the battery cable negative (first) before performing service on the generator. Reconnect battery cable negative (last) after service is complete.

In emergencies

phone or phone numbers of the nearest

fire department

case of an emergency .

always

know the location of the nearest

keep a phone on the job site

. This inf ormation will be invaluable in the

. Also know the

ambulance, doctor

and

Emergencies

Always be prepared for an emergency such as fire, personnel injury , or other emergency situation. It is important to identify all possible emergency situations and to provide adequate prevention methods and response methods.

■

Install the appropriate fire extinguishers 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 that are rated ABC by the National Fire Protection Association (NFPA).

■

ALWAYS know the location of the nearest

fire extinguisher

■

Keep the machinery in proper running condition.

■

NEVER lubricate components or attempt service on a running machine.

■

Always allow the machine a proper amount of time to cool before servicing.

■

Fix damage to the machine immediately and always replace broken parts.

■

Dispose of hazardous waste properly. Examples of potentially hazardous waste are used motor oil, coolant, fuel, and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous waste.

■

ALWAYS know the location of the nearest

first aid kit

■

ALW AYS pro vide an emergency escape route in the event

DO NOT pour waste , oil, coolant or fuel directly onto the

ground, down a drain, or into any water source

■

Whene ver necessary , replace nameplate, operation and safety decals when they become difficult read.

of an emergency.

■

Never leave rags or tools on or near the generator-set.

■

Refer to the

Volvo Engine Owner's Manual

for engine

technical questions or information.

PAGE 10 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 11

IMPORT ANT SAFETY INSTR UCTIONS

Battery Safety

The battery is a major component of the engine-generator set. The genset will not start without a properly maintained battery . Disconnecting the battery prevents the engine from starting. Always observe the following safety guidelines when interaction with the battery is necessary. Servicing of batteries should be performed by authorized personnel only .

1. Wear full eye protection and protective clothing, including rubber gloves and boots when handling a battery.

2. Remove watches, rings or other metal objects when handling a battery .

3. Use tools with insulated handles.

4. In case the battery liquid (dilute sulfuric acid) comes in contact with with plenty of water and discard clothing.

5. In case the battery liquid (dilute sulfuric acid) comes in contact with your eyes, rinse eyes immediately with plenty of water for fifteen minutes, then contact the nearest doctor or hospital, and seek medical attention.

6. Spilled electrolyte is to be washed down with an acid neutralizing 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.

7. DO NOT expose the battery to open flames, sparks, cigarettes etc. The battery contains combustible gases and liquids. If these gases and liquids come in contact with a flame or spark, an explosion could occur .

8. DO NOT lay tools or metal parts on top of batter ies.

9. DO NOT drop the battery; there is the risk the battery may explode.

10. ALWAYS discharge static electricity from the body before touching batteries by first touching a grounded metal surface.

clothing or skin

, rinse skin immediately

14. Only use a battery that is in proper working condition. Replace battery as recommended by manufacturer .

The battery contains electrolyte which is a dilute sulfuric acid that is harmful to the skin and eyes. Electrolyte is electrically conductive and very corrosive.

The installation of the engine-generator set must provide enough ventilation to ensure that gases generated by vented batteries during charging, or caused by equipment malfunction are removed.

risk of fire because they generate hydrogen gas.

If using a serviceable battery, ne v er ov er fill the battery with water above the upper limit.

Always disconnect a battery charger from its AC source before disconnecting the battery cables. Failure to do so can result in voltage spikes high enough to damage the genset DC control circuits and charger .

Make certain the battery is well-ventilated before servicing. Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when the cable is removed or reattached, or when negative (-) battery cable is connected and a tool used to connect or disconnect positive (+) battery cable touches the frame or other grounded metal that is part of the set. Alwa ys remo ve negative (-) cable first, and reconnect it last. Make certain hydrogen gas from the battery, engine fuel, and other explosive fumes are fully dissipated. This is especially important if the battery has been connected to a battery charger.

Lead-acid batteries present a

11. ALWAYS keep the battery charged. If the battery is not charged a buildup of combustib le gas will occur.

12. ALWAYS keep battery charging and booster cables in good working condition. Repair or replace all worn cables.

13. ALWAYS recharge the battery in an open air environment, to avoid risk of a dangerous concentration of combustible gases.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 11

On generators not having a grounded supply circuit, determine if the battery is inadver tently grounded. When inadvertently grounded, remove source of ground. Contact with any part of a grounded battery is capable of resulting in electrical shock. The risk of such shock is reduced when such grounds are removed during installation and maintenance.

Page 12

IMPORT ANT SAFETY INSTR UCTIONS

Fire Protection

■

The design, selection, and installation of fire protection systems is beyond the scope of this manual because of the wide range of factors to consider . In general, ev ery possible measure should be taken to prevent fire hazards and to protect property and people. Consider the follo wing:

■

A protection system must comply with the requirements of the authority having jurisdiction. This could include the building inspector , fire marshal, or insurance carrier.

■

In general, the generator room will be required to have a one hour fire resistance rating. If the generator set will be in a Level 1 (life safety) application, as defined by NFPA 110, the generator room construction will have a two hour resistance rating.

■

The generator room should not be used for storage purposes.

■

Generator rooms should be classified as hazardous locations (as defined by the NEC) solely by reason of the engine fuel.

■

The authority having jurisdiction will usually classify the engine as a low heat appliance when use is only brief, infrequent periods.

■

The authority having jurisdiction may specify the quantity , type, and sizes of approved portable fire extinguishers required for the generator room.

The authority having jurisdiction may have more stringent restrictions on the amount of fuel that can be stored inside the building than published in national standards.

■

Fuel tanks located inside buildings and above the lowest story or basement should be diked in accordance with NFPA standards.

■

The genset should be exercised periodically under at least 30% load until it reaches stable operating temperatures and run under nearly full load at least once a year to prevent fuel from accumulating in the exhaust system.

■

Properly store fuel, batteries, and other fire hazardous material.

■

The genset should be inspected regularly for fire hazards.

■

When open bottom generator is used, it is recommended the assembly be installed over noncombustible materials and located in such a manner such that it prevents a combustible materials from accumulating under the generator set.

■

Installation should provide a safe easy method to clean up spilled engine fluids.

■

Post NO SMOKING signs near generator set, battery storage, and fuel storage areas.

■

Use dry chemical, foam, or carbon dioxide (CO extinguishers on battery fires.

■

A manual EMERGENCY STOP station outside the generator room or remote from a generator set in an outside enclosure is recommended for shutting down the generator set in the event of a fire or other type of emergency.

PAGE 12 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

) fire

Page 13

IMPORT ANT SAFETY INSTR UCTIONS

Lifting the Generator Set

■

Before lifting, make sure the generator's lifting devices are secure and that there is no apparent damage to the generator itself (loose screws, nuts and bolts). If any part is loose or damaged, please take corrective action before lifting.

■

Always drain fuel prior to lifting.

■

Always make sure crane or lifting device has been properly secured to the hook of guard frame on generator .

■

NEVER lift the machine while the engine is running.

■

Use adequate lifting cable (wire or rope) of sufficient strength.

■

When lifting the generator, always use the balanced center-point suspension hook and lift straight upwards.

■

NEVER allow any person or animal to stand underneath the machine while lifting. Make sure the lifting path of the generator set is clear before moving.

■

When loading the generator on a truck, be sure to use the front and back frame bars as a means to secure the generator during transport.

■

Do not lift the generator set by the lifting eyes attached to the engine and/or alternator. These lifting eyes are used only during generator assembly and are not capable of supporting the entire weight of the genset.

■

A four-point lifting method is necessary to lift the genset. To maintain generator balance during lifting, the lifting apparatus must utilize the four skid lifting holes. One method of lifting the genset uses an apparatus of hooks and cables joined at a single rigging point. The use of spreader bars is necessary with this method to avoid damage to the set during the lifting procedure. The spreader bars should be slightly wider than the genset skid so the set is not damaged by lifting cables and only vertical force is applied to the skid while lifting. The genset may also be lifted by placing bares through the skid lifting holes and attaching hooks to the end of the bars. Be sure all lifting equipment is properly sized for the weight of the genset.

Transporting

■

Always shutdown engine before transporting.

■

Nev er transport generator with air intake doors open.

■

Tighten fuel tank cap securely.

■

Drain fuel when transporting generator over long distances or bad roads.

■

Always tie-down the generator during transportation by securing the generator.

■

If the generator is mounted on a trailer, make sure the trailer complies with all local and state safety transportation laws. See the operation manual for towing procedures.

■

The transporting vehicle/trailer must be sized for the dimension and weight of the genset. Consult the set dimensional drawing or contact the factory for information (weight, dimensions) pertinent to planning transport. The overall height of a generator set in transit (including vehicle/trailer) must not exceed 13.5 ft (4.1 m) unless special hauling permits are obtained (check Federal, State, and local laws prior to transporting). Larger units (above 1000 kW) should be tr ansported on low-boy-type trailers with a deck height of 25 in. (635 mm) or less to meet clearance requirements. Large (unboxed) generators with radiators should be loaded with the radiator facing the rear to reduce wind resistance while in transit. Radiators with free-wheel fans must have the fan secured to prevent rotation that might introduce flying objects to the radiator core or fan blades.

■

Even the heaviest of units is capable of movement during shipment unless properly secured. Fasten the set to the vehicle/trailer bed with properly sized chain routed through the mounting holes of the skid. Use chain tighteners to remove slack from the mounting chain. Cover the entire unit with a heavy-duty tarpaulin and secure tarpaulin to the genset or trailer as circumstances dictate.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 13

Page 14

INTRODUCTION

Introduction

Engine-Generator sets provide emergency power in the event of utility power failure, provide power where utility power is not available and can provide an alternative power means in areas where utility power may be more expensive.

Part of the reason for the growing emphasis on emergency/ standby power systems is the proliferation of electronic computers in data processing, process control and life support systems, and any other system that requires a continuous, uninterrupted flow of electrical energy . Gener ator sets must be applied in such a way as to provide reliable, electrical power of the

About This Manual

This manual provides specific recommendations for installation of MQ Power's Industrial generator sets (gensets). This manual will contain the f ollowing information:

1. Application — This section provides information on sizing the correct generator set, determining load characteristics, and environmental considerations.

2. Mounting Recommendations — This section pro vides mounting recommendations such as typical fastening, footing, foundations, proper space requirements, and vibration isolation.

3. Mechanical Connections — This section provides typical information regarding the fuel system, battery system, exhaust system, proper ventilation, and proper cooling.

4. Ventilation and Cooling — This section shows diff erent installation methods for ventilating and cooling the genset.

quality

and

capacity

required.

Safety Considerations

MQ Po wer's gensets have been carefully designed to provide safe and efficient service when properly installed, maintained, 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. This manual is provided to illustrate recommended electrical and mechanical guidelines for a safe and efficient installation.

All systems external to the generator (fuel, exhaust, electrical, etc.) must comply with all applicable codes. Make certain all required inspections and test have been completed and all code requirements have been satisfied before certifying the installation is complete and ready for service.

Always remember: SAFETY FIRST!!! Safety involves two aspects: safe operation of the generator set itself (and its accessories) and reliable operation of the system. Reliable operation of the system is related to safety because equipment affecting life and health, such as life-support equipment in hospitals, emergency lighting, building ventilators, elevators, and fire pumps may depend upon the generator set.

In North Amer ica, many safety (and environmental) issues related to generator set applications are addressed by the following standards of the National Fire Protection Association (NFPA):

Flammable and Combustib le Liquids Code — NFPA 30

National Fuel Gas Code — NFPA 54

National Electrical Code — NFPA 70

Health Care Facilities Code — NFPA 99

Life Safety Code — NFPA 110

Emergency and Standby P ower Systems — NFPA 110

Storage and Handling of Liquified Natural Gas — NFPA 59A

Many national, state, and local codes incorporate the above

5. Electrical Connections — This section provides the location of electrical connection points for DC Controls, AC electrical connections, and system & equipment grounding.

6. Pre-Start Preparation — Checklist of items or procedures needed to prepare the generator set for operation.

PAGE 14 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

standards (and others) by reference. Each of these standards and the codes that reference them are periodically updated, requiring continual review. Compliance with all applicable codes is the responsibility of the facility design engineer. For example, some areas may have certificateof-need, zoning permit, building permit, or other site specific requirements. Be sure to check with all local governmental authorities before designing the generator set installation.

Page 15

INST ALLA TION O VERVIEW

Overview

These installation recommendations apply to typical installations with standard model gensets. Whenever possible, these recommendations also cover factory designed options or modifications. However, because of the large amount of variables involved with any installation, it is not possible to provide specific recommendations for every possible situation.

This manual information for selecting a genset or designing the complete installation. are any questions not answered by this manual, contact your nearest MQ P o wer dealer or distributor f or assistance .

Application and Installation

A standby power system must be carefully planned and correctly installed for proper operation. This involves two essential elements of application and installation.

Application

Application as it applies to genset installations refers to the design of the complete standby power system. Such an effort usually considers power distribution equipment, transf er switches, ventilation equipment, and mounting pads. Consideration is also given to cooling, exhaust, and fuel systems.

Each subsystem 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 consulting engineers are responsible for the designing the complete standby system and for selecting the materials and products to be used.

Installation

Installation refers to the actual setup and assembly of the standby power system. The installers, usually licensed contractors, 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, sheet metal workers, construction workers, etc. to complete the various segments of the installation. This is necessary so all components are assembled using standard methods and practices.

does not

This manual is a reference tool only

provide complete application

. If there

Selection and Application

Generator set size and site location should be considered in the preliminary design and budget estimate. The generator size should be selected according to the required load. Choosing a mounting site located inside the building or outside in a shelter or housing will help determine how the genset will be installed and what specific issues need to be addressed.

Sizing

It is important to assemble a reasonably accurate load schedule as soon as possible for budgeting project costs. If all the load equipment information needed for sizing is not available early in the design planning, estimates and assumptions will have to be made during the preliminary calculation in order to account for all needed pow er . When all the information becomes available, it is important to recalculate the sizing requirements to ensure reliable operation.

Large motor loads, uninterrupted power supplies (UPS), variable frequency drives, and medical diagnostic imaging equipment have a considerable effect on the generator set sizing and should be considered closely. Too, the required power to start a motor can be considerably larger than the power required to maintain the load.

Fuel Requirements

Diesel engine generator sets are recommended for emergency/standby applications. Premium No. 2-D Grade diesel fuel is recommended for performance and engine life.

On-site fuel storage must be provided. The storage life for diesel fuel is up to two years when stored properly. Proper supply tank sizing should allow fuel turnover based on scheduled ex ercise and test periods. To avoid condensation mixing with the fuel, do not provide a fuel tank that is too large. A microbicide may be required if fuel turnover is low or conditions promote the growth of microbes in the fuel.

Always consider emissions requirements when designing the fuel and exhaust system. Refer to the Fuel System section for more information.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 15

Page 16

INST ALLA TION O VER VIEW

Cold Climates and Derating Factors

Extreme temperature and high elevation effect the efficiency of the engine-generator set. Always take into account derating factors of climate and elevation when sizing a generator set.

Use Premium No.1-D Grade diesel fuel when the ambient temperature is below freezing. Fuel heating may be required to prevent fuel filters from clogging when temperatures fall below the cloud point of the fuel at approximately 20°F (-6°C) for No . 2-D and -15°F (-26°C) f or No . 1-D .

Location

Location of the generator set will determine the cost effectiveness of an installation. The generator set can be located inside a building or outside the building with a shelter or weather-protective housing. The location will help determine the layout of the fuel tanks, louvers, ventilation ducts, accessories, etc. Consider the following when deciding where to locate the generator set:





Safety considerations

 



Noise. See pages 27 thru 32 for environmental



considerations.





Ambient temperature

 



Mounting

 



Fuel, exhaust, ventilation, and cooling systems





Location of the distribution switchboard and transfer



switch





Branch circuits for coolant heaters , battery charger, etc.

 



Security from flooding, fire, icing, and vandalism

 



Containment of accidentally spilled or leaked fuel or



engine fluids





Mounting - Ensure generator is located (mounted) over



non-combustible materials and is situated in such a manner as to prevent combustible materials from accumulating under the generator .

Indoor Locations





Dedication of room for the generator sets only. For



emergency power systems, codes may require the generator room be dedicated for that purpose only . Also consider the effect of the large ventilation air flows would have on other equipment in the same room.





Fire rating of the room construction. Most codes specify



a 1 or 2 hour rating. Check with the local fire authority for code guidelines.





Working space. Working space around electrical



equipment is usually specified by code. There should be at least four feet (1200 mm) of clearance around each generator set. The generator should be accessib le for service without removing the set or any accessories.





Type of cooling system. A factory-mounted radiator is



recommended.





V entilation. Large volumes of air flow are inv olved. Room



ventilation fans might be required for a heat exchanger or remote radiator configurations.





Engine exhaust. The engine exhaust outlet should be



as high as practical on the downwind side of the building and away from vents and building openings.





Fuel storage and piping. Codes may restrict fuel storage



inside buildings. It is important to consider a safe method for refueling the fuel tank. Check with the local fire authority for code guidelines.

Outdoor Locations





Airborne noise. Locate and/or route engine exhaust



piping away from nearby windows & doorways.





Outdoor enclosures. Give consideration to type of



outdoor housing, including weather-protective and/or sound attenuated types.





Security. Consider use of security fences and site



barriers.





Property line distances. Ensure before proceeding with



final installation plans you are aware of your property lines.





Engine exhaust. Engine exhaust must be routed away



from building intake vents, windows, doorways and other openings.

PAGE 16 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 17

GENSET SIZING

Generator Set Sizing Calculations

The generator set must be sized to supply the maximum starting (power surge) demands and the steady-state running loads of the connected equipment.

It is important to have the correct generator to meet the demands of the starting kVA (SkVA), star ting kW (SkW), running kVA (RkVA) and running kW (RkW). A value for generator kW (GkW) is also obtained when nonlinear loads are included in the sizing calculation.

Once the starting and running loads have been determined, it is typical to add a margin factor of up to 25% for future expansion or to select a generator set of the next largest

The use of closed-transition autotransformer starters for reduced voltage starting of large motor loads will reduce the size of the generator set required relative to across-the-line starting. Resistor-type reduced-voltage motor starting may actually increase the size of the generator set required due to high starting power factors. Wound rotor motors are the easiest type of motor for a generator set to start.

The first step is to create a reasonably accurate schedule of connected loads as early in the preliminary design as possible. A sample load schedule sheet can be found below on T able 1.

Genset Sizing Procedure

standard rating. A large connected load that does not run during usual power outages, such as a fire pump, can serve as part of a margin factor. For a fuel efficiency standpoint, the running load should stay within approximately 50 to 80% of the generator kW rating. To avoid "wet stacking", the running load should not be less than 30% of the generator set rating.

When calculating the generator size needed for the application, consider the following procedure:

Step 1. Prepare a load schedule Step 2. Enter loads in step sequence on the worksheet Step 3. Enter individual load characteristics on the

It may be necessary to oversize a generator set in applications where the voltage and frequency dip performance specifications are more stringent than usual, particular ly when large motors are started across-the-line or UPS equipment is involved. Applications that involve any of the following nonlinear loads may also make it necessary to oversize the generator set or the generator:



Static Uninterrupted Power Supplies (UPS)



Battery Charging Rectifiers (T elecommunications)



V ariable Frequency Driv es (VFD)



Medical Diagnostic Imaging Equipment

Step 4. Find the load step totals Step 5. Select a generator set

Step 1. Prepare a Load Schedule

All the loads that will be connected to the generator set should be recorded on the load schedule. Identify each load as to type, power rating, and quantity. See Table 1 below for the loads listed (in calculation.

worksheet

italics

) for an example

eludehcSdaoL.1elbaT

#daoLnoitpircseDdaoLdaoLfoepyTgnitaRrewoP.YTQdaoL

:selpmaxE

Wk...................................gnithgiL

AVk..............................SPUcitatS

PH............sevirDdeepSelbairaV

AVk.............srefitceRCDmoceleT

PH.....................................srotoM

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 17

2#&1#spmuPretaW,GretteledoCameN,rotoM

)paT%08(retratsremrof

3#spmuPretaW,GretteledoCameN,rotoM

)paT%08(retratsremrof

gnithgiLtnecsroulFgnithgiLPH01

PH001

Page 18

GENSET SIZING

Generator Set Sizing Calculations (Continued) Step 2. Create a Generator Set Worksheet

a. When creating a worksheet, number a worksheet for each

sequenced load step. The n umber block is in the upper right hand corner of the wor ksheet. Worksheet #1 will coincide with Load Step #1, Worksheet #2 will coincide with Load Step #2, and etc.. The will provide additional information to be followed here. The worksheets need not have load step numbers unless starting is sequential.

b. Enter the individually assigned load numbers (load

schedule) onto the appropriate generator set sizing worksheet. That is, all the load n umbers for load step #1 should be entered on worksheet #1, for load step #2 on worksheet #2, and etc.

c. For each load, enter the

schedule in the column labeled

Figure 1 on page 19 is an example load calculation for an application involving a two-step load starting sequence. Because the application is a two-step load starting sequence, it requires two worksheets as shown. The entries are in

italics

step sequence guidelines

Load QTY

marked on the load

QTY

on the worksheet.

Step Sequence Guidelines





Single Step, Simultaneous Starting — One commonly



used approach is to assume that all connected loads will be started simultaneously in a single step, regardless of the number of transf er switches used. This approach assures that the genset is properly sized to meet the entire load demand and is the most conservative method.





Single Step, with Diversity F actor — This is similar to



simultaneous starting in a single step, except that an estimated diversity factor, of perhaps 80 percent, is applied to reduce the starting kVA (SkVA) and starting kW (SkW) totals to account for whatever automatic starting controls may be provided with the load equipment.





Multiple Step Sequence — Sequenced starting of



loads (where possible) will often permit the most precise load demand for selecting a generator .

A step sequenced start may be approximated, for e xample, by dividing the loads into blocks each served by a separate transfer switch and then using the standard time delay on transfer to stagger connection of each block onto the generator set. However, once all of the loads have been brought up on line with the genset, the load equipment may be frequently started and stopped by automatic controls. In such cases, the genset will have to be sized to start the largest motor last, with all other connected loads on line.

Consider the following when controls or delays are provided to step sequence the loads onto the generator set:



Start the largest motor first. Use only when on a manual starting system.



Load the UPS last. UPS equipment is typically frequency sensitive, especially to the rate of change of frequency. A pre-loaded genset will be more stable in accepting the UPS load.

