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

...
5 (1)

APPLICATION & INSTALLATION MANUAL

MQ POWER

Industrial Generator Set

Application & Installation

Manual

© COPYRIGHT 2007, MQ PPOWER

Revision #4 (09/07/07)

MQPOWER

PARTS DEPARTMENT:

A Division of Multiquip Inc.

POST OFFICE BOX 6254

800-427-1244

CARSON, CA 90749

FAX: 800-637-3284

310-537-3700 • 800-883-2551

SERVICE DEPARTMENT:

FAX:310-632-2656

800-835-2551

E-MAIL:mqpower@multiquip.com

FAX:310-638-8046

WWW:www.mqpower.com

 

 

 

 

 

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 ON-HAND WHEN CALLING

MULTIQUIP’SMAINPHONENUMBERS

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

PARTSDEPARTMENT

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

310-537-3700

MQPOWERSERVICEDEPARTMENT

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

TECHNICALASSISTANCE

 

800-478-1244

FAX: 310-631-5032

WARRANTYDEPARTMENT

800-421-1244, EXT. 279

FAX: 310-537-1173

310-537-3700, EXT. 279

 

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

TABLE 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

Application

 

Genset Sizing .....................................................

17-21

Determining Load Characteristics......................

22-26

Environmental Consideration — dB(A) ..............

27-32

Mechanical 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 Battery ...................................................

54-55

Charging Battery ................................................

56-59

Ventilation 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 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

Appendix

 

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

All specifications in this

 

manual are subject to change

 

without notice.

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

NOTES PAGE

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

SAFETY MESSAGE ALERT SYMBOLS

FORYOUR SAFETY AND THE SAFETY OF OTHERS!

 

Lethal Exhaust Gases

 

 

 

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 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.

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 by one of three words: DANGER,

WARNING, or CAUTION.

You WILL be KILLED or SERIOUSLY INJURED if you DO NOT follow these directions.

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

You CAN be INJURED if you DO NOT follow 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.

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) 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.

Explosive Fuel

Diesel fuel is extremely

flammable, and

its

vapors

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

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.

Burn Hazards

Engine components can generate extreme heat. To prevent burns, DO NOT touch these areas while the engine is running or immediately after operation. NEVER operate the engine with heat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers or guards removed. Keep fingers, hands, hair and clothing away from all moving parts to prevent injury.

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

SAFETY MESSAGE 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.

Respiratory Hazard

ALWAYS wear approved respiratory protection.

Over Speed Conditions

 

Sight and Hearing hazard

 

 

 

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.

ALWAYS wear approved eye and hearing protection.

Guards and Covers In Place

 

Equipment Damage Messages

 

 

 

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

surrounding environment.

NEVER operate the genset without guards and covers in place.

THIS MQ POWER GENSET, OTHER PROPERTY, OR THE SURROUNDING

EQUIPMENT COULD BE DAMAGED IF YOU 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.

Failure 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 hot components can cause serious 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 gives off DEADLY carbon monoxide gas.

NEVER operate the genset in a restricted air flow environment!

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 death!

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 bodily harm or even death!

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

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

IMPORTANT SAFETY INSTRUCTIONS

GENERAL SAFETY

RADIATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 necessary.

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 death!

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!

DO NOT touch or open any of the components mentioned below while the generator is running. Always allow sufficient time for the engine and generator to cool before performing maintenance.

1.Radiator Cap - Removing the radiator cap while the 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.

2.Coolant Drain Plug - Removing the coolant drain plug 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.

3.Engine Oil Drain Plug - Removing the engine oil drain 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 safety precautions and operations techniques before using generator.

DO NOT allow 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 Power for this equipment.Damage 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 parts or bolts before starting.

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.

ALWAYS know the location of the nearest

first aid kit.

ALWAYS provide an emergency escape route in the event of an emergency.

In emergencies always know the location of the nearest phone or keep a phone on the job site. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency.

Maintenance Safety

When performing maintenance on MQ Power 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.

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

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.

DO NOT pour waste, oil, coolant or fuel directly onto the ground, down a drain, or into any water source

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

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)

IMPORTANT SAFETY INSTRUCTIONS

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 clothing or skin, rinse skin immediately 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 batteries.

