Siemens Liquid-cooled Generators Installation Manuallines

Siemens

Liquid-cooled Generators

InstallatIon

GuIdelInes

www.sea.siemens.com/generators • 800-844-0029

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Study the SAFETY RULES in the Owner’s Manual carefully before installing,
operating or servicing any equipment. Use this guide ONLY in conjunction with
the Owner’s Manual and Installation Manual shipped with the generator. The
generator can operate safely, efficiently and reliably only if it is properly installed,
operated and maintained.

The manufacturer cannot anticipate every possible circumstance that might
involve a hazard. The warnings in this manual, and on tags and decals affixed to
the unit are, therefore, not all-inclusive.

Despite the safe design of these generators, operating the equipment
imprudently, neglecting its maintenance or being careless can cause possible
injury or death.

Permit only responsible and capable persons to install, operate or maintain
this equipment.

Potentially lethal voltages are generated by these machines. Ensure all steps are
taken to render the machine safe before attempting to work on the generator.

This booklet is designed to familiarize you with the installation
process for Siemens’ liquid-cooled residential and commercial
generators. This booklet does not replace or supersede any
information contained in any of the written documents shipped
with your equipment. This booklet should only be used in
conjunction with the Owner’s Manual, Installation Manual and
other technical documents shipped with your equipment.

Future product updates and/or modifications will be reflected
in the written documentation included with your equipment.
Always read all accompanying documentation carefully
before attempting to install any generator, transfer switch or
related equipment.

It is essential to comply with all regulations established by the
Occupational Safety and Health Administration (OSHA) and strict
adherence to all local, state and national codes is mandatory.

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GENERAL HAZARDS

• For safety reasons, it is recommended that the equipment be installed,
serviced and repaired by an Authorized Service Dealer or other competent,
qualified electrician or installation technician who is familiar with applicable
codes, standards and regulations. The operator must also comply with all
such codes, standards and regulations.

• Installation, operation, servicing and repair of this (and related) equipment
must always comply with applicable codes, standards, laws and regulations.
Adhere strictly to local, state and national electrical and building codes.
Comply with regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is installed, operated
and serviced in accordance with the manufacturer’s instructions and
recommendations. Following installation, do nothing that might render the unit
unsafe or in noncompliance with the aforementioned codes, standards, laws
and regulations.

• Engine exhaust fumes contain carbon monoxide gas, which can be DEADLY.
This dangerous gas, if breathed in sufficient concentrations, can cause
unconsciousness or even death. For that reason, adequate ventilation must
be provided. Exhaust gases must be piped safely away from any building or
enclosure that houses the generator to an area where people, animals, etc.,
will not be harmed. This exhaust system must be installed properly, in strict
compliance with applicable codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other
moving or hot parts. Never remove any drive belt or fan guard while the unit is
operating.

• Adequate, unobstructed flow of cooling and ventilating air is critical to prevent
buildup of explosive gases and to ensure correct generator operation. Do not
alter the installation or permit even partial blockage of ventilation provisions,
as this can seriously affect safe operation of the generator.

• Keep the area around the generator clean and uncluttered. Remove any
materials that could become hazardous.

• When working on this equipment, remain alert at all times. Never work on the
equipment when physically or mentally fatigued.

• Never use the generator or any of its parts as a step. Stepping on the unit can
stress and break parts, and may result in dangerous operating conditions
from leaking exhaust gases, fuel leakage, oil leakage, etc.

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ELECTRICAL HAZARDS

• All generators covered by this guide produce dangerous electrical voltages
and can cause fatal electrical shock. Utility power delivers extremely high and
dangerous voltages to the transfer switch as well as the standby generator.
Avoid contact with bare wires, terminals, connections, etc., on the generator
as well as the transfer switch, if applicable. Ensure all appropriate covers,
guards and barriers are in place before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry surface to
reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while
barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.

• If people must stand on metal or concrete while installing, operating, servicing,
adjusting or repairing this equipment, place insulative mats over a dry wooden
platform. Work on the equipment only while standing on such insulative mats.