PAGE 18 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 19

GENSET SIZING

teehskroWgniziSteSrotareneG 1#petSdaoL

scitsiretcarahCdaoLlaudividnIslatoTpetSdaoL

AVkSWkSAVkRWkRWkGYTQAVksWksAVkRwkRwkG

>---petsdaolsuoiverpmorflatotWkRretnE—

daoL

.16.773

3.311

9.18

.3—————1 5.01

-.557

—— ————————— —

--petsdaolsuoiverpmorfslatotWkGdna,WkR,AVkRretnE

—— —

822

871

5.01

8.361

-e

8.361

>--------------------------slatoTpetSdaoL

8325.8818.3718.371

7.567

teehskroWgniziSteSrotareneG 2#petSdaoL

scitsiretcarahCdaoLlaudividnI

AVkSWkSAVkRWkRWkGYTQAVksWksAVkRwkRwkG

8.371

---petsdaolsuoiverpmorfslatotWkGdna,WkR,AVkRretnE

9.18

5.8818.3718.371

9.18

8.361

daoL

.2—————198

—— —————

———— —

>---petsdaolsuoiverpmorflatotWkRretnE

—— ———————— — —

>--------------------------slatoTpetSdaoL

7.5525.7727.5526.733

Figure 1. Genset Sizing Worksheets

(Example Two-Step Loading Application)

NOTES: a. For the two 100 HP motors, SkVA = HP x NEMA Code Letter Multiplier (Tab le 6) = 100 x 5.9 x 0.64 = 377.6 b. SkW = SkV A x SPF = 377.6 x 0.3 =113.3 c. RkW = HP x 0.746 / 0.91 = 81.9 d. RkV A = RkW / RPF = 81.9 / 0.92 = 89 e. A GkW total will need to be found because Load #2 is a nonlinear load. Therefore , enter values f or GkW f or the linear loads. GkW= RkW for

linear loads.

f. These values are twice the values in the

individual load characteristics

columns because QTY is 2 for Load #1. g. For the fluorescent lighting, RkW = SkW . SPF and RPF both = 0.95 h. For the 100 HP VFD motor: GkW = RkW x generator sizing f actor = 81.9 x 2.0 = 163.8; SkW = RkW; and SkVA = RkVA.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 19

Page 20

GENSET SIZING

Generator Set Sizing Calculations (Continued) Step 3. Enter Individual Load Characteristics

a. Calculate the values for SkVA, SkW, RkVA, and RkW

and then enter the values on the worksheets. See

determining load characteristics

instructions on how to calculate the values for various types of loads.

b. If the load quantity (QTY) is one, enter the values for

SkVA, SkW, RkVA, and RkW directly onto the columns under the

c. If the load quantity is greater than one, enter the values

for SkVA, SkW, RkVA, and RkW in the columns under the each load entry by the number under QTY and enter the products under the SkW, RkVA, and RkW.

d. If nonlinear loads are included, calculate a GkW value

for each nonlinear load and enter it under the GkW column. Follow the guidelines in part C above for m ultiple nonlinear loads.

load step totals

heading.

individual load characteristics

load step totals

on page 22 for

heading. Then multiply

heading for SkVA,

Step 4. Enter Individual Load Characteristics

Now all the loads on the the

generator set sizing worksheets

characteristics should be calculated and entered on the worksheets, and the worksheets numbered in load step sequence.

Referring back to Figure 1, find the load step totals as follows:

a. Starting with worksheet #1 (Load Step #1), add the

entries in each column under the and enter the sums on the

b. On worksheet #2 enter the

worksheet #1 as instructed on the worksheet.

c. Repeat steps a and b as necessary through all the

worksheets.

d. Go back through all the worksheets and highlight or circle

the highest load step total of SkVA, SkW, RkVA, RkW, and GkW. Generator set selection will be based on these values.

load schedule

should be listed on

load step totals

, all the load

heading

line.

from

e. In order to obtain a total GkW in applications that include

linear as well as nonlinear loads, enter the values for RkW for all the linear loads under GkW as well (RkW = GkW for linear loads only).

PAGE 20 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 21

Generator Set Sizing Calculations (Continued) Step 5. Select a Generator Set

a. Establish the minimum size required

i. At this point the addition of future loads should be

considered. The RkW and RkVA values that were highlighted or circled in Step 4 (previous page) should be multiplied by a factor representing your best judgement.

ii. Referring to the genset specification sheets, pick

the generator set model having a kW/kVA rating that meets the highest RkW and RkVA totals highlighted or circled in Step 4. Use the values calculated for RkW and RkVA in sub-step i above if the future addition of load was factored in.

iii. In addition to the specification sheet, the motor

starting curve should be referenced. Make sure to take into account any derating factors such as high altitudes or ambient temperature.

b. In applications where it is necessary to limit transient

voltage dip to approximately 10 to 20 percent of nominal voltage, multiply the SkVA highlighted or circled in Step 4 by at least 1.25. Repeat the selection steps above.

A transient voltage dip of approximately 20 to 40% can

c. In applications where GkW has been determined (Step

4) and where GkW is greater than the kW rating of the generator set that has been selected, an alternator (AC generator) must be picked for the set which has a kW rating equal to or greater than GkW.

i. See the alternator data sheet for the alternator

ii. If GkW is too high for the alternator selected to meet

iii. If none of the alternators available for the generator

be expected when the genset selected is only slightly greater than the maximum SkVA. The actual transient voltage dip is a function of several factors and is difficult to determine accurately .

GENSET SIZING

temperature rise. Compare GkW to the alternator kW rating at the appropriate voltage. The greater the voltage, the greater the kW rating.

the temperature rise specifications (if any), find the alternator data sheet for the alternator specified for the next lower temperature rise. Compare GkW to the alternator kW rating at the appropriate voltage. Repeat the procedure with any other models. If there are no generator temperature rise specifications that have to be met, consider comparing GkW to the kW rating at the higher temperature rise rating of 125°C.

set has a kW rating sufficient to meet GkW, refer to the specification sheet for the next larger size generator set and repeat the selection process.

NOTE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 21

The running load should not be less then 30 percent of the generator set rating.

Page 22

GENSET SIZING — DETERMINING LO AD CHARACTERISTICS

Determining Load Characteristics Lighting

For all types of lighting loads:

RkW = The sum of the r ated watts of all lamps and ballasts.

Single-Phase Induction Motor

For 1Ø motors, use the SkVA, SkW, RkVA, and RkW values in Table 4 below that correspond to the motor nameplate horsepower and type.

Typical ballast wattages are defined by Table 2 below:

segattaWtsallaB.2elbaT

PMALTSALLAB

taeherP,W04,21-Thcni84W01

tratSdipaR,W04,21-Thcni84W41

tnecseroulFW04tuptuOhgiHW52 W001,yrucreMW53-81 W004,yrucreMW56-52

For all types of lighting loads, except for high intensity discharge (HID), use the following:

SkW = RkW

Due to the starting characteristics of HID lighting, assume that

PHWkRAVkRAVkSWkS

6/13.05.05.38.2 4/14.06.08.48.3 3/15.07.06.55.4 2/17.09.07.71.6

6/13.05.06.20.2 4/14.06.03.36.2 3/15.07.09.31.3 2/17.09.03.552.4 4/30.152.11.77.5

12.16.15.96.7 2/1-16.10.252.414.11

22.27.2912.51

33.31.45.828.22

SkW = 0.75 x RkW

6/13.05.08.23.2

Unless otherwise known, assume the follo wing starting and running power factors (SPF and RPF, respectively , see Table 3 below) for the following types of lighting:

rotcaFrewoPgninnuR&gnitratS.3elbaT

gnithgiLfoepyTFPSFPR

tnecseroulF59.059.0

tnecsednacnI00.100.1

egrahcsiDytisnetnIhgiH58.009.0

Then the following can be calculated:

4/14.06.08.30.3 3/15.07.06.39.2 2/17.09.09.57.4 4/30.152.10.84.6

12.16.16.017.21 2/1-16.10.20.617.21

22.27.22.120.71

33.31.48.135.52

6/13.05.00.18.0 4/14.06.05.12.1 3/15.07.00.26.1 2/17.09.00.34.2

scitsiretcarahCrotoMesahPelgniS.4elbaT

esahPtilpS

nuRnoitcudnI/tratSroticapaC

nuRroticapaC/tratSroticapaC

)CSP(roticapaCtilpStnenamreP

PAGE 22 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 23

GENSET SIZING — DETERMINING LO AD CHARACTERISTICS

Three-Phase Induction Motors

Calculate RkW as follows:

NEMA Code Letter Multiplying Factor Use Table 5 below to calculate the starting kVA. DO NOT

confuse the NEMA (National Electrical Manufacturers Association)

The code letter refers to the ratio of loc ked rotor kVA to HP,

whereas the design letter refers to the ratio of torque to speed. If EFF (motor running efficiency) of the motor is not known, refer to T ab le 5 and use the value corresponding to the motor horsepower .

Calculate RkVA as follows:

If RPF (running power factor) is unknown, ref er to T a b le 5 and use the value corresponding to the motor horsepower .

Calculate SkVA as follows:

1. If the NEMA motor code letter is unknown, refer to

Table 4 on previous page and select the SkVA value corresponding to the code letter and the horsepower. The factors used to generate these values are shown in T ab le 5.

motor code

A0.2 B3.3 C8.3 D2.4 E7.4 F3.5 G9.5 H7.6

J5.7

and

design letters

rotcaFgniylpitluMretteLedoCAMEN.5elbaT

2. If the NEMA motor code letter is unknown, refer to

Table 7 on page 25 and select the SkVA value in bold letters that corresponds to the motor horsepower . The bold letters show the values for the NEMA code letters that are typical for standard motors.

3. If the motor is rated greater than 500 HP and the NEMA

motor code is known, calculate SkVA as follows:

4. If the motor is rated more than 500 HP and the NEMA

motor code is not known, assume a NEMA code letter of G and calculate SkVA as follows:

where 5.9 is the multiplying factor corresponding to NEMA code letter G in Table 5.

K5.8

L5.9 M6.01 N8.11 P2.31 R0.51 S0.61 T0.91 U2.12 V0.32

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 23

Page 24

GENSET SIZING — DETERMINING LO AD CHARACTERISTICS

Determining Load Characteristics (continued)

5. If reduced voltage motor starting is used, determine SkVA as in Steps 1, 2, 3, or 4 on previous page, and then multiply the value by the appropriate multiplying factor in Table 5. Use the following formula:

lluF%

dohteMgnitratS

egatloVlluF0010010010.1—

egatloVdecudeR

remrofsnartotuA

rotcaeRseireS

rotsiseRseireS

egatloV deilppA

08 56 05

46 24 52

08 56 05

Calculate SkW as follows:

1. If SPF (Starting Power F actor) is unknown, ref er to Table 4 on page 22 and use the value corresponding to the motor horsepower.

motor starting is used, use the value for SPF

below .

2. Multiply SkW by 0.5 for motors with low inertia loads (i.e., centrifugal fans, compressors and pumps) where starting torque requirements are low.

lluF%

AVkegatloV

lluF%

egatloV

euqroT

46 24 52

If a resistor-type reduced voltage

in Table 6

scitsiretcarahCdnasdohteMgnitratSegatloVdecudeR.6elbaT

AVkS

gniylpitluM

rotcaF

46.0

24.0

52.0

08.0

56.0

05.0

08.0

56.0

05.0

FPS

— — —

06.0

07.0

08.0

atleDratS001333333.0—

)lacipyT(gnidniWtraP00106846.0—

rotoMrotoRdnuoW001*061*001*6.1—

ehtfoeulavehtnodnepedhcihw,tnerrucgninnurfosrotcafrostnecreperaesehT—*

.sgnidniwrotorehtotdeddasecnatsiserseires

PAGE 24 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 25

GENSET SIZING — DETERMINING LO AD CHARACTERISTICS

Three Phase NEMA Motor Code Table

Table 7 lists the 3Ø motor star ting kVA, starting power factor, and motor factors. Do not confuse the NEMA (National Electrical Manufacturers Association) motor Code and design letters. The code letter refers to the ratio of loc ked rotor kVA to HP, whereas the design letter refers to the ratio of torque to speed.

FPRdna,FFE,FPS,AVkSrotoMesahPeerhT.7elbaT

ABCDEFGHJKLNFPSFFEFPR 4/15.08.09.00.12.13.15.17.19.11.24.2 2/10.17.19.11.24.26.20.33.38.32.47.4 4/35.15.28.22.36.30.45.40.57.54.61.7

1 2 3 4 4 55678892167.00.3707.0

2/1-13566789011131 2478891121315171 36 0111314161810232 50151911242620333

2/1-751528223630454

0102338324743595

51030575461797 020476575859601 52054849601911231 0306001311721241951 0408431151071091212 05001761981212732562

06021102622552582813

57051152382813653793

001002533773524574035 521052814174135395266 051003205665736217497 0020049664579489499501 052005638349160168114231 00300640011311472142419851 05300717110231684116613581 00400883318051896189818112 005000137615881321237328462

sretteLedoCrotoMAMENsrotcaFrotoM

9.2

9.5

9.8

8127.09.6767.0

4207.01.9797.0

825366.05.2828.0

24749516.08.3858.0

7546179865.01.5878.0

57585981135.09.5878.0

00131172124177194.09.6888.0

43115107109163264.06.7898.0

911

76198121273259244.00.8898.0

941

10262255258245324.04.8898.0

871

86220304308357493.09.8809.0

832

53377352457409563.06.9809.0

792

20435401507580763.06.9809.0

753

20566573621758843.00.0909.0

644

076557948949081113.05.0919.0

595

73834926017811574192.09.0919.0

347

4001231147214241077182.02.1919.0

298

9331905199619981063252.07.1919.0

9811

4761688142124732059242.00.2919.0

6841

9002462294529482045322.03.2929.0

4871

3432146237923233031491.01.3929.0

1802

8762810389338973027491.01.3929.0

8732

8433377384248474009571.08.3929.0

3792

28.08.2655.0

87.03.9646.0

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 25

Page 26

GENSET SIZING — DETERMINING LO AD CHARACTERISTICS

Synchronous Motors

Although starting requirements for synchronous motors are lower , it is recommended to determine starting requirements in the same manner as induction motors previously covered.

V ariable Frequency Drives

Variable Frequency Drives are nonlinear loads for which a calculation of GkW is made, in addition to RkW , RkV A, SkW , and SkVA.

Calculate RkW as follows:

Assume 0.9 for EFF (drive running efficiency) unless otherwise known.

Calculate RkVA as follows:

Static UPS

Uninterrupted power supplies are nonlinear loads for which a calculation of GkW will be made, in addition to RkW , RkV A, SkW, and SkVA.

Calculate RkW as follows:

In the equation above:

1. Output kVA is the nameplate kVA capacity of the UPS

2. Battery charging kVA is that required for battery charging, and can range from zero to fifty (0-50%) percent of the UPS kVA rating.

3. If the RPF (Running Power Factor) for the UPS is unknown, assume 0.9 RPF.

4. If the EFF (Running Efficiency) for the UPS is unknown, assume 0.85 EFF.

Unless otherwise known:

Assume 0.9 for RPF (running power factor) unless otherwise known.

Since these drives are all current limiting:

Calculate GkW as follows:

Calculate GkW using the following formula, assuming a generator

When sizing for a pulse width modulated (PWM) drive, consult the drive manufacturer to verify that the drive limits harmonic current is less than 10 percent THD on a high impedance source (e.g. a generator set), assume a sizing factor of 1.4.

Using these factors for GkW results in selecting a generator reactance low enough to limit voltage distortion caused by nonlinear loads to approximately 10 to 15%.

sizing factor of 2

unless otherwise known.

T elecom DC Rectifiers and Battery Charging Equipment

Telecom DC Rectifiers and battery charging equipment are nonlinear loads and similar to static UPS and should be sized using the same method.

PAGE 26 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 27

ENVIRONMENT AL CONSIDERATIONS — dB(A)

Noise Consideration

Because noise effects the surrounding environment, it is important to consider noise factors when installing a genset. The following is a brief approach to evaluating noise sources and noise level reduction.

Noise requires a source, a path, and a receive r. In a standby system, the genset is the source, the path is air or air and a structure which transmits the noise vibrations, and the receiver is a person in the vicinity (including the operator).

Since little prevention can be done with the source or the receiver , the treatment method is to manipulate the pathwa y of noise.

The three main components of noise from an enginegenerator set are:

1. Engine exhaust (low frequency sound)

2. Engine moving parts (low and high frequency sound)

3. Radiator discharge air (high frequency sound).

Noise Laws and Regulations

There are many state and local codes establishing maximum noise levels. Most noise regulations specify the maximum allowable noise level at the property line. Table 8 is an example of typical maximum allowable noise levels. OSHA has specific noise regulations where persons working in a generator room will be required to wear ear protection.

Noise Level Measurement and Decibel / dB(A) Units

T o measure noise properly , the subjective response of human hearing is substituted by an objective measurement of sound measured by a meter. The unit of measurement for sound is the decibel (dB). The decibel is a convenient number on a logarithmic scale expressing the ratio of two sound pressures, comparing the actual pressure to a reference pressure.

Noise regulations are written in terms of "decibels 'A' scale" or dB(A). This term means the sound pressure level has been adjusted to duplicate how the imperfect human ear hears noise. The human ear can only hear within a r ange of frequencies. The dB(A) weighted scale tries to simulate human loudness perception. Loudness is dependent on sound pressure lev el (amplitude) and frequency . See Figure 2 on page 28 for a dB(A) comparison.

Decibel tests are conducted in a "free field". A free field is a sound field in which the effects of obstacles or boundaries on sound propagated in the field are negligible. A "reverberant field" is a sound field in which the effects of obstacles or boundaries on sound propagated in the field are not negligible.

Accurate noise measurements require the microphone to be placed outside the "near field". The near field is defined as the region within one wavelength or two times the largest dimension of the noise source, whichev er is g reater. Noise cannot be measure accurately for compliance with specifications calling for measurements within the near field.

Noise measurements should be made using a sound level meter and octave band analyz er. The microphones should be placed in a circle of 23 feet (7 meters) radius centered on the generator set.

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INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 27

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Page 28

ENVIRONMENT AL CONSIDERATIONS — dB(A)

Comparison Chart dB(A)

Figure 2 below provides a comparison of dB(A) levels for daily noises and the typical range of generator sets. Open generator sets are unhoused units where the path of noise is unobstructed. An acoustic housing encloses the genset to impede and absorb the path of noise.

For applications that require even quieter operation, see the WhisperWatt™ product line f or dB(A) lev els as low as 62. If quieter levels are required, please contact an MQ Power dealer.

Figure 2. dB(A) Comparison Chart

PAGE 28 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 29

ENVIRONMENT AL CONSIDERATIONS — dB(A)

Adding Additional Sound Sources

The noise level at a given location is the sum of the noise levels from all sources, including reflecting sources. For example, the noise level in a free field along side of two identical generator sets would be double the noise level of either set when both sets are running. A doubling of the noise level is represented as an increase of approximately 3 dB(A). In this case, if the noise level from either set is measured as 70 dB(A), the expected result of the combined generators would be 73 dB(A) when both units are running.

Figure 3 below estimates the noise level from multiple noise sources:

1. To find the difference in dB(A) between two of the sources (any pair), locate the dB(A) difference value on the horizontal scale as shown by the horizontal arrow . Add this value to the larger dB(A) value of the pair.

2. Repeat Step 1 between the value just determined and the next value. Keep repeating the process until all noise sources have been accounted for.

Figure 3. dB(A) Comparison Chart

Alternatively, the following formula can be used to add sound pressure levels measured in dB(A):

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 29

Page 30

ENVIRONMENT AL CONSIDERATIONS — dB(A)

Effects of Distance

As the distance between a noise source and receiver increases, the sound level decreases. If a second sound measurement is taken twice as far from the source, the second reading will be approximately 6 dB(A) less than the first reading. If the sound pressure level (SPL at distance d distance d

is known, the sound pressure level (SPL

can be found as follows:

) of a source

It should be noted the background noise level must be at least 10 dB(A) below the noise level of the generator set, the installation must approximate a free field environment and the generator set must be equipped with a critical grade muffler.

) at

Figure 4. below can be used as an alternative to the formula for estimating the sound level at various distances (such as to the property line). For instance , as shown by the dashed arrows, if the noise rating of the generator set is 95 dB(A) at

7 meters, the noise level 100 meters away will be If the sound pressure level (SPL dB(A), then at 7 meters (d

) the sound pressure level (SPL

) at 21 meters (d1) is 100

will be:

approximately 72 dB(A).

)

When using Figure 4, draw a line parallel to the slanted lines

from the known dB(A) value on the vertical scale line to the

vertical line for the specified distance. Then dra w a horizontal

line back to the ver tical scale line and read the new dB(A)

value.

Figure 4. Distance Effects on dB(A)

PAGE 30 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 31

ENVIRONMENT AL CONSIDERATIONS — dB(A)

Reducing Noise

Structure-Borne Noise

Structure-borne noise is transmitted or generated as vibrations in structures. Vibrating structures create sound pressure wav es (noise) in the surrounding air . Connections to a genset can cause vibrations in the building structure, creating noise. Typically, these include the skid anchors, radiator discharge air duct, exhaust piping, coolant piping, fuel lines, and wiring conduit. Also, the walls of a genset housing can vibrate and cause noise.

Reducing Noise

Airborne Noise

Airborne noise is usually the most dominant type of noise. Airborne noise has a directional characteristic, particularly at the high end of the frequency range. Table 9 below shows ways of minimizing airborne noise.

The following will help reduce airborne noise:

1. Redirect noise away from receiv ers. V ertical radiator or exhaust outlets point the noise away from people at grade level and keep them out of the path of noise.

2. Line-of-sight barriers are effective in reducing noise. A

The following will help reduce structure-borne noise:

1. Mounting a genset on spring-type vibration isolators effectively reduces vibration transmission. See the Mounting section of this manual for details (page 33).

2. Flexible connections to exhaust pipe, fuel line, air duct, coolant pipe (remote radiator or heat exchanger systems), and wiring conduit effectively reduce vibration transmission. Flexible connections are required when the genset is mounted on vibration isolators.

3. See Figure 5 on page 32 for typical measures in reducing noise.

sound barrier wall will reduce noise by blocking the sound path of travel. Making noise travel through a 90 degree bend in a duct reduces high frequency noise.

3. Cover enclosure walls, ceiling, and air duct with sound absorbing (acoustic) material.

4. Remote radiators with low speed fans can be used both to reduce the level of noise at the source and to isolate it.

5. Critical grade mufflers are recommended whenever noise control is a concern. The objectionable portion of engine exhaust noise f alls within the range of 125 to 1,000 hertz. Regardless of the grade of muffler selected, its effective (peak) attenuation should be within this frequency range. Typical noise attenuating ratings of mufflers are as follows:

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INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 31

Page 32

ENVIRONMENTAL CONSIDERA TIONS — dB(A)

Acoustic Material

Consider the following when selecting acoustic material:

1. DO NOT use fiberglass as an acoustic material.

Acoustic Material

Figure 5 below illustrates installation methods for reducing noise level to achieve a quieter operating generator set.

Fiberglass is a poor selection of acoustic material because of its low density, poor flame retardant, and poor cleanability.

2. Foam is least likely to deteriorate due to abrasion and has good aesthetics. Howe ver , f oam is difficult to clean and not all foams are fire retardant.

3. A concrete block enclosure is an excellent barrier in regards to noise reduction. The blocks may be filled with sand to make the wall more dense. However, concrete housing tends to become hot and superior cooling methods will be required for proper engine performance.

Structure of

Sufficient Density

to Contain Noise

Vertical

Exhaust

Critical Grade

Muffler 25-35 dB(A)

Attenuation

Wind / Noise Barrier

Flexible Duct

Isolation

Foundation

Section

Vibration

Isolator

Figure 5. Reducing Noise

Flexible Exhaust

Connector

Acoustic

Louvers

PAGE 32 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 33

MOUNTING FOUNDA TION

Mounting

Mounting the generator set is a critical part of the installation. A proper foundation must be able to suppor t the weight of the generator set and its accessories, resist dynamic loads, and not transmit excessive noise and vibration. Foundations can be located on the floor, roof, indoors, or outdoors.