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.

11.ALWAYS keep the battery charged. If the battery is not charged a buildup of combustible 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.

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. Lead-acid batteries present a risk of fire because they generate hydrogen gas.

If using a serviceable battery, never over 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. Always remove 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.

On generators not having a grounded supply circuit, determine if the battery is inadvertently 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.

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

IMPORTANT SAFETY INSTRUCTIONS

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, every possible measure should be taken to prevent fire hazards and to protect property and people. Consider the following:

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.

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 (CO2) fire 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.

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.

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

IMPORTANT SAFETY INSTRUCTIONS

Lifting the Generator Set

Transporting

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.

Always shutdown engine before transporting.

Never 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 transported 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. Generator sets must be applied in such a way as to provide reliable, electrical power of the quality and capacity required.

About This Manual

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

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

2.Mounting Recommendations — This section provides 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 different installation methods for ventilating and cooling the genset.

Safety Considerations

MQ Power'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 America, many safety (and environmental) issues related to generator set applications are addressed by the following standards of the National Fire Protection

Association (NFPA):

zFlammable and Combustible Liquids Code — NFPA 30

zNational Fuel Gas Code — NFPA 54

zNational Electrical Code — NFPA 70

zHealth Care Facilities Code — NFPA 99

zLife Safety Code — NFPA 110

zEmergency and Standby Power Systems — NFPA 110

zStorage and Handling of Liquified Natural Gas — NFPA 59A

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.

Many national, state, and local codes incorporate the above 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 certificate- of-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 14 — INDUSTRIAL GENERATOR SETS — APPLICATION & INSTALLATION MANUAL — REV. #4 (09/07/07)

INSTALLATION OVERVIEW

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 does not provide complete application information for selecting a genset or designing the complete installation. This manual is a reference tool only. If there are any questions not answered by this manual, contact your nearest MQ Power dealer or distributor for 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, transfer 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.

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 power . 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 exercise 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

INSTALLATION OVERVIEW

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) for 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

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.

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 accessible for service without removing the set or any accessories.

Type of cooling system. A factory-mounted radiator is recommended.

Ventilation. Large volumes of air flow are involved. 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.

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

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), starting 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 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.

It may be necessary to oversize a generator set in applications where the voltage and frequency dip performance specifications are more stringent than usual, particularly 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 (Telecommunications)

Variable Frequency Drives (VFD)

Medical Diagnostic Imaging Equipment

GENSET SIZING

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 Table 1.

Genset Sizing Procedure

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 worksheet

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 italics) for an example calculation.

 

 

Table 1. Load Schedule

 

 

Load#

Load Description

Type of Load

Power Rating

Load QTY.

 

 

Examples:

 

 

 

 

Lighting..................................

. kW

 

 

 

Static UPS.............................

. kVA

 

 

 

Variable Speed Drives...........

.HP

 

 

 

Telecom DC Rectifers............

.kVA

 

 

 

Motors.....................................

HP

 

1

Water Pumps #1 & #2

Motor, Nema Code letter G,

100 HP

2

 

 

former starter (80% Tap)

 

 

2

Water Pumps #3

Motor, Nema Code letter G,

100 HP

1

 

 

former starter (80% Tap)

 

 

3

Fluorscent Lighting

Lighting

10 HP

1

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

GENSET SIZING

Generator Set Sizing Calculations (Continued)

Step 2. Create a Generator SetWorksheet

a.When creating a worksheet, number a worksheet for each sequenced load step. The number block is in the upper right hand corner of the worksheet. Worksheet #1 will coincide with Load Step #1, Worksheet #2 will coincide with Load Step #2, and etc.. The step sequence guidelines 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 numbers 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 Load QTY marked on the load schedule in the column labeled QTY on the worksheet.

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

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 transfer 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 Factor — 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 example, 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

 

 

 

Generator Set Sizing Worksheet

 

 

 

Load Step #

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Individual Load Characteristics

 

 

Load Step Totals

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SkVA

SkW

 

RkVA

 

RkW

 

GkW

QTY

skVA

skW

RkVA

Rkw

 

 

Gkw

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Load

 

 

Enter RkW total from previous load step --->

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Enter RkVA, RkW, and GkW totals from previous load step --

 

 

 

#

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

->

 

 

 

1.

