Multiquip MQP60GM, MQP45GM, MQP60IV, MQP30GM, MQP30DZ User Manual
...
APPLICA TION & INST ALLA TION MANUAL
MQ POWER
Industrial Generator Set
Application & Installation
Manual
© COPYRIGHT 2007, MQ PPOWER
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 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)
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
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
VV
entilation and Coolingentilation and Cooling
V
entilation and Cooling
VV
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.
NOTES PA GE
INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 5
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
or
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
if
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.
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
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)
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
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)
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.
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.
■
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 NFPA.
■
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
2
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
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):
z
Flammable and Combustib le Liquids Code — NFPA 30
z
National Fuel Gas Code — NFPA 54
z
National Electrical Code — NFPA 70
z
Health Care Facilities Code — NFPA 99
z
Life Safety Code — NFPA 110
z
Emergency and Standby P ower Systems — NFPA 110
z
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.
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
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)
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
1
2
3
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
PH001
2
1
1
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)
GENSET SIZING
teehskroWgniziSteSrotareneG 1#petSdaoL
scitsiretcarahCdaoLlaudividnIslatoTpetSdaoL
AVkSWkSAVkRWkRWkGYTQAVksWksAVkRwkRwkG
>---petsdaolsuoiverpmorflatotWkRretnE—
daoL
#
.16.773
a
b
3.311
d
98
c
9.18
e
9.18
2
.3—————1 5.01
-.557
f
2
g
—— ————————— —
--petsdaolsuoiverpmorfslatotWkGdna,WkR,AVkRretnE
—— —
>-
f
822
g
01
f
871
g
5.01
8.361
g
01
-e
f
8.361
f,
e
01
>--------------------------slatoTpetSdaoL
8325.8818.3718.371
7.567
teehskroWgniziSteSrotareneG 2#petSdaoL
scitsiretcarahCdaoLlaudividnI
AVkSWkSAVkRWkRWkGYTQAVksWksAVkRwkRwkG
8.371
---petsdaolsuoiverpmorfslatotWkGdna,WkR,AVkRretnE
>
h
9.18
5.8818.3718.371
h
98
h
9.18
h
8.361
daoL
#
.2—————198
—— —————
———— —
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—— ———————— — —
>--------------------------slatoTpetSdaoL
98
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
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
load step totals
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)
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.
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)
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
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
08
56
05
08
56
05
46
24
52
08
56
05
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
46
24
52
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)
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
PH
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
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0306001311721241951
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06021102622552582813
57051152382813653793
001002533773524574035
521052814174135395266
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0020049664579489499501
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INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07) — PAGE 25
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)
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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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)
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
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