Generator sets are typically mounted on a steel skid that provides support. Vibration isolators are recommended between the skid and the foundation to provide stable operation and avoid installation damage. Bolting the generator set directly to the floor or foundation can result in excessive noise and vibration, and possible damage to the genset and floor/foundation. See Vibration Isolators on page 36 for details.

Access to Set

Whenever choosing a generator site location, always allow room for service personnel and operators to gain the proper access to the unit. Always provide adequate lighting around the unit.

Mounting on a Slab Floor

When mounting the genset on a concrete slab floor, a concrete pad should be poured on top of the floor. The concrete pad should be reinforced concrete with a 28 day compressive strength of at least 2500 psi (173 kP a), howev er 3000 psi is recommended. It should be at least 6 inches (150 mm) deep and extend at least 6 inches (150 mmm) beyond the generator skid on all sides. Type J or L bolts may be used to anchor the skid or vibration isolators to the pad. Where allowed, drill-in anchors can be used.

Mounting on a Sub-Base Fuel Tank

When mounting the genset on a subbase fuel cell, the vibration isolators may be installed between the genset and the fuel tank. The fuel tank must be able to suppor t the weight of the genset and resist the dynamic loads. It is recommended that the tank be mounted with air space between the bottom of the tank and the floor underneath to reduce corrosion and permit visual inspections for leaks.

Mounting on a Vibration Isolating Foundation

When mounting the genset on a foundation to reduce the transmission of vibrations to the building, the weight (W) of the foundation should be at least 2 times the weight of the genset itself to resist dynamic loading. Figure 6 on page 34 illustrates a typical vibration isolating foundation.

Consider the following when mounting on a vibration isolating foundation:



The foundation should extend at least 6 inches beyond the skid on all sides. This determines the length (L) and width (w) of the foundation.



Calculate the height (h) of the foundation necessary to obtain the required weight (W) by using the following formula:

where d is the density of concrete, typically 145 lbs/ ft (2322 kg/ m3)



For convenience in general servicing such as radiator, fan belt, and oil filter maintenance, the surface of the mounting base should be at least 6 inches (152 mm) above the floor.



The foundation must extend below the frost line to prevent heaving.



The foundation should be reinforced concrete with a 28 day compressiv e strength of at least 2500 psi (173 kPa), however 3000 psi is recommended.



The total weight (TW) of the genset, fuel, and foundation usually results in a soil bearing load (SBL) of less than 2000 lbs / ft2 (96 kPa). Although this is within the load bearing capacity of most soils, always find out the allowable soil bearing load by checking the local code and the soil analysis report of the building. The soil bearing load can be calculated by using the following formula:

Another method is to size the isolator to support the weight of the engine-generator accessories, subbase fuel cell, and fuel. Isolators should be mounted underneath the tank.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 33

where "L" and "w" are the length and width of the foundation.

Type J or L bolts should be used to anchor the skid or vibration isolators to the foundation.

Page 34

MOUNTING FOUND A TION

Mounting Foundation

Figure 6 below shows the typical foundation installation. Figure 7 below shows the typical footing on a foundation in

soil with a low load bearing capacity.

Figure 6. Typical Foundation

Figure 7. Typical Footing

PAGE 34 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 35

MOUNTING THE GENERATOR SET

General Information

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, state, and federal building codes, fire ordinances, and other applicable regulations.

Always consider the following prior to installation:

Level mounting surface

Adequate cooling air

Adequate fresh induction air

Discharge of radiator hot air

Discharge of exhaust gases

Electrical connections

Accessibility for operation and servicing

Noise levels

Vibration isolation

Mounting

Mount the generator set on a substantial and level base such as a concrete pad described previously in the Foundation section. Provide properly sized mounting bolts to secure the vibration isolators to the skid using flat or bevel washers and hexagonal nuts for each bolt. (See Figure 8 below .)

The isolators should be located as shown on the genset outline drawing.

Location

The 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 distribution panel.

The generator set should be installed in a protected location that is guarded against vandalism, theft, and unauthorized tampering.

Always provide an optimal installation site that is away from extreme ambient temperatures and that will provide maximum protection against adverse weather conditions.

Incorrect installation or service can result in severe personal injury or death, and/or equipment damage. Only qualified service personnel should be allowed to perform electrical and mechanical component installation.

NEVER install genset over combustible materials. Locate genset such that combustible material can not accumulate under the assembly. The possibility exists of fire or explosion, causing damage to the equipment and or severe bodily harm — even death!

Vibration Isolators

Steel spring isolators can provide up to 98% reduction in the force of vibration transmission. Locate the vibration isolator between the genset skid and foundation in accordance with the installation drawing. The installation may require 4, 6, 8, or 12 vibration isolators.

NOTE

Figure 8. Bolt Diagram

Always consult local air quality

authorities before completing your construction plans. In most instances, standby power units must be registered with the local air pollution control district.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 35

Page 36

MOUNTING — VIBRA TION ISOLA T ORS

Vibration Isolators

Installation and Adjustment Procedure

1. Place the vibration isolators 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 the isolator bases rest on must also be flat and level. (See Figure 9 to the right.)

2. Loosen the snubber lock nuts so that the top plate of the isolator is free to move v ertically and horizontally . Be sure 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 the weight of the generator is applied.

4. Once the genset is in position, the isolators may require adjusting so that the set is lev el. 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). 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 pro vide sufficient clearance f or the rocking that occurs during start-up and shutdown. If the 0.25 inch clearance is not present, turn the leveling bolt until the desired clearance is achieved.

Figure 9. Vibration Isolator

Set mounted radiator-cooled generator sets:

Make sure radiator skid and engine/alternator skid are level with each other after adjusting isolators. Improper fan belt alignment may occur is the unit is not level.

5. Adjust the leveling bolts until the set is level and sufficient clearance still remains. The clearance on all isolators should be roughly equal. Once all isolators have been set, lock the leveling bolt in place with the lock nut.

6. The snubber nuts must remain loose to provide better isolation between the genset and support structure.

Figure 10. Vibration Isolator Installation

PAGE 36 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 37

MECHANICAL INST ALLA TION — FUEL SYSTEM (DIESEL)

MECHANICAL CONNECTIONS Introduction

After considering all applicable codes and laws and finding a suitable location site for the generator set, the installer should consider the mechanical connections that will be necessary to make during installation. The four (4) systems that could require mechanical connections are the following:

Fuel system

Exhaust system

Ventilation system

Cooling system

Fuel System Installation

Proper installation of the fuel system is essential in obtaining proper genset performance, safe working conditions, and preventing property and environmental damage.

When planning an installation, check state and local codes regarding fuel storage and handling. Piping and fuel system components must conform to these regulations. Most applications in the United States require that storage tanks, day tanks, and subbase fuel tanks be UL listed. The UL listing indicates that the tank has conformed to a series of construction and testing standards. In addition, most tanks must conform to National Fire Protection Association (NFPA) construction and installation requirements. The three NFPA codes that apply to day tanks and subbase fuel tanks are NFP A 30, Flammab le and Combustible Liquids Code; NFP A 37, Standard for Installation and Use of Stationary Combustible Engine and Gas Turbines; and NFPA 110, Standard for Emergency and Standby Power Systems.

Use only compatible metal fuel lines to avoid electrolysis. This practice is particulary important when fuel lines must be buried. Buried fuel lines must be protected from any kind of corrosion. Use a

flexible

section of tubing between

the engine and fuel supply line to prevent vibration damage. Refer to the generator set manual for outline drawings and

detailed information.

NEVER use galvanized or copper fuel lines and fittings for fuel tank connection. Condensation in the tank and fuel lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines reacts with the acid and contaminates the fuel, which can clog filters and damage the engine fuel injection pump.

Diesel Fuel

MQ Po wer Industrial generator sets use ASTM No. 2 Diesel fuel. If an alternate diesel fuel is required, consult the appropriate engine manual.

The main components of a typical diesel fuel system are the fuel storage tank, fuel lines, transfer fuel tanks or day tanks, and auxiliary fuel pumps or lift pumps. Fuel storage tanks may be located indoors or outdoors, providing they meet local code requirements. The fuel supply tank should be located near the diesel engine to enable the engine mounted fuel transfer pump to operate within its capability. Fuel filters and fuel/water or sediment separators must be easily accessible for regular and scheduled maintenance. It is important to have a clean installation, making ev ery effort to prev ent entrance of moisture, dirt or contaminants of any kind. Clean all fuel system components before installing.

Supply Tank

Locate the supply fuel tank as close as possible to the generator set and within the five (5') foot (1.5 m) lift capacity of the engine fuel pump. Any fuel tank transfer pump capacity and supply piping should be sized on the basis of the maximum fuel flow rating. Refer to the generator set data sheet for detailed fuel consumption data.

If the main fuel tank is installed below the lift capabilities of the standard engine fuel pump, a transfer tank (referred to as a day tank) and auxiliary pump also will be required. If an overhead main fuel tank is installed, a transfer tank and float valve will be required to prevent fuel head pressures from being placed on the fuel system components.

Fuel leaks create fire and explosion hazards which can result in severe personal injury or flexible tubing between the engine and fuel supply to avoid line failure and leaks due to vibration. The fuel system must meet applicable codes.

death!

Always use

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 37

Page 38

MECHANICAL INST ALLATION — FUEL SYSTEM (DIESEL)

Subbase T ank

Base mounted or subbase fuel tanks are used to store fuel directly underneath the engine-generator set, eliminating the need for a remote main fuel supply tank and/or auxiliary fuel transfer pumps. This mounting arrangement offers the convenience of having a fuel supply tank mounted at the generator .

These tanks are designed to be contained in a rectangular base on which the engine-generator set is mounted. Generally, these tanks only increase the height of the generator set since the tank base is usually matched to the generator skid dimension. For many installations, this type of tank offers advantages over above ground and below ground tanks due to stringent environmental laws making it difficult or impossible to gain necessary approvals.

Subbase fuel tanks are available with the UL142 listing under the special purpose tank category of NFP A. These tanks are availab le in various capacities and designs. When a subbase fuel tank is used, the tank should be designed with a stub-up area on the generator-end of the tank.

This feature allows for an open area on the tank assembly whereby electrical terminations can be brought up underneath the engine-generator for final termination (refer to Electrical Connections section).

Using oversized subbase fuel tanks, where the tank is larger than the skid of the generator, can cause difficulty in completing final electrical connections. The tank should be designed with a stub-up area on the generator-end of the tank. However, depending on the placement of the enginegenerator on the tank, feeder terminations may not rise in a close proximity to the circuit breaker. This could require the feeder conductors to enter the circuit breaker enclosure from the side or top, necessitating special fittings and/or hardware. Be sure to check with the local inspection authority before proceeding.

Failure to pro vide an overflo w line to the supply tank from the day tank can cause spilled fuel, safety hazards, and damage to equipment. Wipe up any spilled fuel immediately. Spilled fuel if ignited can cause a fire or explosion, causing damage to the equipment and severe bodily harm — even

death!

Day T ank

Fuel day tanks are used when the engine fuel pump does not have the capacity to draw the fuel from the supply tank; or the supply tank is overhead and presents problems of high fuel head pressure for the system.

In high ambient conditions, the day tank temperature might need to be considered. W arm fuel returning from the engine fuel injection pump should not be returned to the day tank if possible. As fuel temperature increases, fuel density and lubricity decrease, reducing maximum power output and lubrication of fuel handling parts such as pumps and injectors.

may

This tank rather than the day tank.

Supply Tank Lower than Engine Installation

If a supply tank is lower than the engine, the day tank is installed near the generator set and within the engine fuel pump lift capability, but below the fuel injection system. Install an auxiliary fuel pump as close as possible to the supply tank to pump fuel from the supply tank to the day tank. A float switch in the day tank controls operation of the auxiliary fuel pump.

The supply tank top must be below the day tank top to prevent siphoning from the fuel supply to the day tank.

Provide a return line from the engine injection system return connection to the day tank (near the top). Provide a day tank overflow line to supply tank in case the float switch fails to shut off the fuel transfer pump.

Supply Tank Higher than Engine Installation

If a supply tank is higher than the engine, the day tank is installed near the generator set, but below the fuel injection system. Fuel lines should at least be as large as the fuel pump inlet. The engine fuel return line must enter the day tank.

Include a shut-off valve in the fuel line between the fuel supply tank and the day tank to stop fuel flow when the generator set is not in use and the battery is disconnected (Off Mode).

Engine Fuel Connections

Identification tags are attached to the fuel supply line and fuel return line connections by the factory. Flexible lines for connecting between the engine and stationary fuel line are supplied as standard equipment.

be avoided by returning the fuel back to the supply

PAGE 38 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 39

MECHANICAL INST ALLATION — FUEL SYSTEM (DIESEL)



Diesel Fuel Supply

Consider the following when installing a diesel fuel supply system:



Fuel supply tank construction, location, installation, venting, piping, testing, and inspection must comply with all applicable codes. In addition, see NFPA Standards No. 30 and No. 37.



Fuel supply tanks must be adequately vented to prevent pressurization, have provisions for manually draining or pumping out water and sediment, and have at least a five percent expansion space to prevent fuel spillage when the fuel heats up and expands.



The fuel lift pump, day tank transfer pump, or float valve seat should be protected from fuel supply tank debris by a pre-filter or sediment bowl with a 100 to 120 mesh element.



The supply tank must hold enough fuel to run the genset for the prescribed number of hours (NFPA No. 110 Class designation) without refueling. Tank sizing calculation should be based on the hourly fuel consumption rates on the genset specification sheet.



For emergency power systems, codes might not permit the fuel supply to be used for any other purpose, or may specify a drawdown level for other equipment that guarantees the fuel supply for emergency power use.



The cetane rating of No. 2 heating oil is not high enough for dependable starting of diesel engines in extreme cold weather climates. Therefore , separate supply fuel tanks for emergency power and building heating systems may have to be provided.



Approved flexible fuel hose must be used for connections at the engine to prevent damage from genset movement and vibration.



Diesel fuel lines should be black iron pipe. Cast iron and aluminum pipe and fittings must NOT be used because they are porous and can leak.



Galvanized fuel lines, fittings, and tanks SHOULD NOT be used because the galvanized coating reacts with the sulfuric acid that forms when the sulfur in the fuel combines with tank condensation. Such a practice would result in debris that can clog fuel pumps and filters.



Although copper has been used for diesel fuel lines in the past, black iron pipe is preferred. Diesel fuel polymerizes (thickens) in copper tubing during long periods of standby. This can cause the fuel injectors to clog.

Refer to the engine specification sheet for the maximum fuel inlet and return restrictions, the maximum fuel flow, and the fuel consumption. Then refer to Table 10 for the minimum hose and pipe sizes for connections to a supply tank or day tank that is relatively close to the set at approximately the same elevation. Hose and pipe size should be based on the maximum fuel flow rather than the fuel consumption

twice the full-load fuel consumption)

recommended that the fuel inlet and return restrictions be checked before the set is placed into service.



Separate fuel return lines to the day tank or supply tank must be provided for each generator set in a multiple-set installation to prevent the return lines of any idle set from being pressurized. Also, a fuel return line must NOT include a shut-off device. Engine damage will occur if the engine is run when the fuel line is shut off.



A day tank is required whenever pipe friction and/or supply tank elevation, either below the fuel pump inlet or above the fuel injectors, would cause an excessive fuel inlet or return restriction.



For critical start applications, where gensets are paralleled or must satisfy emergency start-time requirements, it is recommended that a fuel tank or reservoir be located such that the lowest possible fuel level is not less than 6 inches (150 mm) above the fuel pump inlet. This will prevent air from accumulating in the fuel line while the genset is in standby, eliminating the period during startup when the air has to be purged.

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INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 39

Page 40

MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS)

Gaseous Fuels

Some MQ Power Industrial generator sets may utilize gaseous fuels such as Pipeline natural gas or Liquid Petroleum Gas (LPG). Regardless of the fuel used, the primary factors in successful installation and operation of a gas fuel system are:



The gas supplied to the generator set must be of acceptable quality.



The gas supply pressure must be measured to ensure that the gas supply at the generator set, not just at the source, is of proper pressure must be available while the generator is running at full load.



The gas must be supplied to the genset in sufficient

BTU Content

The total BTU content of the fuel will determine the rating of the generator set when using fuel of a specific compostion. If any component of the fuel has more than the specific value allowed, der ating will be required. Consult MQ P ower for fuel derating instructions.

TABLE 11. TYPICAL BTU CONTENT OF GASEOUS FUEL

DRY PIPELINE GAS FIELD GAS LPG

LHV HHV LHV HHV LHV HHV

936

BTU/ft

volume to support proper operation.

Pipeline Natural Gas

The most common gaseous fuel for generator sets is

Failure to meet the minimum requirements in these areas will result in the inability of the generator set to operate or carry rated load and will induce poor performance.

pipeline natural gas" has specific qualities based on federal requirements. U.S. pipeline gas is a mixture composed of approximately 98% methane and ethane

called

Pipeline natural gas

with the other 2% being hydrocarbons such as propane

Gaseous fuels are actually a mixture of several different hydrocarbon gases and various contaminants, some of which are potentially damaging to an engine over time.

and butane, nitrogen, carbon dioxide, and water vapor. "Dry" means that is free of liquid hydrocarbons such as gasoline, but NOT that it is free of water vapor.

The quality of the fuel is based on the amount of energy per unit volume in the fuel and the amount of contaminants in the fuel. Most gaseous fuel suppliers can provide a fuel analysis that describes the chemical makeup of the fuel that is to be provide to insure that the fuel is usable for a specific application, and also to verify that the BTU content of the fuel is sufficient to provide necessary kW output of the genset.

Field Gas

The composition of by region and continent. Careful analysis is necessary prior to using field natural gas in an engine because in can contain heavier hydrocarbon gases which may require derating of the output of the engine. Field natural gas may also contain other contaminants such as sulfur.

1,038

BTU/ft

1,203

BTU/ft

1,325

BTU/ft

. In the United States, "dry

Field natural gas

2,353

BTU/ft

2,557

BTU/ft

varies considerably

Energy Content

One of the most important characteristics of gaseous fuel used in a generator set is the heat value of the fuel. The value of a fuel describes how much energy is stored in a specific volume of the fuel. Gaseous fuel has a low heat value (LHV) and a high heat value (HHV). The low heat value is the heat available to do work in an engine after the water in the fuel is vaporized. If the low heat value of the fuel is too low (generally below 905 BTU/ft the engine will not be able to maintain full output power

Liquid Petroleum Gas (LPG)

Liquid Petroleum Gas is available in two grades, commercial and special duty. Commercial propane is used where high volatility is required. Special duty propane (also called HD5) is a mixture of 95% propane and other gases such as butane that allows better engine performance due to the reduction pre-ignition due to

reduced volatility. Special duty propane fuel should meet

)

the ASTM D 1835 specifications for special duty propane.

and may not produce rated power at standard ambient temperature conditions.

PAGE 40 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 41

MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS)

Contaminants

The most harmful contaminants in gaseous fuels are water vapor and sulfur. Water vapor is damaging to an engine because it may cause uncontrolled burning, pre-ignition, or other effects that can damage an engine. Liquid vapor or droplets must be removed from the fuel prior to entry into the engine by use of a dry filter that is mounted in the fuel system prior to the primary fuel pressure regulator. Sulfur and hydrogen sulfides will cause corrosion and serious damage to an engine over a relative short periods of time. The effects of sulfur in the fuel can be counteracted in part by use of high-ash natural lubricating oils. In general, engines should not be operated with fuels in excess of 10 parts per million (ppm).

Gaseous Fuel Supply

Consider the following when installing a natural gas or LPG fuel system:



Gaseous fuel supply system design, materials, components, fabrication, assembly, installation, testing inspection operation and maintenance must comply with all applicable codes and standards. In addition, see NFP A Standards No. 30, No. 37, No. 54 and No . 58.



The layout and sizing of gas piping must be adequate for handling the volume of gas required by the genset and all other equipment, such as building heating boilers supplied by the same source. Full load gas flow must be available at not less that the minimum required supply pressure, typically from 5 to 10 inches WC (water column) depending on the model. Final determination of pipe sizes must however be based upon the method approved by the authority having jurisdiction (see NFPA No. 54).



Most installations will require one or more service gas pressure regulators. Gas supply pressure should not exceed 13.8 or 20 inches WC at the inlet to the generator set depending on the model. High pressure gas piping is not permitted inside buildings (5 psig for natural gas and 20 psig for LPG unless higher pressures are approved by the authority having jurisdiction). Gas pressure regulators must be vented to the outdoors according to code.



All fuel gas systems at service pressures of 125 psig and less shall be installed in accordance with NFPA 54. All fuel gas systems at service pressures in excess of 125 psig shall be installed in accordance with ANSI/ ASME B31.3.



LP-Gas systems, whether liquid or vapor phase, shall be installed in accordance with the provisions of NFPA

58.



The pressure regulator installed on the supply line at the gas source for generator applications should never be a “pilot” regulator . A “pilot” style regulator is the type where the regulator requires a pressure line from the regulator housing to the downstream gas pipe to “sense” when downstream pressure has dropped. Pilot regulators do not work because the response time is unacceptable compared to the large–instantaneous changes in demand from the generator set.



Approved flexible fuel hose must be used for connections at the engine to take up generator set movement and vibration.



Most codes require both manual and electric (battery– powered) shut-off valves ahead of the flexible fuel hose(s). The manual valve should be of the indicating type.



A dry fuel filter should be installed in each line to protect the sensitive pressure regulating components and orifices downstream from harmful foreign substances carried along in the gas stream (rust, scale, etc.).



The rate of vaporization in an LPG tank depends upon the outdoor air temperature, unless the tank is equipped with a heater, and the quantity of fuel in the tank. Even on cold days ambient air heats and vaporizes LPG (mostly through the wetted tank surface) when air temperature is higher than LPG temperature. Withdr awing vapor causes tank temperature and pressure to drop. (At –37° F [–38° C] LPG has zero vapor pressure.) Unless there is enough fuel and enough heat available from ambient air, the vaporization rate will drop off, as the generator set runs, to less than that required to continue running properly .

Leakage of gaseous fuel is extremely dangerous. Natural gas and LPG contain carbon monoxide which can cause severe bodily harm or and fires will occur if gas or propane leakage occurs where there is a spark. To prevent such hazards, immediately shut off all natural gas or propane supplies if a leak is detected. If in an enclosed area, ventilate the area as quickly as possible.

death when inhaled. Also, serious explosions

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 41

Page 42

MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS)

Pipe and Tube Sizing

Sizing gas piping for proper fuel delivery , both f or flow and pressure is very important. T ables 12 thru 16 show maximum gas capacity for equivalent length for various pipe sizes considering the general fuel sysem operating requirements for proper operation of the generator set. The illustrations (Figures 11 thru 13) are typical pipe configurations for proper natural gas, liquid propane and propane vapor distribution. Consult NFP A 54 or other applicable codes f or other operating conditions or other fuel system installation requirements.

Figure 11. Typical Pipe Schematic for Natural Gas Distribution

TABLE 12. NATURAL GAS SCHEDULE 40 IRON PIPE SIZING

Pipe Size (in.)