377.6

a

113.3

b

 

89

d

 

81.9

c

 

81.9

e

2

755.-

228

f

178

f

163.8

f

 

163.8e-

 

 

 

 

 

 

 

 

2f

 

 

 

 

,f

3.

 

 

 

 

 

 

1

 

5 10. g

10g

10.5g

10g

 

 

10e

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Load Step Totals -------------------------->

765.7

238

188.5

173.8

 

173.8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Generator Set Sizing Worksheet

 

 

Load Step #

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Individual Load Characteristics

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SkVA

SkW

RkVA

RkW

GkW

QTY

skVA

skW

RkVA

Rkw

 

Gkw

 

 

 

 

 

 

 

 

 

 

 

 

 

Load

 

Enter RkW total from previous load step --->

173.8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Enter RkVA, RkW, and GkW totals from previous load step ---

188.5

173.8

 

173.8

#

 

 

 

 

 

 

 

 

 

 

 

>

 

2.

 

1

9

8 h

81.9h

89h

81.9h

 

163.8h

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Load Step Totals -------------------------->

89

255.7

277.5

255.7

 

337.6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 (Table 6) = 100 x 5.9 x 0.64 = 377.6

b.SkW = SkVA x SPF = 377.6 x 0.3 =113.3

c.RkW = HP x 0.746 / 0.91 = 81.9

d.RkVA = 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 for GkW for 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 factor = 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 on page 22 for 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 load step totals heading.

c.If the load quantity is greater than one, enter the values for SkVA, SkW, RkVA, and RkW in the columns under the individual load characteristics heading. Then multiply each load entry by the number under QTY and enter the products under the load step totals heading for SkVA, 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 multiple nonlinear loads.

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).

Step 4. Enter Individual Load Characteristics

Now all the loads on the load schedule should be listed on the generator set sizing worksheets, all the load 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 load step totals heading and enter the sums on the load step totals line.

b.On worksheet #2 enter the load step totals from 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.

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

GENSET SIZING

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 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.

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

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

iii.If none of the alternators available for the generator 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.

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

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

GENSET SIZING — DETERMINING LOAD CHARACTERISTICS

Determining Load Characteristics

Lighting

For all types of lighting loads:

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

Typical ballast wattages are defined by Table 2 below:

Table 2. Ballast Wattages

LAMP

BALLAST

 

 

48 inch T-12, 40 W, Preheat

10 W

 

 

48 inch T-12, 40 W, Rapid Start

14 W

High Output 40 W Fluorescent

25 W

 

 

Mercury, 100 W

18-35 W

Mercury, 400 W

25-65 W

 

 

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

SkW = 0.75 x RkW

Unless otherwise known, assume the following starting and running power factors (SPF and RPF, respectively, see Table

3 below) for the following types of lighting:

Table 3. Starting & Running Power Factor

Type of Lighting

SPF

RPF

 

 

 

Fluorescent

0.95

0.95

 

 

 

Incandescent

1.00

1.00

High Intensity Discharge

0.85

0.90

Then the following can be calculated:

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.

Table 4. Single Phase Motor Characteristics

HP

RkW

RkVA

SkVA

SkW

 

 

Split Phase

 

 

1/6

0.3

0.5

3.5

2.8

1/4

0.4

0.6

4.8

3.8

1/3

0.5

0.7

5.6

4.5

1/2

0.7

0.9

7.7

6.1

 

Capacitor Start / Induction Run

 

1/6

0.3

0.5

2.6

2.0

1/4

0.4

0.6

3.3

2.6

1/3

0.5

0.7

3.9

3.1

1/2

0.7

0.9

5.3

4.25

3/4

1.0

1.25

7.1

5.7

1

1.2

1.6

9.5

7.6

1-1/2

1.6

2.0

14.25

11.4

2

2.2

2.7

19

15.2

3

3.3

4.1

28.5

22.8

 