• The National Electrical Code (NEC), Article 250 requires the frame and
external electrically conductive parts of the generator to be connected to
an approved earth ground and/or grounding rods. This grounding will help
prevent dangerous electrical shock that might be caused by a ground fault
condition in the generator set or by static electricity. Never disconnect the
ground wire.

• Wire gauge sizes of electrical wiring, cables and cord sets must be adequate
to handle the maximum electrical current (ampacity) to which they will be
subjected.

• Before installing or servicing this (and related) equipment, make sure that all
power voltage supplies are positively turned off at their source. Failure to do
so will result in hazardous and possibly fatal electrical shock.

• Connecting these units to an electrical system normally supplied by an electric
utility shall be by means of a transfer switch so as to isolate the generator
electric system from the electric utility distribution system when the generator
is operating. Failure to isolate the two electric system power sources from
each other by such means will result in damage to the generator and may also
result in injury or death to utility power workers due to backfeed of electrical
energy.

• Generators installed with an automatic transfer switch will crank and start
automatically when normal (utility) source voltage is removed or is below an
acceptable preset level. To prevent such automatic start-up and possible injury
to personnel, disable the generator’s automatic start circuit (battery cables,
etc.) before working on or around the unit. Then, place a “Do Not Operate” tag
on the generator control panel and on the transfer switch.

• In case of accident caused by electric shock immediately shut down the
source of electrical power. If this is not possible, attempt to free the victim from
the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a non­conducting implement, such as a dry rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and get immediate
medical help.

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• Never wear jewelry when working on this equipment. Jewelry can conduct
electricity resulting in electric shock, or may get caught in moving components
causing injury.

FIRE HAZARDS

• Keep a fire extinguisher near the generator at all times. Do NOT use any
carbon tetra-chloride type extinguisher. Its fumes are toxic, and the liquid can
deteriorate wiring insulation. Keep the extinguisher properly charged and be
familiar with its use. If there are any questions pertaining to fire extinguishers,
consult the local fire department.

EXPLOSION HAZARDS

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately.
Ensure that no combustible materials are left in the generator compartment,
or on or near the generator, as FIRE or EXPLOSION may result. Keep the area
surrounding the generator clean and free from debris.

• Generator sets may operate using one of several types of fuels. All fuel types
are potentially FLAMMABLE and/or EXPLOSIVE and should be handled
with care. Comply with all laws regulating the storage and handling of fuels.
Inspect the unit’s fuel system frequently and correct any leaks immediately.
Fuel supply lines must be properly installed, purged and leak tested according
to applicable fuel-gas codes before placing this equipment into service.

• Gaseous fuels such as natural gas and liquid propane (LP) gas are extremely
EXPLOSIVE. Natural gas is lighter than air, and LP gas is heavier than air;
install leak detectors accordingly.

GENERATOR INSTALLATION

These generators are liquid-cooled, engine-driven generator sets designed to
supply electrical power that operates critical electrical loads during utility power
failure. The generators are factory- installed in a weather resistant, all metal
enclosure and are intended for outdoor installation only.

BEFORE INSTALLATION

Before installing this equipment, check the ratings of both the generator and the
transfer switch. Read “Emergency Isolation Method” and “Total Circuit Isolation
Method” in Section 3 of the Installation Manual. The generator’s rated wattage/
amperage capacity must be adequate to handle all electrical loads that the unit
will power. The critical (essential) loads may need to be grouped together and
wired into a separate “emergency” distribution panel.

If an open bottom is used, the engine-generator is to be installed over non­combustible materials and should be located such that combustible materials
are not capable of accumulating under the generator set.

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Only qualified, competent installation contractors or electricians thoroughly
familiar with applicable codes, standards and regulations should install these
standby electric power systems. Installers must comply strictly with all codes,
standards and regulations pertaining to the installation.