1/4

3/8

1/2

Length

(0.364)

(ft.)

10 43 95 175 360 680 1400 2100 3950 6300 11000 23000 20 29 65 120 250 465 950 1460 2750 4350 7700 15800 30 24 52 97 200 375 770 1180 2200 3520 6250 12800 40 50 60 16 36 66 138 260 530 810 1520 2400 4300 8800 70 80

90 13 29 53 110 205 430 650 1220 1950 3450 7200 100 12 27 50 103 195 400 620 1150 1850 3250 6700 125 11 24 44 93 175 360 550 1020 1650 2950 6000 150 175 200

(0.493)

20 45 82 170 320 660 990 1900 3000 5300 10900 18 40 73 151 285 580 900 1680 2650 4750 9700

15 33 61 125 240 490 750 1400 2250 3900 8100 14 31 57 118 220 460 690 1300 2050 3700 7500

10 22 40 84 160 325 500 950 1500 2650 5500

9 20 37 77 145 300 460 850 1370 2450 5000 8 19 35 72 135 280 430 800 1280 2280 4600

3/4

(0.622)

(0.824)1(1.049)

Maximum Capacity in Cubic Feet of Gas per Hour

1 1/4

(1.380)

1 1/2

(1.610)2(2.067)

2 1/2

(2.469)3(3.068)4(4.026)

TABLE 13. NAT URAL GAS SEMI-R IGID COPPER TUB ING SIZING

1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 2 2 1/2

Tube Size

* Table capacities are based on Type K copper tubing inside diameter (shown), which has the smallest inside

diameter of the copper tubing products.

K&L

(in.)

Outside

Inside *

Length (ft)

10 20 30 40 50 11 23 47 82 116 247 445 701 1461 2584 60 70 80 90

100 125 6.8 14 28 50 70 151 271 427 890 1574 150 175 200 5.2 11 22 39 55 117 210 331 690 1221 250 300

3/8 1/2 5/8 3/4 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8

ACR

0.375 0.500 0.625 0.750 0.875 1.125 1.375 1.625 2.125 2.625

0.305 0.402 0.527 0.652 0.745 0.995 1.245 1.481 1.959 2.435 Maximum Capacity in Cubic Feet of Gas per Hour

27 55 111 195 276 590 1062 1675 3489 6173 18 38 77 134 190 406 730 1151 2398 4242 15 30 61 107 152 326 586 925 1926 3407 13 26 53 92 131 279 502 791 1648 2916

10 21 42 74 105 224 403 635 1323 2341

9.3 19 39 68 96 206 371 585 1218 2154

8.6 18 36 63 90 192 345 544 1133 2004

8.1 17 34 59 84 180 324 510 1063 1880

7.6 16 32 56 79 170 306 482 1004 1776

6.1 13 26 45 64 136 245 387 806 1426

5.6 12 24 41 59 125 226 356 742 1312

4.7 10 20 34 48 103 186 294 612 1082

4.2 8.7 18 31 44 94 169 266 554 980

PAGE 42 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 43

MECHANICAL INST ALLA TION — FUEL SYSTEM (GASEOUS FUELS)

Figure 12. Typical Pipe Schematic for Propane Vapor Distribution

TABLE 14. PROPANE VAPOR SCHEDULE 40 IRON PIPE SIZING

Pipe Size (in.)

1/2

Length

(ft.)

10 20 30 40 50 60 110 231 434 892 1337 2574 7253 10619 14793

80 100 125 150 67 140 265 543 814 1568 4418 6468 9011

200 250 300 350 400

3/4

(0.622)

(0.824)1(1.049)

Maximum capacity in thousands of BTU per hour

291 608 1145 2352 3523 6786 19119 27993 38997 200 418 787 1616 2422 4664 13141 19240 26802 160 336 632 1298 1945 3745 10552 15450 21523 137 287 541 1111 1664 3205 9031 13223 18421 122 255 480 984 1475 2841 8004 11720 16326

94 197 372 763 1144 2203 6207 9088 12661

84 175 330 677 1014 1952 5501 8055 11221

74 155 292 600 899 1730 4876 7139 9945

58 120 227 465 697 1342 3781 5536 7712

51 107 201 412 618 1189 3351 4906 6835 46 97 182 373 560 1078 3036 4446 6193 42 89 167 344 515 991 2793 4090 5698 40 83 156 320 479 922 2599 3805 5301

1 1/4

1 1/2

(1.38)

(1.61)2(2.067)3(3.068)

3 1/2

(3.548)4(4.026)

TABLE 15. PROPANE VAPOR SEMI-RIGID COPPER TUBING SIZING

1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 2 2 1/2

Tub e S i z e

* Table capacities are based on Type K copper tubing inside diameter (shown), which has the smallest inside

diameter of the copper tubing products.

K&L

(in.)

Outside Inside *

Length (ft)

10 20 30 40 50 19 39 79 138 195 417 752 1185 2468 4366 60 70 80 15 30 61 107 152 324 583 919 1914 3386 90

100 125 11 24 48 84 119 254 458 722 1503 2660 150 175

200 8.9 18 37 65 92 197 355 560 1166 2062 225 250 275 7.5 15 31 55 78 166 299 471 981 1736 300

3/8 1/2 5/8 3/4 7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8

ACR

0.375 0.500 0.625 0.750 0.875 1.125 1.375 1.625 2.125 2.625

0.305 0.402 0.527 0.652 0.745 0.995 1.245 1.481 1.959 2.435 Maximum Capa city in Cu bic Feet of Ga s per Hour

45 93 188 329 467 997 1795 2830 5895 10429

31 64 129 226 321 685 1234 1945 4051 7168

25 51 104 182 258 550 991 1562 3253 5756

21 44 89 155 220 471 848 1337 2784 4926

17 35 71 125 177 378 681 1074 2236 3956 16 32 66 115 163 348 626 988 2057 3639

14 28 57 100 142 304 546 862 1796 3177 13 27 54 95 134 287 517 814 1696 3001

10 21 44 76 108 230 415 654 1362 2410 10 20 40 70 99 212 382 602 1253 2217

8.3 17 35 61 87 185 333 525 1094 1935

7.9 16 33 58 82 175 315 496 1033 1828

7.1 15 30 52 74 158 285 449 936 1656

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 43

Page 44

MECHANICAL INST ALLA TION — FUEL SYSTEM

Figure 13. Typical Pipe Schematic for Propane Liquid Distribution

TABLE 16. LIQUID PROPANE SCHEDULE 40 IRON PIPE SIZ ING

Length of

Pipe, ft.

2000

1/2

3/4

(0.622)

(0.824)1(1.049)

733 1532 2885 5924 8876 17094 48164 70519 98238

627 1311 2469 5070 7597 14630 41222 60355 84079

40 50 556 1162 2189 4494 6733 12966 36534 53492 74518 60 504 1053 1983 4072 6100 11748 33103 48467 67519 70 463 969 1824 3746 5612 10808 30454 44589 62116

431 901 1697 3484 5221 10055 28331 41482 57787

404 845 1593 3269 4899 9434 26583 38921 54220

382 798 1504 3088 4627 8912 25110 36764 51216

100

307 641 1208 2480 3716 7156 20164 29523 41128

150

262 549 1034 2122 3180 6125 17258 25268 35200

200

233 486 916 1881 2819 5428 15295 22395 31198

250 300 211 441 830 1705 2554 4919 13859 20291 28267 350 194 405 764 1568 2349 4525 12750 18667 26006

180 377 711 1459 2186 4209 11861 17366 24193

400

169 354 667 1369 2051 3950 11129 16295 22700

450

160 334 630 1293 1937 3731 10512 15391 21442

500

145 303 571 1172 1755 3380 9525 13946 19428

600

133 279 525 1078 1615 3110 8763 12830 17873

700

124 259 488 1003 1502 2893 8152 11936 16628

800

116 243 458 941 1409 2715 7649 11199 15601

900

110 230 433 889 1331 2564 7225 10579 14737

1000 1500

88 184 348 713 1069 2059 5802 8495 11834 76 158 297 611 915 1762 4966 7271 10128

Pipe Size, in.

1 1/4

1 1/2

(1.38)

(1.61)2(2.067)3(3.068)

3 1/2

(3.548)4(4.026)

Please observe the following when servicing natural gas or LPG supply lines:

• Open any valve SLOWLY.

• DO NOT remove plugs or caps on connections if

shut off valves leak.

• Make sure all unloading connections are tight.

• DO NOT tamper with relief valves.

• NEVER place your face or any other part of your

body over safety relief valves.

PAGE 44 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 45

MECHANICAL INST ALLA TION — FUEL SYSTEM

Fuel Storage Regulations

Use extreme care when using, transporting, and storing fuel. Every measure should be taken to protect personnel and the environment from the dangers of fuel. Fuel supply tank design and installation in North America is controlled by regulations that are generally written for fire protection and environmental protection. It is very important to adopt safe methods of storing fuel and to meet all applicable codes and laws.

Even when an installation is exempt from regulation, it should be recognized that cleanup expenses may be very costly for even small amounts of fuel spillage from leaks, overfilling, etc. The trend in diesel fuel storage for onsite gensets, both indoors and outdoors, has been towards Underwriter Laboratories Listed above ground dual-wall subbase tanks with leak detection.

Fuel leaks and spills can cause environmental contamination. Make sure the area surrounding the fuel tanks and lines will prevent fuel from entering soil, sewers, and water .

Envir onmental Protection

Environmental protection regulations exist at both federal and state levels. Different sets of regulations apply to underground versus above-ground fuel storage tanks. These regulations cover design and construction standards, registration, tank testing, leak detection, closure requirements, preparation of spill prevention plans and provisions for financial responsibility and trust fund coverage.

OSHA Standards for Flammable and Combustible Liquids, exempts above ground installations made in accordance with NFPA 37. Exemption status from state regulation must be verified before installation.

Fire Protection

Fire protection regulations adopt by reference one or more of the National Fire Protection Association (NFPA) standards. These standards cov er the maximum amount of fuel that can be stored inside buildings, fuel piping systems, the design and construction of fuel tanks, fuel tank locations, drainage provisions, etc. Local fire marshals may have more restrictive requirements or interpretations of requirements than national standards.

Additional references include:

UL 142, Steel Abo ve-ground Tanks f or Flammable and Combustible Liquids — This safety standard

covers design, construction, and testing requirements for third-party certification.

Uniform Fire Code, Western Fire Chiefs Association and International Conference of Building Officials — This standard covers piping,

valves, fittings, stationary storage tanks (above ground and underground; inside, under, and outside buildings), etc.

API 1615, Installation of Underground Petroleum Product Storage Systems, American Petroleum Institute (API) — This standard covers pre-

installation site analysis, material, and equipment requirements, removal and disposal of used storage systems, excavation, cathodic protection, detection of releases, piping, backfilling and vapor recovery.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 45

Page 46

MECHANICAL INST ALLA TION — EXHA UST SYSTEM

Exhaust System Installation

A proper exhaust system installation will ensure safe working conditions and maximum engine efficiency. All MQ PowerMQP Series, standby, engine-generators have factorydesigned mufflers, exhaust connectors and rain caps available for each model. For best performance and ease of mounting, it is recommended the factory components be used whenev er practical. Ref er to Table 17 on page 49 for a complete listing of factory recommended exhaust silencers for each model. A properly installed exhaust system routes engine exhaust to a safe location where the exhaust can dissipate with fresh air. The exhaust system disperses engine exhaust fumes, soot, and noise away from people, vents and buildings. It is essential to the performance of the enginegenerator set that the installed exhaust system does not exceed the engine manufacturer’s maximum exhaust backpressure limit. Pressure drop of an exhaust system includes losses due to piping, silencer and termination. High backpressure can cause a decrease in engine efficiency or increase in fuel consumption, overheating, and may result in a complete shut down of the engine-generator. Potential damage could result. Ref er to Table 17 on page 49 for back pressure limits for each model generator set.

DO NOT use e xhaust heat to warm a room, compartment, or storage area.

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 the engine exhaust elbow.

Field Installing A Generator Exhaust System

All work should be completed by qualified persons familiar with the installation, construction and operation of generator sets. All work should be completed in accordance with the National Fire Protection Association (NFP A), Unif orm Building Code (UBC) and other state or local codes.

Some generators require little or no engine exhaust component installation. In most cases, if the generator set is equipped with a manufacturer’s installed, weather protective enclosure, the engine exhaust system is generally already mounted and plumbed within or on top of the generator enclosure. There is little or no site work that has to take place. Check with the engine-generator manufacturer for specific details.

Inhalation of exhaust gases can result in severe personal injury or

Use extreme care during installation to provide a tight exhaust system. Terminate exhaust pipe away from enclosed or sheltered areas, windows, doors, and vents.

death!

Figure 14. Mounting Exhaust Thimble

PAGE 46 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 47

MECHANICAL INST ALLA TION — EXHA UST SYSTEM

MECHANICAL INST ALLA TION — EXHA UST SYSTEMIf the engine-generator is not equipped with a factory mounted

exhaust system, such as a unit mounted inside a building or room, the installation of the engine exhaust system has to be planned very carefully. When installing an exhaust system on an open or un-housed generator, consider the

following recommendations:

1. After a thorough review of the exhaust installation requirements, select the engine silencer, piping and exhaust fittings based on the engine manufacturer’s maximum exhaust backpressure limits.

2. Use flexible, corrugated stainless steel exhaust tubing, 12 to 18 inches (305 - 457 mm) in length, to connect the exhaust silencer to the engine e xhaust outlet. This tube or flex connector allows for thermal expansion and engine vibration.

3. Be sure to support the exhaust system (muffler, piping, etc.) to minimize the total weight applied to the engine exhaust manifold and exhaust outlet elbow or turbocharger connection.

4. Exhaust piping should conform to NFPA 37, Stationary Engines and Gas Turbines design practices, and any applicable local codes.

5. Avoid sharp bends in the exhaust piping by using sweeping, long radius elbows and provide adequate support for muffler and all associated piping.

6. Pitch a horizontal run of exhaust pipe DOWNWARD to allow 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. See Figure 15 on page 48.

7. Shield or insulate exhaust piping if there is any possibility of personal contact. Allow at least 12 inches (305 mm) of clearance where piping passes close to a combustible wall or partition.

8. Use an approved, insulated & ventilated, metal thimble where exhaust pipes pass through a combustible wall or partition.

9. Always pipe exhaust gases to the outside of any building or room. Route the engine exhaust away from any building air inlets to avoid engine exhaust fumes from entering the building fresh air intake. Some codes specify that the exhaust outlet terminate at least 10-feet (3 meters) from the property line, 3-feet (1 meter) from an exterior wall or roof, 10-feet from openings into buildings and at least 10-feet above any adjoining grade.

10. The installation of a rain cap is required for the discharge end of the exhaust system piping, if the piping is vertical. The rain cap clamps onto the end of the pipe and opens from the exhaust discharge force from the generator set while running. When the generator set is stopped, the rain cap automatically closes, protecting the exhaust system from rain, sno w, etc.

11. Once the exhaust system has been installed, it is important to regularly inspect the exhaust system both visually and audibly to see that the entire system remains sealed against leakage and safe for operation.

DO NOT use fle xible tubing to form bends or to compensate for misaligned piping.



Reduce corrosion from condensation by installing the

muffler as close as practical to the engine.



Support mufflers and piping by non-combustible hangers or supports. DO NO T use the engine exhaust outlet f or support. W eight on the engine exhaust outlet can cause damage to the engine exhaust manifold or reduce the life of a turbocharger.



Schedule 40 black iron pipe is recommended for exhaust piping.



Pipe bend radius should be as long as practical.



NEVER use exhaust tubing and piping of smaller diameter than the exhaust outlet. Verify the back pressure limitation of the engine, and use exhaust tubing and piping of the appropriate size throughout the exhaust system.



DO NOT use piping that is larger than necessary to avoid corrosion from condensation. Doing so also reduces the exhaust gas velocity available for dispersing the exhaust gases up and away in the outdoor wind stream.



Keep e xhaust pipe diameter changes to a minim um to avoid friction and performance loss.



A genset should not be connected to an exhaust system servicing other equipment, including other gensets. Soot, corrosive condensation, and high exhaust gas temperatures can damage idle equipment served by a common exhaust system.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 47

Page 48

MECHANICAL INST ALLA TION — EXHA UST SYSTEM



Thermally insulate exhaust piping and mufflers as required to prevent burns from accidental contact, prevent activation of fire detection devices and sprinklers, reduce corrosion due to condensate, and reduce the amount of heat radiated to the generator room.

Engine exhaust manifolds and turbocharger housing, unless approved by the engine manufacturer, must never be insulated. This can result in material temperatures that can destroy the manif old and turbocharger.



Exhaust piping must be routed at least 12 inches (305 mm) from combustible construction. Use approved thimbles where exhaust piping must pass through combustible walls or ceilings.



Exhaust pipe (steel) expands approximately 0.0076 inches per foot of pipe for every 100°F rise in exhaust gas temperature above room temperature (1.14 mm per 100°C rise). It is recommended that flexible, corrugated stainless steel tubing be used to take up expansion in long, straight runs of pipe.



Horizontal runs of exhaust piping should slope downwards, away from the engine, to the outdoors or to a condensation trap.



A condensation drain trap and plug should be provided where piping turns to rise vertically. See Figure 15.



A rain cap should be used if the exhaust outlet is vertical.



The exhaust system must terminate outdoors at a location where engine exhaust will disperse away from buildings, animals, and building air intakes. In addition, the exhaust must not be allowed to blacken walls or windows with soot.



It is highly recommended that the exhaust system be carried up as high as practical on the downwind side of buildings and that it is discharged straight up to maximize dispersal.

Exhaust back pressure must not exceed the allowable back pressure of the engine. Excessive exhaust back pressure reduces engine power , engine life , and may lead to high exhaust temperatures and smoke.

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.

Figure 15. Condensation Trap

NOTE

Some codes specify that the exhaust outlet terminate at least 10 feet (3 meters) from the proper ty line, 3 feet (1 meter) from an exterior wall or roof, 10 feet from openings into buildings, and at least 10 feet above the adjoining grade.

PAGE 48 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 49

MECHANICAL INST ALLA TION — EXHA UST SYSTEM

Exhaust System Installation Reference Data

The following Tables are provided for reference when installing the exhaust system.

Table 17. Factory Recommended Engine Exhaust Silencers

MQ Power

Generator Model

Number

MQP20IZ

MQP30GM

MQP30DZ

MQP40IZ

MQP45GM

MQP50IZ

MQP60GM

MQP60IV

MQP80GM

MQP80IV

MQP100GM

MQP100IV MQP125IV MQP150IV COWL TS40TR 4 (101.6) 28 50 (22 .67) MQP175IV MQP200IV MQP250IV MQP300IV MQP350IV

MQP400IV MQP450VO MQP500VO MQP550VO MQP600VO

Silencer

Manufacturer

Name

SILEX JB-2.5 2.5 (63.5) 41 27 (12.15) NETT EE48968 3 (76.2) 50 50 ( 22.67) SILEX JB-2.5 2.5 (63.5) 41 27 (12.15) SILEX JB-2.5 2.5 (63.5) 41 27 (12.15) NETT EE49242 3 (76.2) 50 75 ( 34.05) SILEX JB-2.5 2.5 (63.5) 41 27 (12.15) NETT EE48969 3 (76.2) 50 85 (38.5) SILEX JB-2.5 2.5 (63.5) 41 27 (12.15) NETT EE48970 3 (76.2) 50 100 (45.4)

COWL TS30TR 3 (76.2) 20 34 ( 15.42)

NETT EE49243 3 (76.2) 50 100 (45.4) COWL TS30TR 3 (76.2) 28 34 ( 15.42) COWL TS40TR 4 (101.6) 28 50 (22 .67)

COWL TS45TR 4.5 (114.3) 40 60 (27.21) COWL TS45TR 4.5 (114.3) 40 60 (27.21)

COWL TS60TR 6 (152.4) 40 94 (42 .63) COWL TS60TR 6 (152.4) 40 94 (42 .63)

COWL TS80TR 8 (203.2) 28 1 62 (73.5) COWL TS80TR 8 (203.2) 28 1 62 (73.5) COWL TS80PR 8 (203.2) 40 154 ( 70.0) COWL TS80PR 8 (203.2) 40 154 ( 70.0)

Silencer

Model

Number

Inlet/Outlet

Diameter

In. (mm)

TBD

Maximum Allowable

Back-Pressure

Inches-WC

Total Weight of

Sliencer

lbs. (Kg.)

Table 18. Cross-Sectional Areas of Openings of Various Diameter

Diameter of

Muffler Inlet (In.)

Area of Muffler

Inlet (FT

)

Diameter of

Muffler Inlet (In.)

Area of Muf fler

Inlet (FT2)

2 0.0218 5 0.1363

2.5 0.0341 6 0.1963 3 0.0491 8 0.3491

3.5 0.0668 10 0.5454 4 0.0873 12 0.7854

Table 20. Heat Losses from Uninsulated Exhaust

Pipes and Mufflers

Pipe Diameter

Inches (mm)

1.5 (38) 47 (162) 297 (313) 2 (51) 57 (197) 490 (525)

2.5 (64) 70 (242) 785 (82 8)

Heat From Pipe BTU/MIN-FOOT

(kj/Min-Metre)

Heat From Muffler

BTU/MIN (kj/Min)

3 (76) 84 (291) 1,100 (1,160)

Table 19. Equivalent Lengths of Pipe Fittings (Feet)

Type of Fitt ing

22.533.54 5 6 8 1012

Standard Elbow 5.3 6.4 8.1 9.6 11 14 16 21 26 32

Medium Elbow 4.6 5.4 6.8 8 9 12 14 18 22 26

Long Radius Elbow 3.5 4.2 5. 2 6 7 9 11 14 17 20

45° Elbow 1.5 2 2.3 2.6 3 4 4.5 6 8 9

Nominal Diamet er (Inches)

3.5 (98) 96 (332) 1,408 (1,485)

4 (102) 108 (374) 1,767 (1,864) 5 (127) 132 (457) 2,500 (2,638) 6 (152) 156 (540) 3,550 (3,745)

8 (203) 200 (692) 5,467 (5,768) 10 (254) 249 (862) 8,500 (8,968) 12 (305) 293 (1,014) 10,083 (10,638)

Standard Tee 131417192227344456 67 18 Inch Flexible Tube3333333333 24 Inch Flexible Tube4444444444

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 49

Page 50

MECHANICAL INST ALLA TION — B A TTER Y SYSTEM

Purpose of the Battery

The major function of the battery is to

start the engine

engine varies by model. Cranking current is dependent upon the engine stroke and bore, the number of cylinders, engine/ starter ratio, circuit resistance, temperature, engine oil viscosity, and the accessory loads. A four-cylinder engine could require as much cranking current as an eight-cylinder engine with greater displacement. All of these factors are considered when an original equipment battery is specified by the engine manufacturer.

How Batteries W ork

When two unlike materials such as the battery positive and negative plates are immersed in sulfuric acid (the electrolyte), a battery is created and a voltage is developed. The voltage developed depends on the types of materials used in the plates and the electrolyte used. Electrical energy is produced by the chemical reaction between the different materials and the electrolyte. When the chemical reaction starts, electrical energy flows from the battery as soon as there is a circuit between the battery positive and negative terminals.