Capacitor Start / Capacitor Run

 

1/6

0.3

0.5

2.8

2.3

1/4

0.4

0.6

3.8

3.0

1/3

0.5

0.7

3.6

2.9

1/2

0.7

0.9

5.9

4.7

3/4

1.0

1.25

8.0

6.4

1

1.2

1.6

10.6

12.7

1-1/2

1.6

2.0

16.0

12.7

2

2.2

2.7

21.2

17.0

3

3.3

4.1

31.8

25.5

 

Permanent Split Capacitor (PSC)

 

1/6

0.3

0.5

1.0

0.8

1/4

0.4

0.6

1.5

1.2

1/3

0.5

0.7

2.0

1.6

1/2

0.7

0.9

3.0

2.4

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

GENSET SIZING — DETERMINING LOAD CHARACTERISTICS

Three-Phase Induction Motors

Calculate RkW as follows:

If EFF (motor running efficiency) of the motor is not known, refer to Table 5 and use the value corresponding to the motor horsepower.

Calculate RkVA as follows:

If RPF (running power factor) is unknown, refer to Table 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 Table 5.

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.

NEMA Code Letter Multiplying Factor

Use Table 5 below to calculate the starting kVA. DO NOT confuse the NEMA (National Electrical Manufacturers Association) motor code and design letters.

The code letter refers to the ratio of locked rotor kVA to HP, whereas the design letter refers to the ratio of torque to speed.

Table 5. NEMA Code Letter Multiplying Factor

A

2.0

 

 

B

3.3

 

 

C

3.8

 

 

D

4.2

 

 

E

4.7

 

 

F

5.3

 

 

G

5.9

 

 

H

6.7

 

 

J

7.5

 

 

K

8.5

 

 

L

9.5

 

 

M

10.6

 

 

N

11.8

 

 

P

13.2

 

 

R

15.0

 

 

S

16.0

 

 

T

19.0

 

 

U

21.2

 

 

V

23.0

 

 

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

GENSET SIZING — DETERMINING LOAD 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:

Calculate SkW as follows:

1.If SPF (Starting Power Factor) is unknown, refer to Table 4 on page 22 and use the value corresponding to the motor horsepower. If a resistor-type reduced voltage motor starting is used, use the value for SPF in Table 6 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.

Table 6. Reduced Voltage Starting Methods and Characteristics

 

% Full

% Full

% Full

SkVA

 

Starting Method

Voltage

Voltage

Multiplying

SPF

Voltage kVA

 

Applied

Torque

Factor

 

 

 

 

Full Voltage

100

100

100

1.0

Reduced Voltage

80

64

64

0.64

65

42

42

0.42

Autotransformer

50

25

25

0.25

 

Series Reactor

80

80

64

0.80

65

65

42

0.65

 

50

50

25

0.50

Series Resistor

80

80

64

0.80

0.60

65

65

42

0.65

0.70

 

50

50

25

0.50

0.80

Star Delta

100

33

33

0.33

 

 

 

 

 

 

Part Winding (Typical)

100

60

48

0.6

Wound Rotor Motor

100

160*

100*

1.6*

*— These are percents or factors of running current, which depend on the value of the series resistances added to the rotor windings.

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

GENSET SIZING — DETERMINING LOAD CHARACTERISTICS

Three Phase NEMA Motor Code Table

Table 7 lists the 3Ø motor starting 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 locked rotor kVA to HP, whereas the design letter refers to the ratio of torque to speed.

Table 7. Three Phase Motor SkVA, SPF, EFF, and RPF

HP

 

 

 

NEMA Motor Code Letters

 

 

 

 

Motor Factors

A

B

C

D

E

F

G

H

J

K

L

N

SPF

EFF

RPF

 