After the system has been installed, do nothing that might render the installation
in non-compliance with such codes, standards and regulation

NFPA STANDARDS

The following published standards booklets pertaining to standby electric
systems are available from the National Fire Protection Association (NFPA),
1 Batterymarch Park, Quincy, MA 02269:

• NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES

• NFPA No. 54, NATIONAL FUEL GAS CODE

• NFPA No. 58, LIQUIFIED PETROLEUM GAS CODE

• NFPA 70, NATIONAL ELECTRIC CODE (NEC)

• NFPA 99, STANDARD FOR HEALTH CARE FACILITIES

• NFPA 101, LIFE SAFETY CODE

• NFPA 110, STANDARD FOR EMERGENCY AND STANDBY POWER SYSTEMS

• NFPA 220, STANDARD TYPES OF BUILDING CONSTRUCTION

NOTE:
It is essential to use the latest version of any standard
to ensure that the generator and its accessories
comply with all the applicable standards and local codes.

OTHER PUBLISHED STANDARDS

In addition to NFPA standards, the following information pertaining to the
installation and use of standby electric systems is available:

• Article X, NATIONAL BUILDING CODE, available from the American Insurance
Association, 85 John Street, New York, N.Y. 10038.

• AGRICULTURAL WIRING HANDBOOK, obtainable from the Food and Energy
Council, 909 University Avenue, Columbia, MO, 65201.

• ASAE EP-364.2, INSTALLATION AND MAINTENANCE OF FARM STANDBY
ELECTRIC POWER, available from the American Society of Agricultural
Engineers, 2950 Niles Road, St. Joseph, MI 49085.

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• A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES
AND VENTING SYSTEMS, available from the American National Standard
Institute, 1430 Broadway, New York, NY 10018.

The installer must comply with all applicable state and local codes.

GROUNDING THE GENERATOR

A grounding lug is provided on the generator mounting base for the purpose
of grounding the frame and the external electrically conductive parts of this
equipment to an approved earth ground and/or grounding rods where required
by the National Electrical Code (Figure 1.6). Grounding procedures must meet
local regulations.

BATTERY INSTALLATION

Standby generators installed with automatic transfer switches will crank and start
automatically when NORMAL (UTILITY) source voltage is removed or is below
an acceptable preset level. To prevent such automatic start-up and possible
injury to personnel, do not connect battery cables until certain that normal
source voltage at the transfer switch is correct and the system is ready to be
placed into operation.

Storage batteries give off explosive hydrogen gas. This gas can form an
explosive mixture around the battery for several hours after charging. The
slightest spark can ignite the gas and cause an explosion. Such an explosion
can shatter the battery and cause blindness or other injury. Any area that houses
a storage battery must be properly ventilated. Do not allow smoking, open
flame, sparks or any spark producing tools or equipment near the battery.

Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can
cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted
surfaces, etc. Wear protective goggles, protective clothing and gloves when
handling a battery. If fluid is spilled, flush the affected area immediately with clear
water.

Do not dispose of the battery in a fire. The battery is capable of exploding.

Do not open or mutilate the battery. Released electrolyte can be toxic and
harmful to the skin and eyes.

The battery represents a risk of high short circuit current. When working on the
battery, always remove watches, rings or other metal objects, and only use tools
that have insulated handles.

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VENTED BATTERIES

The electrolyte is a diluted sulfuric acid that is harmful to the skin and eyes.
It is electrically conductive and corrosive. The following procedures are to be
observed:

• Wear full eye protection and protective clothing.

• If electrolyte contacts the skin, wash it off immediately with water.

• If electrolyte contacts the eyes, flush thoroughly and immediately with water
and seek medical attention.

• 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.

Lead acid batteries present a risk of fire because they generate hydrogen gas.
The following procedures are to be followed:

• DO NOT SMOKE when near batteries.

• DO NOT cause flame or spark in battery area.

• Discharge static electricity from your body before touching batteries by first
touching a grounded metal surface.

Servicing of batteries is to be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized
personnel away from batteries.

For recommended batteries, see the “Specifications” section in the Owner’s
Manual. All batteries must be at 100 percent state of charge before they are
installed on the generator.

When using maintenance-free batteries, it is not necessary to check the specific
gravity or electrolyte level. Have these procedures performed at the intervals
specified in the “Maintenance” section in the Owner’s Manual. A negative
ground system is used. Battery connections are shown on the wiring diagrams.
Make sure all batteries are correctly connected and terminals are tight. Observe
battery polarity when connecting batteries to the generator set.

NOTE:

Damage will result if the battery connections are made in reverse.