Lead-acid storage battery voltage is determined by the materials used in its construction. The chemicals used are:

Lead dioxide (PbO2) — the material on the positive

Sponge lead (Pb) — the material on the negative grid

Sulfuric acid (H2SO4) — the electrolyte

The battery also supplements the DC load requirements whenever the load excess the charging system's ability to deliver the necessary power. Charging systems will carry the electrical load under normal conditions. Ho we v er, if the engine is at idle speed, the battery may have to supply a portion of the accessory load. The battery must supply the genset's electrical load requirements if the charging system fails.

The battery can also act as a voltage stabilizer in the charging system. Occasionally, very high transient voltages are generated in the electrical system. This may occur in the making or breaking of a circuit in the system. The battery partially absorbs and reduces these peak voltages, thereby protecting solid-state components from damage.

. The current required to crank the genset

supply current to

MQ Po wer Batteries

MQ Power Industrial Gensets use heavy duty commercial grade, lead acid type, low water-loss batteries. These batteries do not need to be serviced (such as adding water), and when properly maintained only need to be replaced after the pro-rata date (usually 36 months).

Batteries are sized to meet or exceed engine manufacturer's ampere/hour starting requirements and comply with NFP A110 requirements for engine cycle-cranking.

Low Water-loss Batteries

A low water-loss battery is designed to relieve the consumer of routine maintenance requirements such as adding water during the service life of the battery. Low water-loss batteries produce very little gas at normal charging voltages and, therefore, the rate of water loss is very low. MQ Power battery rate of water loss is low enough that the venting systems can be completely sealed, except for small vent holes, and water additions are not necessary for the life of the battery.

The advantages of low water-loss batteries when compared to conventional batteries are:

Do not require servicing

Do not require activation and boost-charging prior to installation

Greater overcharge resistance

Reduced terminal corrosion

Elimination of overfilling and possible addition of harmful impurities

NOTE

When replacing a genset battery, a battery at least equivalent to, and preferably greater than the original battery ratings is recommended.

PAGE 50 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 51

MECHANICAL INST ALLA TION — B A TTERY SYSTEM

Engine Starting System

Battery Star ting Systems

Battery star ting systems for generator sets are 12 volt or 24 volt DC (Figure 16). When installing a battery system to start a generator set, consider the following:





See the Battery Safety Instructions on page 11.

 



Batteries must have enough capacity to provide the



cranking motor current indicated on the genset

specification sheet. The batteries may be either lead-

acid or nickel-cadmium. Refer to the dealer for approved

battery brand names.



A high output engine-driven alternator and automatic





voltage regulator are provided with the genset to

recharge the batteries during operation.





For most emergency power systems, a float-type battery



charger, powered by the normal power source

(commercial power), must be provided to keep the

batteries fully charged during standby. See the battery

charger section for more information.





Local codes or site conditions may require battery



heaters to maintain a minimum battery temperature of

50°F (10°C) if the battery is subject to freezing

temperatures.





Standard gensets include battery racks and battery



cables.





Battery cable resistance must not result in a voltage



drop between the battery and the starter motor of more than 1 volt for 12 volt systems or more than 2 volts for 24 volt systems.

Figure 16. Typical Lead Acid Type Battery

Electrolyte is an acid and must be handled with caution. Servicing instruction from the electrolyte manufacturer must ALWAYS be followed to ensure saf ety . Serious injury can result from careless handling and non-compliance to safety handling instructions.

Overfilling the battery may cause the electrolyte to overflow resulting in corrosion to nearby components. Immediately wash off any spilled electrolyte (battery acid). Additionally, when connecting the positive (+) cable to the battery's positive (+) terminal post, DO NOT allow contact of the wrench or any metallic object to come in contact with the battery's negative (-) terminal post. This ma y result in an electrical short circuit or an explosion.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 51

Page 52

MECHANICAL INST ALLATION — NEW BATTERY

New Battery Installation

Before handling a battery , ref er to page 11 for

instructions

Replacement batteries should equal or exceed the specified battery ratings. Replacing the original battery with one that has a lower capacity may result in poor performance and shorter life. If the replacement battery has considerably less capacity than the specified battery rating, it may not crank the engine at cold temperatures. Difficulty may also be experienced in cranking high compression engines when they are hot. The load on the battery equal to loads experienced at cold temperatures.

A premium battery with higher capacity than the specified battery rating will provide a safety factor that will result in longer battery service.

If the electrical load of the vehicle has been increased by the addition of accessories, and engine cranking occurs frequently, a larger alternator may be required. A larger alternator will provide increased output at low speed operation and will improve battery performance. A replacement battery MUST have the same voltage and polarity specified. Be sure the replacement battery is dimensionally correct and compatible for the battery rack. To ensure a perfect fit for the replacement battery, it should be the same BCI Group Size as the original battery.

Preparation of Charged and W et Batteries

hot start

condition can impose a cranking

battery safety

All batteries should be fully charged and in proper working order before installation.

If a charged and wet replacement battery is being installed, be sure the specific gravity is at least 1.250 or higher and the battery voltage is at least 2.1 volts per cell. If the specific gravity is below 1.250, or the voltage is below 2.1 volts per cell, the battery should be charged.

If it should become necessary to dilute concentrated sulfuric acid to a lower specific gravity ALWAYS pour the acid into the distilled water — do this slowly — NEVER pour water into acid.

NOTE

Use only battery. Tap water can operating life of the battery .

distilled

water in the

reduce

the

Preparation of Dry Charged & Charged and Moist Batteries

Dry charged

activated as described below before they can be used:

Dry Charged Batteries — Activation

1. Fill each cell of the battery to the top of the separators with the correct battery-grade electrolyte as specified in the manufacturer's instructions. Using higher or lower specific gravity electrolyte than that recommended can impair battery performance. Filling each cell to the top of the separators allows for expansion of the electrolyte as the battery is boost charged.

2. When a manufacturer recommends filling gravities of

1.265 or higher , boost charge 12-volt batteries at 15 amps (12-volt heavy duty batteries at 30 amps) until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 60°F (15.5°C) are reached. (In tropical climates, lower filling specific gravities are recommended.)

If the ambient temperature is 32°F (0°C) or less, it is imperative that the above instruction be followed.

3. After boost charge, check level of electrolyte in all cells. If required, add additional electrolyte to bring all levels to the bottom of the vent wells. DO NOT OVERFILL. If the battery requires top-off while in service, add water. NEVER ADD ACID to a battery.

Following the above instructions will insure proper activation of the battery and result in satisfactory performance.

Dry charged batteries may be placed in service immediately after activation. However, to ensure superior performance, the following additional steps are recommended:

Check the specific gravity of all cells. Under good storage conditions, the specific gravity upon activating a dry-charged battery will drop approximately 0.010 points and the temperature will rise 7° to 10°F (4° to 5.6°C) within twenty minutes of activation. A battery under these conditions requires little boost charging. However, should the specific gravity drop 0.030 points or more, with a corresponding increase in temperature, the negative plates become oxidized and the battery should be FULL Y RECHARGED before use . Also, the battery should be recharged if one or more cells gas violently after the addition of electrolyte.

and

charged and moist batteries

must be

PAGE 52 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 53

MECHANICAL INST ALLA TION — NEW B A TTER Y

Dry Charged Batteries (continued)

After electrolyte is added, check the open circuit terminal voltage of the battery . If a 12-v olt battery reads less than 10 volts, this is an indication of either a reverse cell, an "Open" circuit, or a shorted cell, and the battery should be replaced.

When a dry charged battery has been activated and not put into service, it must be maintained, handled, and kept charged like any other wet battery.

Charged and Moist Batteries — Activation

The activation characteristics of the charge and moist batteries differ from conventional dry charged batteries in initial fill level, specific gravity readings, and initial testing procedures.

These batteries are activated the same as dry charged batteries except each cell is filled to the bottom of the vent well. It is only necessary to let it stand 10 minutes after electrolyte is added. The specific gravity will typically fall to a range of 1.200 to 1.230 (corrected to 80°F [26.7°C]). This does not indicated low performance capability . After sev eral days of charge and discharge in normal vehicle service, the specific gravity will rise and level out at a full charge value of 1.245 to 1.255.

To deter mine the performance capability of these batteries during initial activation, they should be given a load test following the 10 minute soak period.

The battery should not be load tested unless the electrolyte temperature is at least 60°F (15.5°C). Apply a test load equal to 1/2 the

Read the voltage at 15 seconds and remove the load. If the battery temperature is 70°F (21°C) or higher and the voltage reading is 9.6 volts or more, the minimum required voltage is 9.5 for 12-volt batteries.

If the voltage readings are below the minimum values, charge the battery at a slow charge rate and retest. If the battery fails the second test, reject it.

cold cranking performance

at 0°F (-17.8°C).

Removing Old Battery

Before removing the old battery, carefully note the location of the positive battery terminal and mark the polarity on the positive cable. By doing this, you will avoid installing the new battery reversed (which could damage the electrical system). Remove the precaution will avoid damage to wiring, and/or the battery, by accidental "grounds" with tools.

Use the proper size box, or pen end wrench, when removing battery cables. Inspect the battery tray for possible damage or corrosion. Be sure the tray and hold-down are mechanically sound and free from corrosion. Corroded par ts may be cleaned with water (to which some household ammonia or baking soda has been added) and scrubbed with a stiff brush. Cleaned parts should be dried and painted. Do not paint the battery or terminals. Clean and tighten the Tighten the starter relay and star ter connections too.

Cables

Battery cables must carry large starting currents with a minimum loss of voltage, since engine cranking speed is dependent on the voltage available at the starting motor. Examine the cables to ensure the insulation is intact and the terminal connectors and bolts are not corroded. Replace all unserviceable parts. Also consider replacing cables that have temporary terminal ends bolted on. Temporary or emergency terminals should be replaced with new cables as soon as possible. As the acid corrodes terminals and cables, their resistance increases and the voltage loss between the battery and the starter increases. This increase in resistance due to corrosion also restricts the flow of charging current to the battery . This condition will e ventually cause the battery to become undercharged and the plates will become sulfated.

Installation

Be sure the battery has been charged as described in this section. If using an MQ Power battery, charge the batter y as described in the low water-loss battery installation on page 56 if needed.

Make sure the battery is level in the battery rack. Be sure there are no foreign objects lying in the tray that may cause damage to the bottom of the battery container. The holddown should be tightened snugly, but not to the point where the battery cracks or distorts.

ground

cable connector first. This

ground

connection.

Figure 17. Typical Electric Starter Motor Connections

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 53

Page 54

BATTERY SYSTEM — TESTING BA TTER Y

Battery Testing

Before conducting any battery tests, refer to page 11 for

battery safety instructions

Low water-loss batteries of the latest design may incorporate flame-arrester vents to reduce the possibility of explosions caused by external sparks. Theref ore , during charging and testing, the flame-arrester vents should remain in place.

Refer to Figure 18,

Step One (1) - Visual Inspection (See Flow Chart, Figure 18 on next page)

a. Visually inspect the battery for container, co ver, or terminal

damage that may have caused leakage of electrolyte or internal damage. If damage is f ound, replace the battery .

b. Check the condition and the size of the battery cables.

Check for corrosion on the battery terminals and cable terminations. Corrosion on side terminal batteries may not be evident until the cables have been removed. Replace badly corroded cables or cables with defective terminations. Make cer tain the ground cable is making a good connection where it is grounded. Check the connection of the cable to the starter relay or solenoid. Proceed to step two.

Step Two (2) - Electrol yte Levels and State of Char ge

Although these batteries are designed to preclude adding water, the volume of reserve electrolyte above the plates may eventually be depleted. In most cases, this will signal the end of the battery's useful life. Since many have sealed covers in place of filler caps, it may not be possible to check the electrolyte levels by looking directly into the cells. However, many low water loss batteries are contained in translucent plastic cases which may allow electrolyte levels to be seen. Other models utilize built-in hydrometers which also serve as electrolyte level indicators. If electrolyte levels can be seen and found to be low , check f or a charging system malfunction.

If the electrolyte level is below the top of the plates in any cell, and if vents are removable, add water before proceeding further. If water cannot be added, replace the battery.

The battery must be at an adequate state of charge in order for the following load test to be valid. If the battery does not contain a built-in hydrometer, the state-of charge can be estimated with an accurate voltmeter.

Battery T esting Chart

on page 55.

a. If the stabilized open circuit voltage is below 12.4 volts,

charge the battery (or check battery charger connection). A stabilized voltage reading is assumed after the battery has remained on open circuit for a minimum of 4 hours or, pref erably , ov ernight. When a h ydrometer reading can be taken, a value of 1.225 @ 80°F (26.7°C) can be used instead of the 12.4 voltage reading. If the battery has a built-in hydrometer, follow the instructions of the manufacturer. After the battery is charged, proceed to step 2.c.

b . If the state-of-charge of a battery cannot be determined,

it must be charged. After the battery is charge, proceed to step 2.c.

c. Remove surface charge by attaching load test leads to

the terminals and applying a load equal to 1/2 of the cold cranking amps at 0°F (-17.8°C) rating of the battery for 15 seconds. Manufacturers may prescribe specific methods. Follow specific instructions when they are available. Proceed to step 3.

d. If the stabilized voltage of the battery was 12.4 or above

when it was first examined, or the built-in hydrometer indicated the battery was charge, proceed to step 3.

Step Three (3) - Load Procedure

The load test is conducted to determine if the battery has adequate electrical performance or if it has to be replaced. This procedure is valid only if the battery is at or above the state of charge specified in step 2.

a. Connect the voltmeter and load test leads to the battery

terminals; be sure the load switch is in the "Off" position Proceed to step 3.b.

b . Apply a load test equal to 1/2 of the cold cranking rating

of the battery at 0°F (-17.8°C). Read voltage after fifteen (15) seconds with the load connected. Remove load. Estimate or measure the battery temperature and compare voltage reading with the voltage chart (see Figure 17 on page 53). If the voltage is less than the minimum specified, replace the battery. If the voltage meets or exceeds the specified minimum, return the battery to service.

PAGE 54 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 55

BATTERY SYSTEM — B A TTERY TESTING CHART

Figure 18. Battery Testing Chart

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 55

Page 56

BATTERY SYSTEM — CHARGING B A TTERY

Charging Low W ater-loss Batteries

Before charging the battery , refer to page 11 f or

instructions

Do not allow untrained personnel charge a battery until they have been thoroughly instructed in the step-by-step procedures of charging and all safety precautions.

Battery chargers operate automatically or should include a charge duration control of some type. This control is a timer which the operator sets.

Follow the manufacturer's instructions on the charger. If, when charging the battery, violent gassing or spewing of electrolyte occurs, or the battery case feels hot (125°F/52°C), cease charging to avoid damaging the battery.

Always turn the charger to the "Off" position (if not automatic) before connecting the leads to the battery. If there is any doubt about the charger being off, disconnect the charger from the power source.

battery safety

Battery Storage

Low water-loss batteries have excellent shelf life due to their low self-discharge rates. One of their major advantages is they normally can be installed without charging if good stock rotation and inventory controls are maintained.

The batteries must be kept in an upright position. It is possible for electrolyte to escape through the vents if the batteries are turned on their sides or top. Batteries should be stored in a cool, dry place. Storage above 80°F (26.7°C) increases self-discharge. If batteries are discharged, the electrolyte may freeze when subsequently stored below 20°F (-7°C). It is advantageous to store fully charged batteries at low temperatures, because the self-discharge rate drops as the temperature decreases.

Batteries in stock should be recharged when the open circuit voltage falls to 12.2 volts or when indicated by the built-in hydrometer as specified by the manufacturer.

If the battery does not indicate it is charged after the proper amount of charge time recommended, the charge should be repeated. If the battery is still uncharged after two charges, the battery should be replaced.

For best results, batteries should be charged while the electrolyte is at room temperature (55-85°F/13-30°C). A battery that is extremely cold or has remained in a completely discharged condition may not accept current for several hours after starting the charger.

Since age, capacity, state of charge, and type of batteries vary ,

time

and

attention

any charging process.

If a battery is to be recharged overnight (16 hours), a timer or voltage controlled (16.0 volts) charger is recommended. If the charger does not have such controls, a 3 amp rate should be used for batteries of 80 minutes or less reserve capacity, and 5 amps for batteries with 80 to 125 minutes reserve capacity. Batters over 125 reserve minutes should be charged at the specified slow charge rate.

must be given to batteries during

PAGE 56 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 57

BATTERY SYSTEM — B A TTER Y CHARGER

Battery Charger Introduction

The following section will cover the optional battery chargers offered f or Industrial Generators with 12 or 24 V olt systems .

Operation

Apply AC power to the charger (Figure 19). The charger should start immediately. The charger will automatically recharge and maintain the battery with no further attention

MQ Power battery chargers offer accurate, completely

from the user. automatic charging of lead-acid and nickel-cadmium batteries. The battery charger's output voltage automatically adjusts to changing input, load, battery and ambient conditions. The result is fast battery charging without overcharging and consequent loss of battery electrolyte. Standard features include AC line compensation, precision voltage regulation, current limiting, automatic dual-rate charging, ammeter and temperature compensation.

Auto Boost Feature

After a battery has been discharged or when AC power is restored following a power failure, the charger operates in the high-rate constant current mode until the battery voltage rises to the preset boost level. Once this boost level is reached, the charger operates in constant voltage boost mode until the battery's current acceptance falls to less than 70% of the charger's rated output. The charger then re verts to the lower float voltage, where it operates until another battery discharge or AC failure occurs.

Table 22. LC Battery Charger Specificat ions

Figure 19. LC Battery Charger

T emperature Compensation

All batteries have a negative temperature coefficient. The battery charger is equipped with temperature compensation to assure correct charging in all conditions. Float voltage increases slightly as ambient temperature decreases, and decrease as ambient temperature increases.

Current Limiting & Overload Protection

The charger is electronically current limited. When the

Maximum Output Current 3.0 Amps

Output Voltage Regulation ±1%

charger is operating into a fully discharged battery, or is otherwise overloaded, charging voltage reduces so that the

Operating Temperature Range -10°C to 50°C

charger's rated output power in watts is not e xceeded. The charger will operate satisfactorily into a short circuit indefinitely. In addition, AC and DC fuses are used for overload protection.

Indicators and Adjustments

The battery charger has a 2.5" scale DC ammeter located on the outside of the battery charger aluminum enclosure. There is also an internal adjustment for float voltage. This also adjusts the boost voltage which is set at 5% higher

Float (12V — 24V) 13.3 — 26.6

Boost (12V — 24V) 14.0 — 28.0

than the float voltage.

Input Voltage 115VAC ±10%

Input Frequency 57-63Hz

Output Voltage 12 or 24VDC (nominal)

Float Voltage Adjustable

Boost Voltage 5% Above Float Voltage

Humidity Range 5% to 95% Non-condensing

Housing Clear Anodized Aluminum

Table 23. Standard Factory Setting

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 57

Page 58

BATTERY SYSTEM — B A TTER Y CHARGER

FC & FCA Battery Charger

In addition to the LC battery charger, a variation of full featured battery chargers are offered. The FC & FCA battery chargers have all of the standard features previously listed, and also include the following:

Comprehensive alarm system that meets NFPA requirements.

Soft start that ensures smooth star t-up.

AC & DC breakers (20 & 25 amp units).

DC voltmeter.

Separate internal adjustment for float & boost voltages.

Separate internal adjustment for low and high DC alarms.

Alarm indicators and remote contacts.

Output Voltage increases to 10 Amps.

All battery chargers are unfiltered and are UL listed with the standard 120 input voltage. See the following paragraphs for details on each battery charger for 12 (or 24) volt systems.

LC12(24)-500-2 Battery Charger

This is the most basic battery charger model. It provides 12 (24) VDC at 3.0 amps, 120 VAC 60 Hz single phase, automatic dual rate, temperature compensated, and has no alarms.

FC12(24)-10-2011U Battery Charger

This battery charger provides more output current than the basic charger. It pro vides 12 (24) VDC at 10 amps, 120 V A C 60 Hz single phase, automatic dual rate, temperature compensated, and has no alarms.

FCA12(24)-10-2411U Battery Charger

This is a full featured battery charger. It provides 12 (24) VDC at 10 amps, 120 VAC 60 Hz single phase, automatic dual rate, and is temperature compensated. In addition, it contains the following alarms:

AC On LED

AC Fail LED & Form C contact

Charger Fail LED & Form C contact

Low Battery Voltage LED & Form C contact

High Battery Voltage LED & Form C contact

Figure 22. Temperature Compensation Graph

Figure 20. FC/FCA Battery Charger

Figure 21. Charging Current Graph

PAGE 58 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 59

BATTERY SYSTEM — B A TTER Y CHARGER SAFETY

Battery Charger Installation

All work should be completed by qualified persons familiar with the installation, construction and operation of generator sets. All work should be completed in accordance with the National Electric Code (NEC), Uniform Building Code (UBC) and other state or local codes.

If the battery charger installation is to be completed on-site, consider the following recommendations:

1. Select a suitable mounting location for the battery

charger. If indoors, the charger can be installed in a NEMA 1 or NEMA 2 enclosure. If outdoors, the charger must be installed in a NEMA 3R, outdoor enclosure.

2. Mount the battery charger as close to the engine starting

batteries as possible.

3. If the battery charger is to be generator set mounted,

the charger should be shocked mounted to reduce engine vibration. F ailure to do so could cause premature battery charger failure.

4. V erify the correct operational voltage for the charger and

ensure the feeder providing power to the charger is protected by an appropriately sized, UL approved, circuit protection device.

5. All wiring and conduits should be sized and installed

per NEC requirements.

6. AC voltage input terminations should match the voltage

requirements of the battery charger. Ensure the DC output voltage of the charger matches the battery charging system of the engine-generator set.

7. Final DC wire terminations can be made by fitting the

battery charger B+ (positive) to the B+ (positive) terminal on the engine electric star ter mechanism. The battery charger ground (negative) should be fitted to the same lug where the engine starting batter y ground cable is routed.

8. Secure all final battery charger connections (AC and

DC) prior to energizing the circuit protection device feeding A C power to the charger.

9. Energize AC power and check the battery charger for proper operation.

Battery Charger Safety

The following safety precautions should always be used with

MQ Po wer battery chargers.

DO NOT operate if battery charger is dropped or otherwise damaged.

DO NOT expose charger to rain or snow.

DO NOT disassemble charger. Return to factory for service and repairs. Incorrect assembly may result in a risk of electric shock or fire.

ALWAYS de-energize and disconnect the AC input and the battery from the charger if contact with the battery charger is necessary. Failure to do so may result in electric shock.

During normal operation, batteries may produce explosive hydrogen gas. NEVER smoke, use an open flame, or create sparks near the battery or charger.

Changing the factory-set potentiometer voids the warranty. Contact the factory if the setting on the charger is incorrect.

If the charger is not working correctly, first check the

following:

1. Is AC power available to the charger?

2. Is the charger connected to a battery of the correct voltage? (The charger must be connected to a battery for it to operate at the correct voltage.)

3. Is the charger damaged? (Check for debris, particularly metal, inside the charger enclosure.)

4. If the charger appears not to be working check the battery's state of charge. If the battery is fully charged it is sometimes normal for the charger to indicate zero current flow . Also check the battery for shorted or open cells.