1/4

0.5

0.8

0.9

1.0

1.2

1.3

1.5

1.7

1.9

2.1

2.4

2.9

0.82

62.8

0.55

1/2

1.0

1.7

1.9

2.1

2.4

2.6

3.0

3.3

3.8

4.2

4.7

5.9

0.82

62.8

0.55

3/4

1.5

2.5

2.8

3.2

3.6

4.0

4.5

5.0

5.7

6.4

7.1

8.9

0.78

69.3

0.64

1

2

3

4

4

5

5

6

7

8

8

9

12

0.76

73.0

0.70

1-1/2

3

5

6

6

7

8

9

10

11

13

14

18

0.72

76.9

0.76

2

4

7

8

8

9

11

12

13

15

17

19

24

0.70

79.1

0.79

3

6

10

11

13

14

16

18

20

23

25

28

35

0.66

82.5

0.82

5

10

15

19

21

24

26

30

33

38

42

47

59

0.61

83.8

0.85

7-1/2

15

25

28

32

36

40

45

50

57

64

71

89

0.56

85.1

0.87

10

20

33

38

42

47

53

59

67

75

85

95

118

0.53

85.9

0.87

15

30

50

57

64

71

79

89

100

113

127

142

177

0.49

86.9

0.88

20

40

67

75

85

95

106

119

134

151

170

190

236

0.46

87.6

0.89

25

50

84

94

106

119

132

149

167

189

212

237

295

0.44

88.0

0.89

30

60

100

113

127

142

159

178

201

226

255

285

354

0.42

88.4

0.89

40

80

134

151

170

190

212

238

268

302

340

380

475

0.39

88.9

0.90

50

100

167

189

212

237

265

297

335

377

425

475

590

0.36

89.6

0.90

60

120

201

226

255

285

318

357

402

453

510

570

708

0.36

89.6

0.90

75

150

251

283

318

356

397

446

502

566

637

712

885

0.34

90.0

0.90

100

200

335

377

425

475

530

595

670

755

849

949

1180

0.31

90.5

0.91

125

250

418

471

531

593

662

743

837

943

1062

1187

1475

0.29

90.9

0.91

150

300

502

566

637

712

794

892

1004

1132

1274

1424

1770

0.28

91.2

0.91

200

400

669

754

849

949

1059

1189

1339

1509

1699

1899

2360

0.25

91.7

0.91

250

500

836

943

1061

1186

1324

1486

1674

1886

2124

2374

2950

0.24

92.0

0.91

300

600

1004

1131

1274

1424

1589

1784

2009

2264

2549

2849

3540

0.22

92.3

0.92

350

700

1171

1320

1486

1661

1853

2081

2343

2641

2973

3323

4130

0.19

93.1

0.92

400

800

1338

1508

1698

1898

2118

2378

2678

3018

3398

3798

4720

0.19

93.1

0.92

500

1000

1673

1885

2123

2373

2648

2973

3348

3773

4248

4748

5900

0.17

93.8

0.92

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

GENSET SIZING — DETERMINING LOAD 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.

Variable Frequency Drives

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

Static UPS

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

Calculate RkW as follows:

Calculate RkW as follows:

In the equation above:

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

Calculate RkVA as follows:

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

Since these drives are all current limiting:

Calculate GkW using the following formula, assuming a generator sizing factor of 2 unless otherwise known.

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%.

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:

Calculate GkW as follows:

Telecom 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)

ENVIRONMENTAL 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 receiver. 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 pathway 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

To 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 range of frequencies. The dB(A) weighted scale tries to simulate human loudness perception. Loudness is dependent on sound pressure level (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, whichever is greater. 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 analyzer. The microphones should be placed in a circle of 23 feet (7 meters) radius centered on the generator set.

Table 8. Typical Criteria for Outside Noise Levels

Noise Zones

Peak Day

Peak Night

Continuous

Continuous

Day

Night

dB(A)

dB(A)

 

 

dB(A)

dB(A)

 

 

 

 

 

 

 

 

 

 

Urban —

Residential

62

52

57

47

 

 

 

 

 

 

Suburban —

Residential

57

47

52

42

Very Quite Suburban or

52

42

47

37

Rural Residential

 

 

 

 

Urban — Nearby Industry

67

57

62

52

 

 

 

 

 

Heavy Industry

72

62

67

57

 

 

 

 

 

 

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

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

ENVIRONMENTAL 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 for dB(A) levels 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)

ENVIRONMENTAL 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

Loading...
+ 65 hidden pages