5. If the battery is being overcharged or undercharged, check whether the output voltage settings have been tampered with. The potentiometers should be co vered with either white adhesive paper dots or a hard red varnish.

6. If charger is still not working proper ly, call the factory for assistance.

Always be sure that the ground terminal provided on the battery charger is connected to a grounded wiring system.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 59

Page 60

MECHANICAL INST ALLA TION — VENTILATION AND COOLING

Engine Cooling

Liquid-cooled engines are cooled by pumping coolant ( a mixture of water and antifreeze) through passages in the engine cylinder block and heads by means of an enginedriven pump. The engine, pump, and radiator (or liquid-toliquid heat exchanger) form a closed-loop, pressurized cooling system. The most common genset configuration has a mounted radiator and engine-driven fan to cool the coolant and ventilate the generator room. Alternate methods for cooling the coolant include a mounted liquid to liquid heat exchanger, a remote radiator, or a remote liquid-to-liquid heat exchanger. These alternate methods are covered later in this section.

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 adequate air flo w.

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 (Figure 24) 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 .

Wind will restrict free airflow if it blows directly into the air outlet vent. If possible, locate the outlet vent so the effects of wind are eliminated. See Figure 23.

Figure 23. Wind Barrier

Figure 24. Wind Barrier Installation

PAGE 60 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 61

MECHANICAL INST ALLA TION — VENTILA TION AND COOLING

For outdoor installations, weather and silenced housings are availab le for the industrial generator . Housed industrial units typically do not use ventilation louvers. However, louvers are another ventilation option and can be found on MQ Po wer Studio generators and will be referenced in this manual for information purposes.

Louvers

Louvers are automatic ventilation doors that open when the engine engages and close while not in use. Louvers protect the genset and equipment room from the outside environment. Their operation of opening and closing should be controlled by operation of the genset.

In cooler climates movable or discharge louvers are used. These louvers allow the air to be recirculated back to the equipment room. This enables the equipment room to be heated while the genset engine is still cold, increasing the engine efficiency.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 61

Page 62

MECHANICAL INST ALLA TION — MOUNTED RADIATOR COOLING

Factory Mounted Radiator V entilation

Ventilation of the generator set is necessary to remove the heat and fumes dissipated by the engine, generator , battery , and its accessories as well as provide combustion air.

When the genset has a factory mounted radiator (Figure 25 below), the fan draws air over the set and pushes it through the radiator which has flanges for connecting a duct to the outdoors.

Consider the following when installing a factory mounted radiator genset:





See the genset specification sheet for the design airflow



through the radiator, allowable airflow restriction, and minimum air inlet and outlet opening areas.

air flow restriction must not be exceeded

pressure (air flow restriction) should be measured to make sure the system is not too restrictive, especially when ventilating air is supplied and discharged through ducts, restrictive grilles, screens, and louvers.





Refer to the ASHRAE (American Society of Heating,



Refrigeration and Air Conditioning Engineers) publications for recommendations on duct design if air ducts are required. Note that the inlet duct must handle combustion air flow, ventilating air flow, and must be sized accordingly.





Louvers and screens over air inlet and outlet openings



restrict air flow and vary widely in performance. A louver assembly with narrow vanes, for example, tends to be more restrictive than one with wide vanes. The effectiv e open area specified by the louver or screen manufacturer should be used.

The allowa ble

. The static



The airflow through the radiator is usually sufficient for





generator room ventilation.





The radiator fan will cause a slight negative pressure in



the room. Theref ore it is recommended that combustion equipment such as the building heating boilers not be located in the same room as the genset. If this is unavoidable, it is necessary to determine if there will be detrimental effects, such as backdraft. If so, means such as extra large room inlet openings and/or ducts, pressurized fans, etc. may be required to reduce the negative pressure to acceptable levels.



Other than recirculating radiator discharge air into the





generator room in colder climates, all ventilating air must be discharged directly to the outdoors. It must not be used to heat any space other than the generator room.





A flexible duct connecter must be provided at the



radiator to take up genset movement, vibration, and transmission of noise.





Ventilating air inlet and discharge openings should be



located or shielded to minimize fan noise and the effects of wind on airflow .

Figure 25. Factory Mounted Radiator

PAGE 62 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 63

MECHANICAL INST ALLA TION — MOUNTED RADIA T OR COOLING

Mounted Radiator Cooling System

A generator set with a factory-mounted radiator is an integral cooling and ventilating system. This is the recommended configuration involving the least amount of auxiliary equipment, piping, control wiring, and coolant.

Mounted radiator cooling system uses a set mounted radiator and engine pusher fan to cool engine water. 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 grill.

A primary consideration for mounted radiator installations is the necessity of moving large quantities of air through the generator room.

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 (See Figure 26 below). Locate the air inlet to the rear of the genset. Make the inlet vent opening 1-1/2 to 2 times larger than the radiator area to ensure proper cooling.

Locate the cooling air outlet (as close as possible) directly in front of the radiator. 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.

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 circulation of heated air. Before installing the duct, remove the radiator core guard.

Figure 26. Duct Air Installation

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 63

Page 64

MECHANICAL INST ALLA TION — REMO TE RADIA TOR COOLING

Remote Radiator Cooling (optional)

Remote radiator cooling substitutes a remote mounted radiator and an electrically driven fan for the set mounted components (see Figure 27 on next page). Removal of the radiator and the fan from the set reduces noise levels without forcing dependence on a continuous cooling water supply . The remote r adiator installation must be completely protected against freezing conditions.

Application of a remote radiator to cool the engine requires proper design. Consider the following:





It is recommended that the radiator and fan be sized on



the basis of a maximum radiator top tank temperature of 200°F (93°C) and a 115% cooling capacity to allow for fouling. Refer to the

coolant flow rate

page 88 for radiator sizing.





The capacity of the radiator top tank or auxiliary tank



must be equivalent to at least 15% of the total volume of coolant in the system to provide a coolant "drawdown capacity" (10%) and space for thermal expansion (5%). Drawdown capacity is the volume of coolant that can be lost by slow, undetected leaks and the normal relieving of the pressure cap before air is drawn into the coolant pump. Space for thermal expansion is created by the fill neck when a cold system is being filled.





T o reduce radiator fin f ouling, radiators have a more open



fin spacing (nine fins or less per inch) should be considered for dirty environments.





Coolant friction head external to the engine (pressure



loss due to pipe, fitting, and radiator friction) and coolant static head (height of liquid column measured from crankshaft center line) must not exceed the maximum allowable values on the genset specification sheet.

specifications in Table 27 beginning on

heat rejected to coolant

and



Radiator hose 6 to 18 inches (152 to 457 mm) long,





complying with SAE 20R1, or equivalent standards, should be used to connect coolant piping to the engine to absorb genset movement and vibration.





It is highly recommended that the radiator hoses be



clamped with two premium grade "constant-torque" hose clamps at each end to reduce the risk of sudden loss of engine coolant due to a hose slipping off from pressure.

Major damage can occur to an engine if it is run without coolant in the block.





A coolant drain valve should be located at the lowest



part of the system.





Depending on the amount of coolant in the system, ball



or gate valves are recommended. Globe valves are too restrictive. This will isolate the engine so the entire system does not have to be drained before servicing the engine.





To obtain the



the fan load indicated on the genset specification sheet to the power rating of the set and subtract the power consumed by the remote radiator fan, ventilating fans, coolant pumps, and other accessories required for the genset to run.

NOTE

net power

Excessive coolant static head (pressure) can cause the coolant pump shaft seal to leak. Excessive coolant friction head (pressure loss) will result in insufficient engine cooling.

available from the genset, add

PAGE 64 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 65

MECHANICAL INST ALLA TION — REMO TE RADIA TOR COOLING

Remote Radiator Cooling

Figure 27 below shows a typical installation of a remote radiator type cooling system.

NOTE

The coolant flow is provided by the engine mounted pump

Figure 27. Remote Radiator Installation

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 65

Page 66

MECHANICAL INST ALLA TION — HO T WELL COOLING

Hot Well Installation

Figure 28 below shows a typical installation of a remote radiator with a hot well cooling system.

A remote radiator with a hot well can be used if the elevation of the radiator above the crankshaft center line exceeds the allowable coolant static head on the genset. Refer to the generator specification sheet. In a hot well system, the engine coolant pump circulates coolant between engine and hot well and an auxiliary pump circulates coolant between hot well and radiator . A hot well system requires a careful design and proper installation. In addition to the considerations under the remote radiator, consider the following:





The bottom of the hot well should be above the engine



coolant outlet.





Coolant flow through the hot well / radiator circuit should



be approximately the same as coolant flow through the engine. The radiator and the auxiliary pump must be sized accordingly. The pump head must be sufficient enough to overcome the sum of the static and friction heads in the hot well / radiator circuit.

One foot of pump head is equivalent to 0.43 PSI of coolant friction head (pressure loss) or one foot of coolant static head (height of liquid column).





The liquid holding capacity of the hot well should not be



less than the sum of the following volumes:

1/4 of the coolant volume pumped per minute through the engine (e.g., 25 gallons if the flow is 100 gpm), plus

1/4 of the coolant volume pumped per minute through the radiator (e.g., 25 gallons if the flow is 100 gpm), plus

Volume required to fill the radiator and piping, plus

Five percent (5%) of the total system volume for thermal expansion





Careful design of the inlet and outlet connections and



baffles is required to minimize coolant turbulence and maximize blending of engine and radiator coolant flows.



Coolant must be pumped to the bottom tank of the





radiator and returned from the top tank, otherwise the pump will not be able to completely fill the radiator.





The auxiliary pump must be lower than the low level of



coolant in the hot well so it is always primed.





The radiator should have a vacuum relief check valve



to allow drain down to the hot well.





The hot well should have a high volume breather cap to



allow the coolant level to fall as the auxiliary pump fills the radiator and piping.





To obtain the



net power

available from the genset, add

Figure 28. Hot Well Installation

PAGE 66 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 67

MECHANICAL INST ALLA TION — HEAT EXCHANGER COOLING

Heat Exchanger

A heat exchanger installation uses a shell and tube type heat exchanger instead of the standard radiator and fan (see Figure 29 below). Engine jacket and coolant circulates through the shell side of the two heat exchangers while the cooling water is pumped through the tubes. Engine coolant and raw water do not mix. This type of cooling separation is necessary because raw water can contain scale-forming lime or other impurities.

This system can reduce set enclosure airflow requirements and noise levels. Proper operation depends on a constant supply of raw water for heat removal. Adjust the flow to maintain the proper engine jacket water coolant temperature and the coolant temperature. The engine coolant side of the system can be protected from freezing; the raw water side cannot be protected.

The engine, pump, and liquid-to-liquid heat exchanger form a closed, pressurized cooling system. The engine coolant and raw cooling water do not mix. Consider the following:





The installation will require a powered ventilating system.

 



To obtain the net power available from the genset, add



the fan load indicated on the specification sheet to the power rating of the set and subtract the power consumed by the remote radiator fan, ventilating fans, coolant pumps, and other accessories required for the genset to run.





A pressure reducing valve must be provided if water



source pressure exceeds the heat exchanger pressure rating.





The heat exchanger and water piping must be protected



from freezing if the ambient temperature can fall below 32°F (0°C).





A thermostatic water valve (nonelectric) is recommended



to modulate water flow in response to coolant temperature. A normally closed battery powered shutoff valve is also required to shut off the water when the set is not being used. (Always leave water on if a standby application)





There must be sufficient raw water flow to remove the



heat rejected to coolant indicated on the specification sheet. Note that a gallon of water absorbs approximately 8 BTU each 1°F rise in temperature (specific heat). Also, it is recommended that the raw water leaving the heat exchanger not exceed 140°F (60°C). Use the following formula:

If a set rejects 19,200 Btu per minute and the raw water inlet temperature is 80°F, the raw w ater required is:

[19,200/(60x8)] = 40 gpm

Figure 29. Heat Exchanger Installation

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 67

Page 68

COOLANT TREA TMENT

Coolant Treatment

Antifreeze (ethylene or propylene glycol base) and water are mixed to lower the freezing point of the cooling system and to raise the boiling point. Refer to Table 24 to determine the concentration ethylene or propylene glycol necessary for protection against the coldest ambient expected. Antifreeze/water mixture percentages in the range of 30/70 to 60/40 are recommended for most applications.

Propylene glycol based antifreeze is less toxic than ethylene based antifreeze, offers superior liner protection, and eliminates some fluid spillage and disposal reporting

Coolant Heaters

An optional water jacket heater can be installed to keep the engine warm for starting under adverse weather conditions. Thermostatically controlled engine coolant heaters are usually recommended to accurately control coolant temperature. For Level 1 emergency power systems, NFPA 110 requires that engine coolant be kept at a minimum 90°F (32°C).

Connect the heater to a power source that will be on when the engine is NOT running (such as commercial power or other independent powers source).

requirements. Replaceable coolant filters and treating elements minimize

coolant system fouling and corrosion. They are compatible with most antifreeze formulations.

Table 24. Freezing and Boiling Points vs. Concentration of Antifreeze

Mixture Base

Ethylene Glycol

Freezing Point

Boiling Point

0/100 30/70 40/60 50/50 60/40 95/5 32°F

(0°C)

212°F

(100°C)

Mixture Percentages (Antifreeze/Water)

4°F

(-16°C)

220°F

(104°C)

-10°F

(-23°C)

222°F

(106°C)

-34°F

(-36°C)

226°F

(108°C)

-65°F

(-54°C)

230°F

(110°C)

8°F

(-13°C)

345°F

(174°C)

Propylene Glycol

Freezing Point

Boiling Point

32°F

(-0°C) 212°F

(100°C)

10°F

(-12°C)

216°F

(102°C)

-6°F

(-21°C)

219°F

(104°C)

-27°F

(-33°C)

222°F

(106°C)

-56°F

(-49°C)

225°F

(107°C)

-70°F

(-57°C)

320°F

(160°C)

PAGE 68 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 69

ELECTRICAL INST ALLA TION — DC CONTROL WIRING

Control Wiring

The genset control box is located either on top or on the side of the alternator housing (see Figure 30 below). It contains connection points for remote control and monitor options which are located on the terminal block within the electronics box.

Stranded copper wire must be used for all customer connections to the electronics box. Solid copper wire may break due to vibration.

Remote Control / Monitor Connections

Customer remote control / monitor connections are attached to the terminal block. Optional equipment such as a remote annunciator panel, sensing devices used to monitor genset operation, remote start/stop switches, etc. are attached to this terminal block. Driver signals for customer supplied relays are also provided for several alarm and shutdown conditions.

Terminal Block Wiring

Due to the wide variety of devices that can be attached to the relay outputs of terminal blocks, the electrical contractor must determine the gauge of be used at the relay connections.

Switched B+

Switched B+ is fused. See relay connection description.

Digital Connections

Digital connections to the genset controller should be terminated directly to the controller with the following requirements:

18 gauge twisted pair cable with an overall shield

Overall cable should include the number of twisted pairs as indicated on the customer connection diagram

Network cable SHOULD NO T be run in the same conduit as the AC power output conductors

Length should be 1000 feet maximum

stranded copper

wire that is to

When making connections to the terminal for customer control / monitor control functions, be sure the battery power is disconnected from the terminal block by removing the 5 amp control power fuse.

Figure 30. Control Box Location

Always run control circuit wiring in a separate metal conduit from AC power cables to avoid inducing currents that could cause problems within the control circuits.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 69

Page 70

DC CONTROL WIRING — CONTR OL BOX B ACK PANEL

Control Box

The control box contains the following:





Digital Control Module



There are several digital control modules available for MQ Power industrial generator sets. Reference your supplied digital control manual for detailed information.





Control Box Back Panel Components



Figure 31 shows the components found in the Control Box back panel. The actual configuration of these components ma y vary with each control module model depending on the desired specifications and DC controls used. However. the typical contents are as follows:

Standard Electronic Governor

TB1 Terminal Block

Control Relays

Fuses

The definitions below describe the components of the "Control Box" back panel

Electronic Governor (Standard) – This

electronic speed control exhibits fast and precise response to transient load changes. When used in conjunction with a proportional electric actuator, the governor offers closed loop governing.

Either isochronous or droop governing modes can be selected. The engine's idle speed is variable and selected by a simple switch closure. Engine exhaust smoke during start-up can be minimized when the starting fuel adjustment is optimally set.

Start Relay (K2) – This relay interfaces

with the engine (75-150kW) and electronic governor controller (if present) for start and stop functions of the generator.

Idle Relay (K4) – This optional relay is

installed to interface with the voltage regulator sensing circuits when the optional idle switch is used.

Shunt T rip Relay (K5) – This relay optional

relay is installed to trip the main output circuit breaker under fault conditions. This circuit can be wired to the genset controller to trip the breaker or a shutdown condition.

This relay can also be wired to an external (customer supplied) circuit for external trip control of the breaker .

Figure 31. Typical Inner Control Box Panel

Low Coolant Level Relay (K3) – This

relay is installed to interface with the low coolant level s witch to the genset controller.

Relay DIN Rail – This rail holds all the relays used for DC controls.

Terminal Bloc k One (TB1) – This terminal block is used for DC control wiring. See the generator set wire diagram (Figure 34) on page 72 for details.

Control Power Fuse – This fuse protects terminal block one (TB1) from overcurrent. Remove this fuse when servicing TB1.

PAGE 70 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 71

DC CONTROL WIRING — CONTROL BO X B ACK PANEL

L1 L2

L3 (3 PH)

L1 L2 L3 (3 PH)

USE COPPER WIRE ONLY, MINIMUM SIZE 4 AWG

TORQUE TO 120 LB - IN

Figure 32. Wiring Terminal Information

TE MP ERATURE RATI NG OF WIRE

THAT IS INT ENDE D TO BE US ED FOR CONNE CTI ON OF THE UNIT

60 or 75°C

60°C AWG 60°C co p p e r wire1AWG 60°C copper or aluminum wire 75°C AWG 75°C c o p p e r wire2AWG 75°C co p pe r o r aluminum wi re

90°C AWG 90°C c o p p e r wire2AWG 90°C co p pe r o r aluminum wi re

1. When the wire size for 60°C wire is included in the marking, it shall be based on the ampacities given in Table 310-16 of the National El ec tric al Co d e , A NSI/NF PA 70-1996 of no l e ss tha 115 pe rce nt o f the max . curre nt that the c irc uit carrie s d uring rated cond itions.

2. The c o nd ucto r s iz e s hall b e no sma lle r than the l arg er o f the fol lo wing : a. The c o nd ucto r s iz e us e d fo r the te mp e rature te s t or

b. The 75C° wire s iz e b ase d o n the amp ac itie s g iv en in Table 310-16 o f the Natio nal E le c trical Co d e, A NSI/NFPA 70-1996.

COPPER CONDUCTORS

ONLY

AWG 60°C copper wire AWG 75°C c o p p e r wire

ALUMI NUM CONDUCTORS OR COPPER-CLAD CONDUCTORS

AWG 60°C co pp e r o r aluminum wire

AWG 75°C co p pe r o r aluminum wi re

1 2

Figure 33. Wire Temperature Rating

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 71

Page 72

DC CONTROL WIRING — CONTR OL BOX B ACK PANEL

Figure 34. Generator Set Wire Diagram

PAGE 72 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 73

A C ELECTRICAL CONNECTIONS

Overview

This section provides the procedure that is used to connect the AC electrical system of the Industrial generator set.

As with all servicing, disconnect the battery charger and the battery cables (negative [-] first) to prevent accidental starting before working on unit.

Local regulations often require that wiring connections be made by a licensed electrician, and that the installation be inspected and approved before operation. All connections, wire sizes, materials used, etc. must conform to the requirements of all electrical codes in effect at the installation site.

Always disconnect a battery charger from its AC source before disconnecting the battery cables. Failure to do so can result in voltage spikes high enough to damage the DC control circuits.

Accidental starting of the generator set while working on it can

death

cause severe personal injury or even accidental starting by disconnecting the starting battery cables (negative [-] first).

. Prevent

Improper wiring can cause a fire or electrocution, resulting in property damage, severe injury, or even

NOTE

Check that the load cables from the genset are properly connected.

T ransfer Switch

Each of the operations described in this section should be done only by persons trained and experienced in electrical maintenance. Improper procedures may result in property

death

damage, bodily injury, or even

In a standby application, a transfer switch (Figure 35) must be used for switching the load from the normal power source to the genset. Either a manual or automatic transfer switch may be used. Follow the installation instructions provided with the transfer switch when connecting the load and control wiring. Only a licensed electrician should perform the installation of a transfer switch.

Backfeed to a utility system can cause property damage,

death

personal injury, or even buildings electrical system except through an approved device and after the building main switch is opened. When connecting to a building's electrical system, always have a licensed electrician perform the installation.

! DO NOT connect to any

death

Before starting the genset, verify that all electrical connections are secure, and that all wiring is complete. Replace and secure any access panels that have been removed during installation.

Connecting the genset AC electrical system involves the following:

Installation of a transfer switch (standby applications only)

Generator voltage connections

Load connections

Standard and optional AC equipment connections (e.g.

Figure 35. Typical Transfer Switch

control box heater, coolant heater, etc.)

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 73

Page 74

AC ELECTRICAL CONNECTIONS

Emergency Standby Generator Systems (600 Volts and below) The National Electric Code (NEC) requires the engine-generator be provided with phase overcurrent protection such as fuses or circuit breakers. In some applications, ground fault protection may be also be required.

Generator Main Line Circuit Breaker

a) Generator-Mounted Main Line Circuit Breaker (MCB) -

Industry practice is to provide a molded-case circuit breaker, sized to protect the generator feeder conductors against overcurrent, and provide provisions for a disconnecting means, to meet National Electric Code (NEC) requirements.

Field Installing A Generator Main Line Circuit Breaker

All work should be completed by qualified persons familiar with the installation, construction and operation of generator sets. All work should be completed in accordance with the National Electric Code (NEC), Uniform Building Code (UBC) and other state or local codes.

DO NOT attempt to field install a main line circuit breaker while the engine-generator is capable of starting and running. Serious injury or

b) Neutral Conductors – The ampacity of the neutral

conductor is generally permitted to be equal to or greater than the calculated maximum single-phase unbalance of the load. Where a significant portion of the load is nonlinear, the neutral conductor should be sized in accordance with anticipated neutral current but never less than 100 percent rated.

the generator control is in the OFF position, then disconnect the engine starting battery by lifting the cables (ground cable first). It is advisable to use "Lock-Out" tags accordingly.

When installing a main line circuit breaker NOT factory supplied by MQ Power, it is code required that the circuit

Sizing A Generator Main Line Circuit Breaker

Sizing a generator main line circuit breaker is typically the result of electrical engineering review of generator load schedules and design calculations for a feeder and its overcurrent device, keeping in mind that the primary purpose of the generator main line circuit breaker is to protect the feeder conductors as per the National Electric Code (NEC).

breaker be UL listed. The overcurrent protective device should be installed with the correct voltage, current and short-circuit interruption ratings that are appropriate for the generator output. The interrupting capacity of the circuit breaker must be equal to or greater than the amount of fault current that can be delivered at the point in the system where the circuit breaker is applied.

death

could result. Make sure

MQ Po wer off ers several factory-mounted circuit breaker options per model, based on generator output voltage and current ampacity . Unless specified otherwise, these circuit breakers, both thermal-magnetic and electronic trip types, are factory sized for the maximum output current of each engine-generator, with regards to their respective voltage connection. The circuit breakers are mounted on the engine-generator so as to meet code requirements which stipulate the overcurrent protective device be located within 25-feet of the generator output terminals.

It should be noted too, when sizing a main line circuit breaker, that feeder ampacity and overcurrent device ratings should be calculated by summing the total of load currents of all branch circuits being supplied by the engine-generator, multiplied by any applicable demand factors allowed by National Electric Code (NEC). In any event, the minimum size of the generator main line circuit breaker should be at least equal to the ampacity rating of the feeder conductors (or the next largest standard rating).

PAGE 74 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Once the circuit breaker has been properly sized and the appropriate cable and lugs have been determined, the circuit breaker should be mounted on the engine-generator in a suitable location. The circuit breaker should be mounted on the engine-generator so as to minimize vibrations produced by the engine while running.

Connection Of Generator Leads For Correct Voltage Output

It is required of the installer to connect the generator main stator leads (12-lead generator) in a configuration required to meet the system voltage output requirement. Refer to the MQ Power reconnection diagram to review the various voltage connection configurations. Once the voltage selection and correct wiring configuration has been completed, the wiring is terminated at the circuit breaker input lugs and/or bus bar .

Page 75

Electrical T erminations

A C ELECTRICAL CONNECTIONS

Most engine-generators, whether located indoor or outdoors are usually mounted on a concrete pad and typical electrical terminations are brought up underneath the engine-generator for final termination. This cable entry or “stub-up” underneath the generator set provides for easy termination of the feeder conductors and makes for a clean, professional looking installation. Check code compliance before proceeding.

a) Separately Mounted Fuel Tank - When a separately

mounted fuel tank is used, the electrical stub-up underneath the generator set is simplified because of the open bottom design of the generator skid. The final cable terminations rise from the stub-up entry location underneath the engine-generator, in a close pro ximity to the circuit breaker enclosure. When code required, these feeders should be provided in suitable and properly sized conduits that attach to the circuit breaker enclosure. The feeder cables then connect directly to the output lugs and/or bus bars provided on the main line circuit breaker .

b) Subbase Mounted Fuel Tank - When a subbase fuel

tank is used (refer to Fuel System section), the tank should be designed with a stub-up area on the generatorend of the tank. This f eature allo ws f or an open area on the tank assembly whereby electrical terminations can be brought up underneath the engine-generator for final termination, just like the open bottom design generator skid. (This feature is standard f or all MQ Power sub base tanks and is typically a purchasable option from most tank manufacturers) When code required, the feeder conductors should be provided in suitable and properly sized conduits that attach to the circuit breaker enclosure. The feeder cables then connect directly to the output lugs and/or bus bars provided on the main line circuit breaker .

c) Oversize Subbase Tank - Specification requirements

sometimes require an oversized tank to meet specific generator run-time demands. This can cause difficulty in completing final electrical connections. The tank should be designed with a stub-up area on the generatorend of the tank. However, depending on the placement of the engine-generator on the tank, feeder terminations may not rise in a close proximity to the circuit breaker enclosure. This could require the feeder conductors to enter the circuit breaker enclosure from the side or top, necessitating special fittings and/or hardware.

If the engine-generator is fitted with a weatherproof outdoor enclosure, it may be required to penetrate the side of the generator housing to facilitate final cable terminations. This will likely require special conduit, fittings and hardware. The f eeder conductors would enter the housing on the side where the circuit breaker is mounted. The f eeder conductors w ould enter the circuit breaker enclosure from the bottom, top or side as necessary, to complete final cable terminations. Check with the local inspection authority before proceeding.

Closed Bottom Generator - If the engine-generator is closed bottom, such as in a sound attenuated design, the bottom floor of the engine-generator must be cut to allow for a bottom entry electrical stub-up. If this is not possible, it may be required to route the feeder conductors on the outside of the engine-generator to reach the circuit breaker enclosure. This will likely require special conduit, fittings and hardware. The feeder conductors would enter the housing on the side where the circuit breaker is mounted. The f eeder conductors would enter the circuit breaker enclosure from the bottom, top or side as necessary, to complete final cable terminations. Check with the local inspection authority before proceeding.

NOTE

capacity, quantity of conductors per phase & size of output lugs available for each breaker, for each model MQ Power Standby Generators.

Refer to National Electric Code (NEC) Table 210.24 for specific circuit breaker current ratings for various

size conductors.

Refer to Table 25 “Main Line Circuit Breaker Sizing Information” on page 85 for a complete listing of MQ P ower generator main line circuit breakers av ailable from the f actory. This tab le details information about circuit breaker ampacity ratings, interrupt

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 75

Page 76

AC ELECTRICAL CONNECTIONS — SYSTEM GR OUNDING

AC WIRING Generator V oltage 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 the line-toline voltage is the higher rating.

The generators are available at the voltages shown in the wiring diagram of the genset. The genset is connected at the factory to produce a specified voltage per customer order .

Before shipping, the factory tests the generator set at the specified voltage.

Load Connections (Connecting the Load)

All loads are connected to the generator by bolting the

stranded

generator output circuit breaker . The terminals are marked for identification to indicate the line and neutral connections.

load wires to the appropriate terminals on the

Grounding

The following is a brief description of system and equipment grounding of permanently installed AC generators within a facility wiring system. It is important to follow the requirements of the local and county electrical codes.

System Grounding

System grounding is the intentional grounding of the neutral point of a wye-connected generator, the corner of a deltaconnected generator, or the neutr al point of one phase winding of a delta-connected generator, depending on the system voltage required in the application. It is common to ground the neutral point of a wye-connected generator and bring out the neutral (grounded circuit conductor) in a 3Ø four-wire system.

A corner-grounded delta system has a grounded circuit conductor that is not a neutral and a "wild leg" that must be identified by orange color coding and connected to the middle pole of the 3Ø equipment.

Load Balancing

When connecting loads to the generator set, balance the loads so the current flow from each line terminal is about the same. This is especially important if both single phase and three phase loads are connected.

Unbalanced loading

of a genset causes unbalanced phase voltages.

Any combination of 1Ø and 3Ø loading can be used as long as each line current is about the same, within 10% of the median value and no line current exceeds the nameplate rating of the generator. Check the current flow from each line after connections by observing the control panel ammeter.

System Grounding Methods

Solid Grounding

This method is typically used and required by the National Electrical Code (NEC) on all low voltage systems (600 volts and below) with a grounded circuit conductor (most often a neutral).

The system is grounded with a direct connection by a conductor (the grounding electrode conductor) with no intentional impedance to earth (grounding electrode).

Ungrounded

Ungrounded systems are special applications where no intention of connection is made between the AC generator system and earth. These systems are occasionally used on 3Ø three-wire systems (no grounded circuit conductor) operating at 600 volts or below, where continuity of power with one ground fault is required or desirable, and qualified service electricians are on site. An example would be a critical process industry.

NOTE

Correct grounding in standby systems that are solidly grounded is a function of the transfer switch equipment used (solid neutral or switched neutral).

PAGE 76 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 77

A C ELECTRICAL CONNECTIONS — SYSTEM GROUNDING

System Grounding (continued)

Figure 36 below illustrates a typical system grounding for a 3-pole and 4-pole Automatic Transfer Switch (ATS).

3-Pole ATS

In the 3-pole ATS, note the generator neutral is connected to the A TS and is NO T bonded to ground at the generator . A neutral to ground bonding jumper is factory installed in all industrial gensets. Remove the jumper from the alternator saddle box to meet electrical codes and grounding requirements if required.

4-Pole ATS

In the 4-pole ATS system, a grounding electrode conductor and a bonding jumper are used to connect the generator neutral to ground. In some installations, a current transformer (CT) may be required for ground fault monitoring.

Bonding and grounding must be performed properly . All metallic parts that could become energized under abnormal conditions must be properly grounded. F ailure to do so can cause electric current to flow, causing severe injury or death!

T ypical requirements f or 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.

Figure 36. Typical System Grounding

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 77

Page 78

A C ELECTRICAL CONNECTIONS — EQUIPMENT GROUNDING

Equipment Grounding

Equipment grounding is the bonding together and grounding of all noncurrent carrying (during normal operation) metallic conduit, equipment enclosures, generator frame, etc.

Equipment grounding provides a permanent, continuous, low-impedance electrical path back to the power source. Proper grounding practically eliminates "touch potential" hazards and facilitates clearing of protective devices during ground faults, the equipment grounding system is bonded to the AC system grounded circuit conductor (neutral) at a single point by a main bonding jumper at the source. See Figure 37 below.

Figure 37. Typical System & Equipment Grounding Connections at the Utility Service Equipment

PAGE 78 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 79

ELECTRICAL DISTRIBUTION SYSTEM

Electrical Distribution System

Figure 38 below is a one-line diagram of a typical electrical distribution system that incorporates an emergency generator set.

Figure 38. Typical Electrical Distribution System

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 79

Page 80

NOTE

General

Before attempting the initial start of the generator set, be sure it is serviced and ready for operation. Perform the following:

Check ventilation and exhaust systems

Check all mechanical connections

Check the lubrication system for leaks

Check control configuration options

For genset inspection, start-up and operational procedures, refer to the MQ P ower Operators manual f or the genset in use.

PRE-ST ART PREPARA TION

Battery Connections

Refer to Battery Safety Section on page 11. The battery cables are supplied with the generator set.

Service batteries, if necessar y, as specified in the batter y section of this manual. Install battery. Connect battery charger and jacket water heater if equipped.

Make sure the Run/Off/Manual switch is in the OFF position before connecting the battery cables. F ailure to do so will result in immediate starting of the genset when connecting the generator set.

Ventilation

Verify all vents and ducts are open and free from any obstructions. Ver ify dampers, if used, operate properly.

Exhaust System

Check the exhaust system for proper installation. Verify there is at least 12 inches (305 mm) clearance between exhaust pipes and combustible materials, all connections are tight, and the exhaust will not disperse near doors, windows, vents, or other openings.

Mechanical Checks

Check the generator set for loose or damaged components and repair or replace as required.

Digital Control

Configure digital control as specified in digital control manual.

Electrical System

Verify all electrical connections are secure and wiring is complete and inspected. Replace and secure any access panels that may have been removed during installation.

Starting

After the installation is complete, make sure the lubricating system is primed and the system is working properly. Routine inspections are recommended.

Refer to the specified genset Operation manual f or important safety precautions and recommended procedures f or starting the genset. Only use the star t-up procedures outlined in the "Genset Operation Manual" when starting of the genset is required.This is important to verify proper operation. Start the genset as outlined in the operation manual and verify all engine and generator display readings are accurate values.

PAGE 80 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 81

Run the Generator Set

The final check is to observe the drive belt when the engine is running.

1. Open the generator main line AC circuit breaker. -

When starting the engine for the first time after completing the generator set site installation, confirm that the drive belt is properly fitting in all grooves in the pulleys. This only requires visual inspection.

2. If the belt wanders, walks, or jumps between pulleys,

either the fan drive needs to be realigned, or the belt was improperly installed.

Wear safety glasses and stand far from the running fan drive without guards installed. A misaligned fan drive or improperly installed drive belt can cause the belt to break. A properly aligned and installed belt can grab loose clothing or body parts, causing severe injury.

6. Recheck coolant levels after engine cools. Add coolant if required.

7. Check oil level. Add oil if required.

8. Visually check the unit for fuel, water , or coolant leaks.

9. Double check for loose fittings and/or connectors.

10. Re-connect the battery cables and tighten securely.

11. Program and/or adjust the configuration of the generator controls to the appropriate, required position. If the unit is to remain in-service, place the control in the "AUTO" position.

12. Close the generator main line AC circuit breaker.

13. The unit is now ready to automatically start and provide emergency standby power.

PRE-ST ART PREPARA TION

3. If the belt or drive needs to be corrected, stop the engine and disconnect the negative lead (-) of the starting battery. Then disassemble the fan drive guard, realign the fan drive pulley, and check for alignment again.

4. After the belt is properly installed, start the genset and check for belt walk again.

5. Stop the genset and disconnect the battery negative. Attach the remaining side guard bracket to the pedestal and side fan drive guard to the bracket.

Contact with hot coolant can result in serious burns. Allow the engine to cool before loosening the radiator cap or coolant drain.

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 81

Page 82

APPENDIX — INST ALLA TION CHECKLIST

INST ALLA TION CHECKLIST

General



Genset wattage capacity is sufficient to handle maximum anticipated load.



At least three (3) feet of clearance is provide around entire genset for servicing and ventilation.



Genset is located in an area not subject to flooding.



All operators have been thoroughly briefed on correct operating and exercise procedures.



All operators have been thoroughly briefed on preventive maintenance procedures.



All operators have read and understand all Safety Precautions and know how to react in an emergency.

Genset Support



Floor, roof , or earth on which the genset is mounted 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 rests. Vibration isolators are installed appropriately based on size requirements.



Supporting base is large enough and exceeds 12 inches on all sides of genset.



Genset is securely fastened to foundation or subbase fuel tank.

Cooling Air Flow



Cooling system is efficient, properly cools the engine, and ventilates genset area.



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.

Diesel Fuel System



Fuel tanks meet or exceed all local, state, and national codes.



Fuel lines are properly installed, supported, and protected against damage.



Flexible fuel lines is installed between main fuel supply line and genset to protect against vibration, expansion, and contraction.



Fuel line shut-off 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 shutdown.



Fuel system is properly primed.



No fuel leaks exist in supply line or engine fuel system.

Gaseous Fuel System



The gas supplied to the genset is of acceptable quality.



The gas supply has sufficient pressure and volume to operate the genset at full load.



Gaseous fuel supply system design, materials, components, fabrication, testing and inspections comply with all applicable codes.



Proper layout and sizing of gas piping is adequate for handling the volume of gas required.



No leaks exist in any gas line or connection.

Exhaust System



Exhaust piping is not restricted by tight bends and allowed to flow at maximum velocity.



Condensation drain is installed at appropriate area.



Exhaust system is tight and leakproof.



Exhaust is routed safely outdoors to a well ventilated area away from people and building vents



Operators are thoroughly briefed on the dangers of carbon monoxide gas, preventing the buildup of this gas in inhabited areas.



Areas around the genset are well ventilated. No possibility of exhaust fumes entering building doors, windows, or intake fans.



Exhaust piping passing through walls or ceilings have approved fireproof materials and are in compliance with all codes.



Exhaust piping is large enough 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 and equipment are correctly grounded.

Genset Pre-start



All laws and codes are meet and all certificates received.



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 shut-off valves are operational.



Fuel system is primed.



Operators have read the instruction manual.

PAGE 82 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 83

APPENDIX — MAIN-LINE CIRCUIT BREAKER

TABLE 25. FACTORY RECOMMENDED MAIN LINE CIRCUIT BREAKERS

FOR MQ POWER INDUSTRIAL GENERATORS

Generator

Model

MQP20IZ

MQP30DZ/

MQP30GM

MQP40IZ

MQP45GM

MQP50IZ

MQP60GM/

MQP60IV

MQP80GM/

MQP80IV

MQP100GM

MQP100IV

MQP125IV

NOTES:

1. Refer to National Electric Code (NEC) for specific conductor sizes based on current and temperature ratings.

2. Lug sizes are given for standard cir cuit breaker setup. All lugs listed are made of aluminum and are compatible w ith both aluminum a nd copper co nductors.

ABB or

Cutler Hammer

Model No.

T1NQ070TL T1NQ060TL 240V - 3Ø 60 60

T1NQ030TL 480V - 3Ø 30 30

T3NQ125TL

T1NQ050TL 480V - 3Ø 45 50 #1 ~ 6 T3NQ150TW T3NQ125TW 240V - 3Ø 120 125

T1NQ060TL 480V - 3Ø 60 100 60 22,000 #1 ~ 6

T3NQ175TW T3NQ150TW 240V - 3Ø 150 150 #1 ~ 2

T1NQ070TL 480V - 3Ø 75 100 80 22,000 #1 ~ 6

T4NQ250BW T3NQ175TW 240V - 3Ø 180 175 #1 ~ 2

T1NQ100TL 480V - 3Ø 90 100 100 22,000 #1 ~ 4

JG3250

FJ3125 480V - 3Ø 113 225 125 14,000 #4 ~ 1/0 120 KG3300 240V - 1Ø 275 KG3350 208V - 3Ø 347 350 KG3300 240V - 3Ø 301 300 FG3150 480V - 3 Ø 150 225 150 14,000 #4 ~ 1/0 120 KG3350 240V - 1Ø 313 KG3400 208V - 3Ø 399 400 3/0 ~ 250 2 KG3350 240V - 3Ø 346 350 250 ~ 500

JG3225 480V - 3Ø 173 250 175 14,000 #4 ~ 350 275

Generator

Output

(Voltage)

240V - 1Ø 83 208V - 3Ø 69 70

240V - 1Ø 125 208V - 3Ø 104 100 240V - 3Ø 90 90

240V - 1Ø 167 208V - 3Ø 130 150

240V - 1Ø 208 208V - 3Ø 173 175 #1 ~ 2

240V - 1Ø 250 208V - 3Ø 208 200 #1 ~ 1/0

240V - 1Ø 250 208V - 3Ø 260 240V - 3Ø 226 225

Generator

Output (Amps)

Breaker

Frame Size

(Amps)

100

225

Technical data for this unit is TBD

225

250

400

Breaker

Tri p Ra t i n g

(Amps)

125

175

200

250

300

350

Interrupting Rating RMS

(Sym Amps)

22,000 #1 ~ 6 1

22,000

25,000 #1 ~ 2

25,000

18,000 #4 ~ 350

18,000 250 ~ 500

18,000

Cable Size

(kcmil)

{Note 1}

#1 ~ 4

#1 ~ 1/0

#1 ~ 2/0

250 ~ 500 1

Max. No.

Cables Per

Phase

Typ e O f

Connection

{Note 2}

Aluminum

Lugs

Aluminum

Lugs

Spaded

Terminal

Aluminum

Lugs

Spaded

Terminal

Aluminum

Lugs

Spaded

Terminal

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Tor q u e R a t i n g

Of Lugs (in./lbs.)

275

375

CONTINUED ON NEXT PAGE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 83

Page 84

APPENDIX — MAIN-LINE CIRCUIT BREAKER

TABLE 25. FACTORY RECOMMENDED MAIN LINE CIRCUIT BREAKERS

FOR MQ POWER INDUSTRIAL GENERATORS

Generator

Model

MQP150IV

MQP175IV

MQP200IV

MQP250IV

MQP300IV

MQP350IV

MQP400V Technical data for this unit TBD

MQP450VO

MQP500VO

MQP550VO MQP600VO

NOTES:

1. Refer to National Electric Code (N EC) for specific cond uctor sizes base d on current and temperature ratings.

2. Lug sizes are given for standard ci rcuit breaker setup. All lugs listed are m ade of aluminum and are compatible with both aluminum and copper conduc tors.

ABB or

Cutler Hammer

Model No.

KG3350 240V - 1Ø 333 400 350 LG3600 208V - 3Ø 520

JG3225 480V - 3Ø 226 250 225 14,000 #4 ~ 350 1 LG3600 240V - 1Ø 542

LG3601 208V - 3Ø 607 LG3602 240V - 3Ø 526 KG3300 480V - 3Ø 263 400 300 14,000 250 ~ 500 1 375

MDL3700 208V - 3Ø 694 800 700 65,000 3/0 ~ 400 3

LG3600 240V - 3Ø 601 600 600 18,0 00 400 ~ 500 2 275 KG3300 480V - 3Ø 301 400 300 14,000 250 ~ 500 1 375

NG31000

LG3500 480V - 3Ø 453 600 500 14,0 00 3/0 ~ 350 2 275

NG31200 208V - 3Ø 1214 NG31000 240V - 3Ø 1052 1,000 3/0 ~ 400 3

LG3600 480V - 3Ø 526 600 600 14,0 00 4/0 ~ 500 2 275

RD316T33W

MDL3700 480V - 3Ø 677 800 700 50,000 3/0 ~ 400 3 375

RD320T33W

MDL3800 480V - 3Ø 752 800 800 50,000 3/0 ~ 400 3 375

Generator

Output

(Voltage)

208V - 3Ø 104 1 240V - 3Ø 902

208V - 3Ø 156 1 240V - 3Ø 1353 4

208V - 3Ø 1735 240V - 3Ø 1503 1,600 125,000 500 ~ 1000 4

Generator

Output (Amps)

Breaker

Frame Size

(Amps)

600

600 600 18,0 00 400 ~ 500 2

1,200 1,000 18,000 3/0 ~ 400 3

1,200

2,500 1,600 125,000 500 ~ 1000

2,500

Breaker

Tri p Ra t i n g

(Amps)

600 400 ~ 500

Technical data for this unit TBD

1,200

2,000 125, 000 #2 ~ 600 6

Technical data for this unit TBD Technical data for this unit TBD

Interrupting

Rating RMS

(Sym Amps)

18,000

(cont.)

Cable Size

(kcmil)

{Note 1}

250 ~ 500 1

4/0 ~ 500 4

Max. No.

Cables Per

Phase

Type Of

Connection

{Note 2}

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Aluminum

Lugs

Tor q ue R a ti n g

Of Lugs (in./lbs.)

375

275LG3450 240V - 3Ø 451 450 #4 ~ 4/0

275

375

550

500

CONTINUED FROM PREVIOUS PAGE

PAGE 84 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 85

APPENDIX — GENERA T OR SPECIFICA TIONS

TABLE 26. MQ POWER INDUSTRIAL GENERATOR SPECIFICATIONS

Generator Model MQP20IZ MQP30DZ MQP30GM MQP40IZ M QP45GM MQP50IZ MQP60GM MQP60IV

Standby Power

Output Rating

Prime Power

Output Rating

Design Synchronous, Revolving Field, Self-Ventilated, Drip-Proof, Single Bearing

Number Of Poles 4-pole Design

Generator RPM 1800 Insulation Class Class H

Excitation System Brushless, Shunt Excitation Design

Armature Connection Wye or Delta

Frequency 60 Hertz

Voltage Output

Powe r Fac t or 1

Amperage Output -

120/240VA C

Voltage Output

Powe r Fac t or 0. 8

Amperage Output -

120/208VA C

Amperage Output -

120/240VA C

Amperage Output -

277/480VA C

Voltage Regulation

(No Load To Full Load)

Control Panel Operation

(ICS-30 Control)

Control Panel

Storage Temperature

Cooling System Ra ting 104°F (40°C) With 50/5 0% Mixture Glycol & Water

20 kW

(25 kVA)

18 kW

(22.5 kVA)

83 125 167 TBD 208 250

69 104 138 TBD 173 208

60 90 120 TBD 150 180

30 45 60 TBD 75 90

30 kW

(37.5 kVA)

27 kW

(33.75 kVA)

30 kW

(37.5 kVA)

27 kW

(33.75 kVA)

Generator Output Single Phase (1Ø)

120,127,139, 240, 254, 277

Broad Range Reconnectable

Generator Output Three Phase (3Ø)

208, 220, 240, 416, 440, 480

Broad Range Reconnectable

Environmental Operation

40 kW

(50 kVA)

36 kW

(45 kVA)

±1.0%

0°C ~ +50°C

-20°C ~ +70°C

Technical

data TBD

50 kW

(62.50 kVA)

45 kW

(56.25 kVA)

60 kW

75 kVA

54 kW

(67.5 kVA)

60 kW 75 kVA

54 kW

CONTINUED ON NEXT PAGE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 85

Page 86

APPENDIX — GENERA T OR SPECIFICA TIONS

TABLE 26. MQ POWER INDUSTRIAL GENERATOR SPECIFICATIONS (cont.)

GENERATOR MQP80GM MQP80IV MQP100GM MQP100IV MQP125IV MQP150IV MQP175IV MQP200IV

Standby Power

Output Rating

Prime Power

Output Rating

Design Synchronous, Revolving Field, Self-Ventilated, Drip-Proof, Single Bearing

Number Of Poles 4-pole Design

Generator RPM 1800 Insulation Class Class H

Excitation System Brushless, Shunt Excitation Design

Armature Connection Wye or Delta

Frequency 60 Hertz

Voltage Output

Powe r Fa ct or 1

Amperage Output -

120/240VA C

Voltage Output

Power Factor 0.8

Amperage Output -

120/208VA C

Amperage Output -

120/240VA C

Amperage Output -

277/480VAC

Voltage Regulation

(No Load To Full Load)

Control Panel Operation

(ICS-30 Control)

Control Panel

Storage Temperature

Cooling System Rating 104°F (40°C) With 50/50% Mixture Glycol & Water

75 kW

(93.75 kVA)

68 kW

(85 kVA)

75 kW

(93.75 kVA)

68 kW

(85 kVA)

313 417 301 333 729 481

260 347 434 520 607 694

226 301 376 451 526 601

113 150 188 226 263 301

100 kW

(125 kVA)

90 kW

(112.5 kVA)

Generator Output Single Phas e (1Ø)

Generator Output Three Phase (3Ø)

Environmental Operation

100 kW

(125 kVA)

90 kW

(112.5 kVA)

120,127,139, 240, 254, 277

Broad Range Reconnectable

208, 220, 240, 416, 440, 480

Broad Range Reconnectable

125kW

(156 kVA)

113 kW

(141 kVA)

±1.0%

0°C ~ +50°C

-20°C ~ +70°C

150 kW

(187.5 kVA)

135 kW

(169 kVA)

175 kW

(219 kVA)

158 kW

(197.5 kVA)

200 kW

(250 kVA)

180 kW

(225 kVA)

CONTINUED ON NEXT PAGECONTINUED FROM PREVIOUS PAGE

PAGE 86 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 87

APPENDIX — GENERA T OR SPECIFICA TIONS

TABLE 26. MQ POWER INDUSTRIAL GENERATOR SPECIFICATIONS (cont.)

GENERATOR MQP250IV* MQP300IV MQP350IV MQP400IV* MQP450VO MQP500VO MQP550VO MQP600VO

Standby Power

Output Rating

Prime Power

Output Rating

Design Synchronous, Revolving Field, Self-Ventilated, Drip-Proof, Single Bearing

Number Of Poles 4-pole Design

Generator RPM 1800 Insulation Class Class H

Excitation System Brushless, Shunt Excitation Design

Armature Connection Wye or Delta

Frequency 60 Her tz

Voltage Output

Powe r Fa ct or 0. 8

Amperage Output -

120/208VAC

Amperage Output -

120/240VAC

Amperage Output -

277/480VA C

Voltage Regulation

(No Load To Full Load)

Control Panel Operation

(ICS-30 Control)

Control Panel

Storage Temperature

Cooling System Rating 104°F (40°C) With 50/50% Mixture Glycol & Water

* Data for this unit is preliminary.

250 kW

(312.5 kVA)

225 kW

(281 kVA)

867 1,041 1,214 1,388 1,561 1,735 1,908 2082

752 902 1,052 1,203 1,353 1,503 1,654 1804

376 451 526 601 677 752 827 902

300 kW

(375 kVA)

270 kW

(337.5 kVA)

350 kW

(437.5 kVA)

315 kW

(394 kVA)

Generator Output Three Phase (3Ø)

208, 220, 240, 416, 440, 480

Broad Range Reconnec table

Environmental Operation

400 kW

(500 kVA)

360 kW

(450 kVA)

0°C ~ +50°C

-20°C ~ +70°C

(562.5 kVA)

±1.0%

450 kW

400 kW

(500 kVA)

500 kW

(625 kVA)

450 kW

(562.5 kVA)

550 kW

(687.5 kVA)

500 kW

(625 kVA)

600 kW

(750 kVA)

540 kW

(675 kVA)

CONTINUED ON NEXT PAGECONTINUED FROM PREVIOUS PAGE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 87

Page 88

APPENDIX — ENGINE SPECIFICA TIONS

TABLE 27. MQ POWER INDUSTRIAL GENERATOR DIESEL ENGINE SPECIFICATIONS

GENERATOR MODEL MQP20IZ MQP30DZ MQP40IZ MQP50IZ MQP60IV MQP80 IV

Diesel Engine Model

Engine RPMs 1800

Engine Design 4 Cycle Diesel, Water Cooled Displacement (liters) 2.2 2.9 3.1 4 .3 4.5 Number of Cylinders 4

Bore x Stroke (millimeters) 85 x 96 90 x 90 95 x 107 105 x 1 25 104 x 132

Horsepower @ Rated Spe ed 34.5 67.0 66.0 87.4 96.2 12 7

Governor Type Mechanical Electronic

Frequency Regulation ± 0.25% Of Mean value for cons tant loads from no lo ad to full load

Fuel Injection Pump Ma ke / Type Bosch / Zexel Delphi DP21 0 Bosc h / Zexel Stanadyne

Recommended Fuel Type ASTM-D975 #1 & #2 Die sel

Maximum Fuel Flow (gal/hr ) 6.34 25.8 39.6 23.7

Maximum Suction Head A llowable (feet) 1.64 23.6 3.3 10

Gal/hr at full load 2.2 2.7 3.4 4.2 5.1 6.8 Gal/hr at 3/4 load 1.6 1.9 2.4 3.2 3.6 4.4 Gal/hr at 1/2 load 1.2 1.3 1.7 2.3 2.3 3.2 Gal/hr at 1/4 load 0.9 0.6 1.0 1.5 1.7 1.9

Battery Voltage 12VDC

Battery Type Maintenance Free

Battery Cold Cranking Amps (ea.battery) 500 525 600 750

Starting System

Belt-Driven Battery Charging Alter nator

Exhaust Manifold Type Dry Manifold

Exhaust Flow at Rated kW (c fm) 162.4 273.0 332.0 342.5 244.8 370.2

Exhaust Temperature at Rated Output (°F) 1000 984 856 810 993 885

Maximum Allowable Backpressur e (in/wc) 40.9 7.3 40.9 2 3

Heat Rejection to Exhaus t (btu/min) 1081 1 649 3188 4269 352 7 46 08

Type Of System Gear Driven

Total Oil Capacity with Filter (gal) 2.1 2.0 2.5 3.4 3.3

Oil Filter Design Full Flow with replacea ble spin-on paper eleme nt type filter

Oil Cooler Integral

Oil Pressure at Rate d Speed/Temp (psi) 35 32 43 - 85 43 - 72

StandardRadiator D esign Standard Horizontal Discharge

Ambient Temperature Rating (F°) 104 122 180 104 122 122

Coolant Capacity - engine only (gal) 0.7 0.8 1.3 2.2

Coolant Flow (gal/min) 54 26.1 1 9.5 35 32.6 32.4

Radiator Cooling Air ( cfm) 3810 2560 2330 3707 7140 5897

Heat Rejection to Coo lant (btu/min) 1309 1470 1992 2447 2534 2260

Maximum Static Pressur e Head (psi) 7.25 1.45 TBD TBD TBD TBD

Isuzu

4LE1PV02

Denso

Negative Gnd

Kokusa n D enki

20A

Deutz

TD 2009 L4

Fuel System

Fuel Consumption

Engine Electrical Syst em

Mitsubishi

Negative Gnd

Nippon Denso

50A

Engine Exhaust Syste m

Engine Lubrication Syste m

Engine Cooling Syste m

Isuzu

4JG1TPV

Hitachi

50A

Isuzu

4BG1TRV

Denso

Negative Gnd

Iveco Motors

NEF45SM2

Bosch

Negative Gnd

Denso

60A

CONTINUED ON NEXT PAGE

Iveco Motors

NEF45 TM1

Bosch

90A

PAGE 88 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 89

APPENDIX — ENGINE SPECIFICA TIONS

TABLE 27. MQ POWER INDUSTRIAL GENERATOR DIESEL ENGINE SPECIFICATIONS (CONT.)

GENERATOR MODEL MQ P100IV MQP125IV MQP15 0IV MQP175IV MQP200IV MQP250IV

Diesel Engine Mode l

Engine RPMs 1800

Engine Design 4 Cycle Diesel, Aftercooled Displacement (liters ) 4.5 6.7 8.7 Number of Cylinders 4 6 -

Bore x Stroke (millimeters) 104 x 132 117 x 135 -

Horsepower @ Rated S peed 143.8 190.4 218.5 268 375 -

Governor Type Electronic -

Frequency Regulation ± 0.25% Of Mean value for constant load s from no load to fu ll load -

Fuel Injection Pump Make / Type Stanadyne -

Recommended Fue l Type ASTM-D975 #1 & #2 Diesel -

Maximum Fuel Flow (gal /hr) 23.7 37 66 -

Maximum Suction Head Allowable (feet) 10 TBD TBD TBD TBD -

Gal/hr at full load 7.6 10.0 11.1 13.5 18.7 Gal/hr at 3/4 load 5.7 7.4 8.5 10.2 14.0 Gal/hr at 1/2 load 4.0 4.9 5.9 6.4 9.3 Gal/hr at 1/4 load 2 .4 2.4 2.8 3 .1 4.6 -

Battery Voltage 14VDC 24VDC -

Battery Type Maintenance Free -

Battery Cold C ranking Amps (ea .battery) 800 -

Starting System Bosch Negative Gnd -

Belt-Driven Batter y Charging Alter nator Bosch 90A -

Exhaust Manifold Type Dry M anifold -

Exhaust Flow at Rated kW (cfm) 782 1024 1326 1326 1940 -

Exhaust Temperature at Rated Output (°F) 887 896 1040 1040 932 -

Maximum Allowable Backpressure (in/wc) 20 -

Heat Rejection to Ex haust (btu/min) 4343 7244 773 6 9355 12812 -

Type Of System Gear Driven -

Total Oil Capac ity with Filter (gal) 3.4 4.5 7.4 -

Oil Filter Design Full Flow with replaceable spin-o n paper element type filter -

Oil Cooler Integral -

Oil Pressure at Rated Speed/Temp (psi) 43 - 72 -

Standard Radiator D esign Standard Hori zontal Discharge -

Ambient Temperature Rating (F°) 122 -

Coolant Capacity - engine only (gal ) 2.2 2.8 3.9 -

Coolant Flow (gal/min) 27 44.6 75.8 -

Radiator Cooling A ir (cfm) 6356 12077 15420 15360 -

Heat Rejection to Coola nt (btu/min) 2333 3622 4437 5530 6809 -

Maximum Static Pres sure Head (ps i) TBD TBD TBD TB D TBD -

Iveco Motors

NEF45TM2

Iveco Motors NEF67TM1X

Fuel System

Fuel Consumption

Engine Electrical System

Engine Exhaust Syst em

Engine Lubrication S ystem

Engine Cooling Syst em

Iveco Motors

NEF67TEX1

Iveco Motors NEF67TE2X

Iveco Motors

Cursor87TE1X

Te c hnica l d ata f or

this unit is TBD

CONTINUED ON NEXT PAGECONTINUED FROM PREVIOUS PAGE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 89

Page 90

APPENDIX — ENGINE SPECIFICA TIONS

TABLE 27. MQ POWER INDUSTRIAL GENERATOR DIESEL ENGINE SPECIFICATIONS (CONT.)

GENERATOR MODEL MQP300IV MQP350IV MQP400IV MQP450VO M QP500VO MQP550IV

Diesel Engine Model

Engine RPMs 1800 - 1800

Engine Design 4-cycle, direct injectio n, aftercooled - 4-cycle, direct injection, aftercooled Displacement (liters) 10.3 12.9 - 16.1 Number of Cylinder s 6 - 6

Bore x Stroke (millimeters) 125 x 140 135 x 1 50 - 144 x 165

Horsepower @ Rated Speed 417 497 - 743 796

Governor Type Electronic - Electronic GAC #ACB275 Electronic

Frequency Regulation ± 0 .25 of mean value for constant lo ads from no load to 100% rated load

Fuel Injection Pump Make / Type Stan adyne - Valeo Delphi E1

Recommended Fu el Type ASTM-D975/No. 1-D & No. 2-D - ASTM-D975/No. 1-D & No. 2-D

Maximum Fuel Flow (gal/hr) 40.9 - 56.8 50 53

Maximum Suction Head A llowable (feet) TBD TBD - 9.8

Gal/hr at full load 23.4 26.9 - 36.8 35.6 33.1 Gal/hr at 3/4 load 17.4 20.1 - 27.6 25.8 24.2 Gal/hr at 1/2 load 11.5 13.4 - 18.4 17.3 17.3 Gal/hr at 1/4 load 5.7 6.7 - 9.2 9.9 10.5

Battery Voltage 24VDC - 24VDC

Battery Type Maintenance Free - Maintenanc e Free

Battery Cold Cranking Amps (ea.battery) 800A - 800A

Starting Sys tem Denso - Negative gnd - Melco 105P70 - Nega tive gnd

Belt-Driven Battery Charging Alternator Bosch 90A - Bosch 90A

Exhaust Manifold Type Dr y Manifold - Dry Manifold

Exhaust Flow at Rated kW (cfm) 1 964 3366 - 4117 389 9 4153

Exhaust Temperature at Rated Output (°F) 926 1076 - 1035 893 954

Maximum Allowable Backpressure (in/wc) 20 - 28.1 40.1

Heat Rejection to Exh aust (btu/min) 15465 19149 - 2 7410 25136 28435

Type Of Sys tem Full pressure - Fu ll pressure

Total Oil Capacity with Filter (gal) 7.9 9.2 - 16.9 12.7

Oil Filter Design Full flow, replaceable spin-on, paper - Full flow, replaceable spin-on, paper el ement

Oil Cooler Integal - Integal

Oil Pressure at Rate d Speed/Temp (psi) 43 - 72 36 - 72 - 43 - 72 44 - 94

Standard Radiator Design S tandard horizon tal discharge - Standard horizontal dis charge

Ambient Temperature Rating (F°) 122 - 104

Coolant Capacity - en gine only (gal) 4.0 5.3 - 7.6 8.7

Coolant Flow (gal/min) 146 - 166 122

Radiator Cooling Air ( cfm) 20640 23307 - 14476 14620 16103

Heat Rejection to C oolant (btu/min) 7976 9880 - 13364 1 3137 14104

CONTINUED FROM PREVIOUS PAGE

Iveco Motors

Cursor10 TE1X

Iveco Motors

Cursor13 TE2X

Fuel System

Fuel Consumption

Engine Electrical Syste m

Engine Exhaust Syst em

Engine Lubrication Sys tem

Engine Cooling System

Te c hnica l d ata f or

this unit is TBD

Volvo

TAD1631GE

Volvo

T AD1641GE

Volvo

TAD1642GE

PAGE 90 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 91

APPENDIX — ENGINE SPECIFICA TIONS

TABLE 28. MQ POWER INDUSTRIAL GENERATOR GASEOUS FUEL ENGINE SPECIFICATIONS

GENERATOR MODEL MQP30GM MQP45GM MQP60GM MQP80GM MQP100GM

Diesel Engine Model

Engine RPMs 1800

Engine Design 4 Cycle Natural gas, Water cooled

Displacement (liters) 2.4 4.3 5.7 8.1

Number of Cylinders 4

Bore x Stroke (millimeters) 93 x 100 101.6 x 88.4 107.9 x 111

Horsepower @ Rated Speed 50 65 95 150

Governor Type Electronic

Frequency Regulation ± 0.5% Of Mean value for cons tant loads from no lo ad to full load

Recommended Fue l Type Pipeline Natural Gas or L iquid Propane

Fuel Supply Line Inlet

(Natural gas / Liquid Pr opane)

Fuel Supply Pressure

(Natural gas / Liquid Pr opane)

Gal/hr at full load

(Nat. gas-cf/hr / Liq. Prop.-gal/hr)

Gal/hr at 3/4 load

(Nat. gas-cf/hr / Liq. Prop.-gal/hr)

Gal/hr at 1/2 load

(Nat. gas-cf/hr / Liq. Prop.-gal/hr)

Gal/hr at 1/4 load

(Nat. gas-cf/hr / Liq. Prop.-gal/hr)

Battery Voltage 24VDC

Battery Type Maintenance Free

Battery Cold Cranki ng Amps (ea.batter y) 800

Starting System GM/Delco Negative gnd

Belt-Driven Batter y Charging Alte rnator Remy 70A

Exhaust Flow at Rated kW (c fm) 246 341 4 79 645 620

Exhaust Temperature at Rated Output (°F) 1292 1300 1250

Maximum Allowable Backpressu re (in/wc) 50 41

Heat Rejection to Ex haust (btu/min) 3285 4469 5669 8428 10630

Type Of System Rotor on Crank

Total Oil Capacity with Filter (gal) 1.4 1.3 1.6 2.2

Oil Filter Design Full Flow, bypass if plugged

Oil Pressure at Rated Sp eed/Temp (psi) 1 6 40 - 45 40 - 60

Standard Radiator D esign Standard Horizontal Discharge

Ambient Temperature Rating (F°) 113 122

Coolant Capacity - engine only (gal) 1.0 4.5 6.5

Coolant Flow (gal/min) 15.25 32.6 37

Radiator Cooling Air ( cfm) 3200 3870 5700 9300

Heat Rejection to Coolan t (btu/min) 1800 2182 3120 3540 4390

General Motors

Vortec 3000

416 / 4.68 552 / 6.03 817 / 8.82 1080 / 1 1.79 1360 / 14.86

312 / 3.51 414 / 4.50 612 / 6.60 810 / 8. 73 1020 / 11.13

208 / 2.34 276 / 3.00 408 / 4.40 540 / 5.82 680 / 7.42

104 / 1.17 138 / 1.50 204 / 2.20 270 / 2.91 340 / 3.74

General Motors

Vortec 4300

Fuel System

4.0-6.0 in/H

Fuel Consumption

Engine Electrical System

Engine Exhaust Syst em

Engine Lubrication Sys tem

Engine Cooling System

250 psi

General Motors

Vortec 5700

3/4" pipe, 1" hose/ 1/4" NPT 3/8" hose

General Motors

Vortec 8100

7.0-11.0 in/H2O/

General Motors

Vortec 8100

250 psi

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 91

Page 92

APPENDIX — DIMENSIONS AND WEIGHTS

TABLE 29. MQ POWER GENERATOR DIMENSIONS & WEIGHTS

GENERATOR MQP20IZ MQP30DZ MQP30GM MQP40IZ MQP45GM MQP50IZ MQP60GM MQP60IV MQP80GM MQP80IV MQP100GM MQP100IV

Open Unit with Skid- mount base

Length (in.) 84 84 84 1 00 100 116 116

Width (in.) 34 34 34 34 34 49 49

Height (in.)* 48 43 48 43 53 50 56 50 58 58

Generator Weight (lbs)** 1 ,076 1,305 1,185 1 ,466 1,2 52 1,839 1,480 1,810 1,985 2,360 1,985 2,3 60

Standard Housed Un it with Skid-mount base

Length (in.) 84 84 84 1 00 100 116 116

Width (in.) 34 34 34 34 34 49 49

Height (in.)* 66 66 66 67 67 76 76

Generator Weight (lbs)** 1 ,503 1,732 1,612 1,893 1,680 2,38 7 2,027 2,358 2,6 20 2,995 2,620 2,995

Sound Attenuated U nit with Skid-mount b ase

Length (in.) 84 84 84 1 00 100 116 116

Width (in.) 34 34 34 34 34 49 49

Height (in.)* 66 66 66 67 67 76 76

Generator Weight (lbs)** 1 ,566 1,785 1,665 1,946 1,732 2,4 49 2,089 2,56 5 2,675 3,045 2,675 3,045

* All weights are appr oximate and do not inclu de fuel.

CONTINUED ON NEXT PAGE

PAGE 92 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

Page 93

APPENDIX — DIMENSIONS AND WEIGHTS

TABLE 29. MQ POWER GENERATOR DIMENSIONS & WEIGHTS (cont.)

GENERATOR MQP125IV MQP150IV MQP175IV MQP200IV MQP250IV** MQP300IV MQP350IV MQP400IV** MQP450VO MQP500VO MQP550VO MQP600VO

Open Unit with Skid-mount base

Length (in.) 116 115 115 115 131 131 131 131 145 145 145 145

Width (in.) 4949575757575757 61616171

Height (in.) 57 68 68 68 68 71 71 71 78 78 78 78

Generator Weight (lbs.)* 2,660 3,406 2,869 3,459 TBD 4,168 4,824 TBD 6,307 6,307 6,577 7,062

Standard Housed Unit with Skid-mount base

Length (in.) 116 115 115 115 131 131 131 131 145 145 145 145

Width (in.) 4949575757575757 61616161

Height (in.) 76 76 100 100 104 104 104 104 112 112 112 112

Generator Weight (lbs.)* 3,295 4,892 3,469 4,059 TBD 4,168 5,674 TBD 7,387 7,387 7,657 8,142

Sound Attenuated Unit with Skid-mount base

Length (in.) 116 139 150 150 166 166 166 166 184 184 184 184

Width (in.) 4949575757575757 61616171

Height (in.) 76 76 100 100 104 104 104 104 112 112 112 112

Generator Weight (lbs.)* 3,350 5,152 3,734 4,324 TBD 5,283 5,939 TBD 7,687 7,687 7,957 8,442

* All weights are approximate and do not include fuel. ** Data for this unit is preliminary.

CONTINUED FROM PREVIOUS PAGE

INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 93

Page 94

PARTS AND OPERA TION MANUAL

APPLICA TION & INST ALLA TION MANUAL

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER

ON-HAND

WHEN CALLING

MUL TIQUIP’S MAIN PHONE NUMBERS

800-421-1244 FAX: 310-537-3927 310-537-3700

PARTS DEP ARTMENT

800-427-1244 FAX: 310-637-3284 310-537-3700

MQ POWER SERVICE DEP ARTMENT

800-835-2551 FAX: 310-638-8046 310-537-3700

TECHNICAL ASSIST ANCE

800-478-1244 FAX: 310-631-5032

WARRANTY DEP ARTMENT

800-421-1244, EXT. 279 FAX: 310-537-1173 310-537-3700, EXT. 279

MQPO WER

A Division of Multiquip Inc.

POST OFFICE BOX 6254 CARSON, CA 90749 310-537-3700 • 800-883-2551 F AX: 310-632-2656 E-MAIL: mqpower@multiquip.com WWW: www .mqpower.com

PARTS DEPARTMENT:

800-427-1244 F AX: 800-637-3284

SERVICE DEPARTMENT:

800-835-2551 F AX: 310-638-8046

Multiquip MQP60GM, MQP45GM, MQP60IV, MQP30GM, MQP30DZ User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual