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Home My WebLink AboutGENERAL INFORMATION_t �li��fi�il�lraflLL�11��J�C•73/l�l�l�IL�T 1�4[+�_iirJi[+11G11f1�199J1�.r�cli1'1�:►�T1lnlJ�l'/� Natural Gas Natural gas is lighter than air. It is found in the gaseous state at normal ambient temperatures and pressures. It is highly explosive and can be ignited at the slightest spark. For that reason, fuel lines must be free of leaks and adequate ventilation is absolutely essential. Local fuel/gas codes usually dictate the maximum pressure at which natural gas can enter a structure. In order to reduce the gas pressure to that required by law, a PRIMARY REGULATOR is required. LP Gas Liquefied petroleum (LP) gas is heavier than air. The gas vapors are explosive and, like natural gas, can be ignited by the slightest spark. LP tank pressure is dependent on the ambient temperature and can be as high as 200 psi. A primary regulator is required at the tank to reduce the pressure to the required five to 14 inches of water col- umn for units less than 70kW, or 11 to 14 inches of water column for units 70kW and larger. i 114 THE NATURAL GAS SYSTEM A typical natural gas system is shown in Figure 1.10. The maxi- mum pressure at which the gas can enter a building is established by code and may vary from area to area. A primary regulator is required to reduce gas supply pressures to the required safe level before the gas enters a structure. The primary regulator may or may not be provided by the gas supplier. The gas distribution company will usually provide piping from the main distribution line to the generator site. It is the respon- sibility of the gas supplier to ensure that sufficient gas pressure is available to operate the primary regulator. From the primary regulator, gas flows to the generator connection. A flexible length of gas line is required between rigid piping and the gas connection at the generator. The generator fuel system consists of an electrical fuel shutoff valve/regulator assembly and a gas actuator. The secondary regulator reduces gas pressure to about five inches of water column before the gas Is delivered to the actuator. NOTE: Gas pressure from the primary regulator (supplied by the installing contractor) to the generator's fuel shutoff valve should not exceed 14 inches of water column. Follow the local codes on selecting the required AGA approved, and UL listed, for NG application flexible portion of the fuel line (supplied by the installing contractor). This type of system utilizes the vapors formed above the liquid fuel in the supply tank (see Figure 1.11). Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. Gas pressure requirements for an LP vapor system at the frame of the generator are the same as those listed for natural gas in "The Natural Gas System". See Table 1 for information regarding the vapor capacity of LP tanks. The installer should be aware of the following: • When ambient temperatures are low and engine fuel consump- tion is high, the vapor withdrawal system may not function efficiently. • Ambient temperatures around the supply tank must be high enough to sustain adequate vaporization or the system will not deliver the needed fuel volume. • In addition to the cooling effects of ambient air, the vaporization process itself provides an additional cooling effect. 116 GASEOUS FUEL SYSTEM PIPING NOTE: The information below is to assist in planning gaseous fuel installation. In NO WAY should this information be interpreted to conflict with applicable fuel gas codes. Contact the local jurisdiction if questions arise. The following general rules apply to piping used in gaseous fuel systems: • The piping should be of black iron, rigidly mounted and pro- tected against vibration. • Install the supplied length of flexible hose between the generator connection point and rigid piping. A CAUTIONI AThe supplied flexible hose is not to be installed underground or in contact with ground. The flexible hose is for in -line installation only. Bends, kinks or off -center in -line installation of flexible hose is NOT allowed. Piping must be of the correct size to maintain the required sup- ply pressures and volume flow under varying conditions (see Calculating volumetric Flow Rate and Pipe Size). Installed piping must be properly purged and leak -tested, in accordance with applicable codes and standards. Use an approved pipe sealant or joint compound on all threaded fittings, to reduce the possibility of leakage. NOTE: In the absence of local purging and leak test standards, NFPA No. 54 may be used as a guide. Primary Regulator (Supplied by Installing Contractor) Z—r— Manual Shutoff Valve Figure 1.10 — Typical Natural Gas System Generator Base I Flex Fuel Line (Supplied with Unit) Gas Actuator Figure 1.11— Typical LP Gas Vapor Withdrawal System Fuel Shutoff/Regulator Assembly 11 -14" Water Column Recommended (> = 70kW) 5 -14" Water Column Recommended (< 70kW) — Manual Shutoff Valves Generator Base Gas Actuator �— Fuel Shutoff/Regulator Assembly Flex Fuel Line (Supplied 11 - 14" Water Column with Unit) Recommended (> = 70kW) 5 - 14" Water Column Primary Regulator Recommended (< 7okW) (Supplied by Fuel Tank Installing Contractor) 9 1.9 CALCULATING VOLUMETRIC FLOW RATE AND PIPE SIZE If the Owner's Manual identifies the fuel consumption requirements by a volumetric flow rate (units of ft3/hr), skip the next section and go on to the section, Calculating Pipe Size. If the Fuel Consumption requirements are given in units of Ib/hr, follow the next section, Calculating Volumetric Flow Rate. T Since the fuel consumption requirements (from the owners manual) are given as a mass flow (units of Ib/hr), the volumetric flow rate (ft3/hr) must be identified before the appropriate pipe size can be selected. The relationship between the mass flow rate (lb/hr), density (lb/ft3), and volumetric flow rate (fts/hr) can be described by Equation 1. According to Equation 1, the volumetric flow rate can be calculated by dividing the mass flow rate by the density. You may need to contact your fuel vendor to identify the density or specific gravity for your fuel. If your vendor provides the specific gravity (relative to air) Table 1 can be used to identify the appropriate density. Since the density of natural gas and LP is temperature dependant, the maximum temperature of the fuel (at the fuel shutoff/regulator assembly) should be measured so the fuel consumption requirements can be more accurately identified for the generator. A sample calculation (Example 1) is included in this section. Equation 1: m v=- P Where: iv = Volumetric Flow Rate (ft3/hr) m = Mass Flow Rate (lb/hr) p = Density from Table 1 - (r-so) C C = 11111 (for Natural Gas) or 3333 (for LP) T = Temperature of the fuel into the fuel shut-off/regulator Example 1: Determine the volumetric flow rate for a generator that requires 91.34 Ib/hr of natural gas at 100% load. Solution: Specific gravity according to the local vendor: 0.5 Density of Natural Gas from Table 1: 0.0383 Ib/fts Maximum Temperature of the fuel going into the generator: 90OF C=11111 (for Natural Gas) from Equation 1 m = 91.34lb/hr v = o and p = 0.0383 - (90160) p = 0.0356 Ib/ft3 10 Thus: 91.34 v = 0.0356 And: v = 2566 ft3/hr LCULATING PIPE SIZ Now that the volumetric flow rate has been identified, the mini- mum pipe size can be determined by using Table 2. This table is based on a specific gravity of 1.00 (specific gravity of air). For that reason, a correction is required when the fuel used has a different specific gravity. The fuel's specific gravity can be obtained from the fuel supplier. The table is also based on a pressure drop of 0.3, which allows for a nominal amount of restrictions from bends, fittings, etc. Example 2 illustrates how to calculate the pipe size for the generator. Example 2: Determine the iron pipe size for a generator that requires 2566 ft3/hr of Natural. Gas. The unit is located 75 feet from the fuel source. Solution: Specific gravity of natural gas according to the local vendor: 0.5 Multiplier for the given specific gravity from Table 1: 1.1 According to Table 2, a 2-1/2 inch pipe will deliver 1750 ft-3/hr of air if it is located 75 feet from the fuel source. To determine the I volumetric flow rate of natural gas, multiply the given flow rate by the multiplier (from Table 1): Natural gas flow rate = air flow rate (ft3/hr) * Multiplier = 1750 ft3/hr * 1.10 Natural gas flow rate = 1925 ft3/hr Since the flow rate through a 2-1/2 inch iron pipe is less than the flow rate required by the generator (2430 ft3/hr), we must evaluate the next larger pipe (3 inches) by the same method. Natural gas flow rate = air flow rate (ft3/hr) * Multiplier = 3000 ft3/hr * 1.10 Natural gas flow rate = 3300 ft3/hr A 3 inch pipe is required at the given distance of 75 feet. Pressure drop does not have to be considered unless an unusual number of fittings, bends or other restrictions are used. In such unusual cases, the fuel supplier will usually specify which multiplier is applicable. NOTE: The installed piping system shall be capable of providing the Fuel Consumption requirements as identified in the specifica- tions section of the Owners Manual. Specific Gravity(1) Multiplier Density lb/f13 Specific Gravity(1) Multiplier Density Ib/f13 Pressure Drop Multiplier 0.5 1.1 0.0383 1 0.775 0.0765 0.1 0.577 0.55 1.04 0.0421 1.2 0.707 0.0918 0.2 0.815 0.6 1 0.0459 1.4 0.655 0.1072 0.3 1 0.65 0.962 0.0497 1.5 0.633 0.1148 0.5 1.29 0.7 0.926 0.0536 1.7 0.594 0.1301 1 1.83 0.8 0.867 0.0612 1.9 0.565 0.1454 2 2.58 0.9 0.817 T 0.0689 .2.1 0.535 0.1607 5 4.08 Note 1: Relative to air at 30 inches Hg, 60T Length of Pipe (in Feet) Iron Pipe Size (IRS Inches) 1/2" 3/4" 1" 1-1/4" 1;1/2" 2" 1 2-1/2" 3" 4" 6" 8" 15 76 172 345 750 1220 2480 3850 0500 13880 38700 79000 30 52 120 241 535 650 1780 2750 4700 9700 27370 55850 45 43 99 199 435 700 1475 2300 3900 7900 23350 45600 60 38 86 173 380 610 1290 2000 3450 6800 19330 39500 75 77 155 345 545 1 1120 1750 3000 '6000 17310 35300 90 70 141 310 490 1000 1560 2700 5500 15800 32250 105 65 131 285 450 920 1430 2450 5100 14620 29850 120 120 270 420 860 1340 2300 4800 13680 27920 150 109 242 380 780 1 1220 2090 4350 12240 25000 180 100 225 350 720 1120 1950 4000 11160 22800 210 92 205 320 660 1030 1780 3700 10330 21100 240 190 300 620 970 1680 3490 9600 19740 270 1 178 1 285 580 910 1580 3250 9000 18610 300 1 170 270 545 860 1490 3000 8500 17660 450 140 226 450 710 1230 2500 7000 14420 600 119 192 390 600 1030 2130 6000 1 12480 11 mur-c u — unrun unrnun r uv vnurnnc u►unnuL mornu To Use: Go to the First column and pick the required kW load and then pick the minimum ambient temperature (400, 200 or 0° F) that the generator would be operating in. The third column (tank capacity) will give the required tank size to continually produce the given fuel flow. Operating Max kW Minimum Hours @ Tank Capacity Length Dia Overall Vapor Temp Max kW Gallons Inches Inches Ht. Inches 30 40 24 20 20 35 120 57 24 33 10 0 67 35 40 26 25 20 36 i150 68 24 33 12 0 72 60 40 26 40 20 38 250 94 30 39 20 0 74 80 40 26 50 20 40 1325 119 30 39 25 0 77 100 40 31 60 20 51 500 119 37 46 30 0 100 150 40 35 100 20 53 1850 165 41 50 50 0 105 170 40 36 120 20 51 �1000 192 41 50 60 0 103 Propane storage tanks can provide either a liquid or a vapor supply to jthe generator. The above chart is for vapor withdrawal only and provides the kW output or amount of vapor that can be withdrawn at a given temperature while keeping the temperature of the liquid above the boiling point. If the withdrawal rate is too high, the LP temperature goes below the boiling point, the pressure drops to zero and no vapor can be with- drawn. A primary regulator is also required at the tank to reduce the line pressure to the generator to 5-14 inches of water column. Propane Conversions: 36.38 ft3 = 90,500 btu = 1 gal • 11b = 21,500 btu'= 8.56 ft3 Propane Storage Tank 12 1.10 ELECTRICAL CONNECTIONS 1 GROUNDING THE GE 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 1.12). Consult a qualified electrician for. grounding requirements in the area. Grounding procedures must meet local regulations. ®Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result. Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in con- nected electrical devices. In addition, grounding helps dissipate static electricity that often builds up in ungrounded devices. Figure 1.12 — Generator Grounding Lug (typical) UNDING LUG 1.10.2 BATTERY CHARGER CONNECTION The generator has been equipped with a battery charger integrated in the control panel. Power leads for the charger have been run to the connection box (Figure 1.13). Connect the power leads for the battery charger to the 120 VAC T1/LINE connection and the neutral lead to the NEU connection. This is a 15 Amp circuit supplied by the customer. (Refer to the Connection Diagrams section in this manual, or the wiring diagram in the Owner's Manual that is supplied with the unit.) Figure 1.13 — Battery Charger Connection 1.11 ,BATTERY INSTALLATION F11 bl AStandby generators installed with automatic transfer switches will crank and start automati- cally when NORMAL ,(UTILITY) source voltage is removed or is below an acceptable preset level. To prevent such automatic start-up and pos- sible 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. j ®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 smok- ing, 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 i affected area immediately with clear water. ADo not dispose of the battery in a fire. The bat- tery is capable of exploding. ADo not open or mutilate the battery. Released electrolyte can be toxic. and harmful to the skin and eyes. 13 QThe 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. MIUMVI! UPI J.1111 _; . A CAUTIONI AThe electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following proce- dures are to be observed: • Wear full eye protection and protective clothing, • Where electrolyte contacts the skin, wash it off immediately with water, • Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and • 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. ALead acid batteries present a risk of fire because they generate hydrogen gas. The fol- lowing procedure are to be followed: • DO NOT SMOKE when near batteries, • DO NOT cause flame or spark in battery area, and • Discharge static electricity from body before touching batter- ies by first touching a grounded metal surface. Servicing of batteries is to be performed or supervised by person- nel 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 proce- dures 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 genera- tor set. NOTE: Damage will result if the battery connections are made in reverse. Before connecting the battery, make certain that normal utility volt- age at the transfer switch is correct and the system is ready to be put into operation. Check the engine oil, the coolant level, belt tension, and if so equipped, the gearbox oil (Figure 1.14). 14 Figure 1.14 — Check Engine Oil Check the battery to make sure it is fully charged before install- ing. Follow all safety procedures detailed in the Owner's Manual and observe polarity when connecting the battery. Make sure all termi- nal connections are tight (Figure 1.15). Figure 1.15 — Check Terminal Connections 1.12 GENERATOR ACTIVATION When battery power is applied to the generator during the installa- tion process, the controller will light up. However, the generator still needs to be activated before it will automatically run in the event of a power outage. Activating the generator is a simple one time process that is guided by the controller screen prompts. Once the product is activated, the controller screen will not prompt you again, even if you discon- nect the generator battery. After obtaining your activation code, please complete the follow- ing steps at the generator's control panel in the Activation Chart (shown on the following page). CHOOSE LANGUAGE TROUBLESHOOTING Display Reads: Use ARROW keys to scroll to desired language. If the wrong language is chosen, it can be Press ENTER to select. changed later using the "edit" menu. Language - English + Escape . . Enty Display Reads: Press ENTER to begin the activation process. If ESCAPE is pressed instead of ENTER, your generator will only run in manual mode (for Activate me (ENT) or test purposes) and NOT ACTIVATED will be dis- ESC to run in manual ! played. You will need to remove the generator ! control panel fuse AND disconnect the T1, N1, N2 connector in the external connection box (if Escape �0 �� equipped) or disconnect the utility input (main breaker) to the transfer switch for 3-5 seconds. ! Reconnect and start over with step 1. Display Reads: If you do not have your activation code, go to www.activategen.com or call 1-888-9ACTIVATE Activate go to (922 8482). (WA'wmactivategen.com If you already have your activation code, wait 3-5 seconds for the next display. Escape �� Enty ENTER ACTIVATION CODE (Passcode) TROUBLESHOOTING Display Reads: Use ARROW keys to scroll and find the first num- ber of your Activation Code. Ser�123456789 Press ENTER to select. Pas Repeat this step until all digits have been entered. Use ESCAPE to correct previous digits. Eseape . . Enty Display Reads: Activation is complete when all digits are entered What happens if "Wrong Passcode Try Again" above and your screen shows this display. appears? "SELECT HOUR (0-23)" Follow the controller prompts to continue setting Reenter the activation code. If a second attempt - 6 +" the time function. Refer to your Owner's Manual is unsuccessful, check the number against the with questions. code given on activategen.com. If it is correct and the generator will not accept it, contact Eseape�� Ewer 1-888-9ACTIVATE (922-8482). 15 i 2.1 TRANSFER SWITCH The - generator system should be used in conjunction with a matched automatic transfer switch. The NEMA 3R enclosure is weather proof and can be used indoors or outdoors. 2.2 UNPACKING Carefully unpack the transfer switch. Inspect closely for any dam- age that might have occurred during shipmentAThe purchaser must file with the carrier any claims for loss or damage incurred while in transit. Check that all packing material is completely removed from the switch prior to installation. Attach ahy lifting device to the transfer switch mounting holes or brackets only. DO NOT LIFT THE SWITCH AT ANY OTHER POINT. Always inspect the transfer switch for shipping damage. i 2.3 MOUNTING Mounting dimensions for the transfer switch enclosure can be found in the transfer switch owner's manual..Enclosures are typi- cally wall -mounted. The transfer switch must be mounted vertically and must be level and plumb. ACAUTIONI Handle transfer switches carefully when install- ing. Do not drop the switch. Protect the switch against impact at all times, and against con- struction grit and metal chips. Never install a transfer switch that has been damaged. Install the transfer switch as close as possible to the electrical loads that are to be connected to it. Mount the switch vertically to a rigid supporting structure. To prevent switch distortion, level all mounting points. If necessary, use washers behind mounting holes to level the unit. Never install the switch where water or any corrosive substance might drip into the enclosure. FITS and HTS switches are open transition switches. Because load circuits can only be connected to one power supply at a time, open transition switches prevent electrical feedback between utility circuits and generator circuits (Figure 2.1). Figure 2.1— Connect Power Leads 16 3.1 BASIC STANDBY ELECTRIC SYSTEM Figure 3.1 shows a schematic diagram of a basic standby electric system. Both the UTILITY power supply and the STANDBY (GEN- ERATOR) output are connected to an approved transfer switch. The transfer switch is required by electrical code and serves the following functions: • Allows the LOAD circuits to be connected to only one power supply at a time. • Prevents electrical backfeed between the generator and the UTILITY power circuits. Figure 3.1— Basic Standby Electric System unun Po11FR SUPHY snumer sos MM uxe CINCUff DRUM ORCUrr BRUHR Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker. 3.2 STANDBY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of the generator. If the generator is powering only designated loads, within the wattage/ amperage capacity, during utility power outages, consider using the emergency circuit isolation method. Designated electrical loads are grouped together and wired into a separate "Standby Distribution Panel." Load circuits powered by that panel are within the wattage/amperage capacity of the genera- tor set. When this method is used, it is difficult to overload the gen- erator. The transfer switch must meet the following requirements: - It must have an ampere rating equal to the total amperage rating of the standby distribution panel circuit. • Have it installed between the building's main distribution panel and the standby distribution panel. The generator powers only designated loads that are grouped together and wired into a separate emergency distribution panel. The transfer switch is installed between the main distribution panel (A) and the emergency distribution panel (E) (Figure 3.1). The amperage rating of the transfer switch must be equal to, or greater than, the highest amperage rating of the utility and genera- tor breakers feeding the switch. Figure 3.1= Standby Isolation 3.3 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed, use the "Total Circuit Isolation Method." It is possible for the generator to be overloaded when this isolation method is employed. The following apply to the transfer switch in this type of system. • Ampere rating of the transfer switch must equal the ampere rating of the normal incoming utility service. • The transfer switch is installed between the utility service entrance and the building distribution panel. The generator will be backing up all electrical loads within the circuit, so the amperage rating of the transfer switch must be equal to, or greater than, the amperage rating of the normal utility service. Unless a service entrance rated transfer switch is used, a main service disconnect (D) must be located before the transfer switch. The transfer switch is installed between the utility service entrance and the building distribution panel (A) (Figure 3.2). Figure 3.2 — Total Circuit Isolation 3.4 ALL TRANSFER SWITCH INSTALLATIONS Power wiring, control wiring and wiring for the 15 or 20 Amp cir- cuit required for the 2-Amp smart charger should be in separate conduit. In all installations, a ground wire will run through the power conduit from the generator connection panel to the transfer switch (Figure 3.3). Figure 3.3 — Ground Wire In any three-phase application, the phase rotation of the generator power lines must match the phase rotation of the utility power lines at the transfer switch (Figure 3.4). 17 Figure 3 4 — Match Phase Rotation While supporting the lugs, use a torque wrench to tighten the lugs on the generator circuit breaker and the transfer switch. Torque specifications are in the Transfer Switch, Owner's Manual (Figure 3.5). Consult the Technical Manual that comes with the transfer switch for. wiring diagrams and any product changes, "modifications or updates. Figure 3.5 — Torque Lugs 3.5 NEXUS TRANSFER SWITCHES Generators equipped with the Nexus Digital Controller will be matched to a Nexus or RTS transfer switch. N = Normal Utility Supply E = Generator Connection Panel T = Load Distribution Panel 3.6 CONNECTION DIAGRAMS All wiring in the standby electric power system must be in strict compliance with applicable codes, standards and regulations. Such wiring must be properly supported, routed, and connected. In addition, wiring must be properly sized to carry the maximum load current to which is will be subjected. The connections between the generator and transfer switch will vary depending on the equipment ordered. In each case there are two types of interconnections, load wiring and control wiring. QMake sure to turn OFF both the NORMAL (UTILITY) and STANDBY (EMERGENCY) power supplies before trying to connect power source and load lines to the transfer switch. Supply voltages are extremely high and dangerous. Contact with such high voltage power supply lines causes extremely hazardous, possibly lethal, electrical shock. A CAUTIONI. ABe.sure to maintain proper electrical clearanc- es between live electrical parts and grounded metal. Allow at least one-half inchof clearance circuits up to 400 amps. AExtremely high and potentially lethal supply voltages are present at the transfer switch when verifying phase rotation. This operation should only be performed by a trained electrician. 3.6.1 NEXUS CONTROLLER TO A RTS/NEXUS SMART The Nexus controller generator consists of an AUTO/OFF/ MANUAL switch and a 2-line LCD display. See Figure 3.6 for an interconnec- tion diagram. See "Control Wiring" for control wire sizing recom- mendations. OMake sure to turn OFF the NORMAL (UTILITY) power supply before trying to connect the Utility 1 and Utility 2 control wires. Supply voltages are extremely high and dangerous. Contact with such high voltage power supply lines causes extremely hazardous, possibly lethal, electrical shock. A CAUTIONI When installing these switches, terminals 178 and 183 (2-wire Terminals 178 and 183 in the generator AC con- nection box are not used in this application. start) are not used. Connection of any wires to these terminals may result in unwarrantable damage to the control board. 18 J UTILITY SUPPLY FROM QT SERIES ENGINE GENERATOR SERVICE DISCONNECT CONNECTION PANEL ® O O O w z ZZHz �nn LOAD SHED NUMB IIII am IIIIIIIIII IIIII MODULE MATCH WIRE TO TERMINAL NUMBERS �Nmm� O E1 E2 ® NEUTRAL BLOCK 0 GROUND GROUND RTS TRANSFER SWITCH 11 006 eee00 000 000 000 00 Dm oo00 ooe00 oe 2 NEUTRAL BLOCK N1ITEi CUSTOMER LOAD POWER LEADS AND TRANSFER SWITCH LEADS (DISTRIBUTION PANEL) III BE RUN IN TWO DIFFERENT CONDUITS, LIQUID COOLED INSTALLATI❑N The load wires consist of wires run between the generator main circuit breaker and the transfer mechanism, and a neutral wire. See "Wire Recommendations/Sizing" for load wire sizing information. 3.6.2 BLOCK HEATER CONNECTIONS Block heater kits can be purchased at the authorized dealer. The block heater will not function unless it is plugged into the AC outlet and the outlet is properly wired to an AC power supply (by' the installer) (Figure 3.7). Figure 3.7 — AC Outlet for Block Heater and Battery Charger (to be wired by installer) FRAME RAIL 3.7 WIRE RECOMMENDATIONS/ SIZING (SEE TABLE 4) 3.7.1 CONTROL WIRING Control system interconnections on a Nexus Series controlled generator consist of N1 and N2, T1, NEU, and leads 23 and 194. Control system interconnection leads must be run in a conduit that is separate from the AC power leads. Recommended wire gauge size depends on the length of the wire: Max. Cable Length Recommended Wire Size 460 feet (140m) No.18 AWG. 461 to 730 feet (223m) No. 16 AWG. 731 to 1,160 feet (354m) No.14 AWG. 1,161 to 1850 feet (565m) No. 12 AWG. I 312 LOAD WIRING b b I 12OVAC SUPPLY TO BATTERY Power source and load line conductors must be properly sup- omo a CHARGER, ANB BLOCK HEATER ported, of approved insulative qualities, and of the correct wire gauge size. 20A, 120VAC When connecting power, source, and load lines remove surface GFCI OUTLET oxides from stripped ends of conductors with a wire brush. Apply joint compound to stripped ends of conductors. Tighten terminals to the specified torque value, as given in the owner's manual for the transfer switch. Recommended wire gauge size depends on the current rating of the generator main circuit breaker. 20 TABLE 4 - ALLOWABLE AMPACITIES OF INSULATED CONDUCTORS RATED 0-2000 VOLTS, 60° TO 90° C (140° TO ' 194° F), NOT MORE THAN THREE CONDUCTORS IN RACEWAY OR CABLE OR EARTH (DIRECTLY BURIED), BASED ON SIZE TEMPERATURE RATING OF CONDUCTOR SIZE 600 C 750 C 900 C I 600 C 750 C 900 C 1400 F 1670 F 1940 F 1400 F 1670 F 194- F TYPES TYPES TYPES TYPES TYPES TYPES TWY, UFY FEPWY TA, TBS, SA TWY RHY, RHWY TA, TBS RHY, RHWY SIS, FEPY UFY THHWY SA, SIS, AWG THHWY FEPBY ' THWY THHNY AWG kcmil THWY RHHY, RHW2 THWNY THHWY THWNY THHNY, THHWY XHHWY THW2, THWN2 XHHWY THW2, THWN2 USEY RHHY, RHW2 USEY, ZWY USE2, XHH USE2 XHHWY XHH, XHHW , XHHW2 ZW2 L XHHW2 ZW2 COPPER I ALUMINUM OR COPPER CLAD ALUMINUM 18 — — 14 — — — — 16 — — 18 — — — — 14 20Y 20Y 25Y — — — — 12 25Y 25Y 30Y 20Y 20Y 25Y 12 10 30 35Y 40Y ! 25 30Y 35Y 10 8 40 50 55 30 40 45 8 6 55 65 75 40 50 60 6 4 70 85 95 55 65 75 4 3 85 100 110 65 75 85 3 2 95 115 130 75 90 100 2 1 110 160 150 85 100 115 1 1 /0 125 150 170 100 120 135 1 /0 2/0 145 175 195 115 135 150 2/0 3/0 165 200 225 130 155 175 3/0 4/0 195 230 260 150 180 205 4 0 250 215 255 290 170 205 230 250 300 24 285 320 190 230 255 300 350 260 310 350 210 250 280 350 400 280 335 380 225 270 305 400 500 320 380 430 260 310 350 '500 600 355 42 475 285 340 385 600 700 385 460 520 310 375 420 700 750 400 475 535 320 385 435 750 800 410 490 555 330 395 450 800 900 435 520 585 355 425 480 900 1000 455 545 615 1 375 445 500 1000 1250 495 590 665 - 405 485 545 1250 1500 520 625 705 435 520 585 1500 1750 545 650 735 455 545 615 1750 2000 560 665 750 470 560 630 2000 Unless otherwise specifically permitted in the NEC, the over current protection for conductor types marked with an Y shall not exceed 15 amperes for No. 14, 20 amperes for No.12, and 30 amperes for No. 10 copper; or 15 amperes for No.12 and 25 amperes for No. 10 aluminum and copper -clad aluminum after any correction factors for ambient temperature and number of conductors have been applied. 21 UTILITY SUPPLY FROM SERVICE DISCONNECT QT SERIES ENGINE GENERATOR CONNECTION PANEL ® O O OLl w CUSTOMER SUPPLIED Z NEUTRAL WIRE jz) LOAD SHED -oJ= -Z MODULE ZZH NOTE, MATCH WIRE NUMBERS TO TERMINAL NUMBERS El E2 ® NEUTRAL BLOCK Q NEUT 00 I I -,I\ e - mCU O O B GROUND L POWER LEADS AND TRANSFER SWRQH LEADS j= BE RUN IN TWO DIFFEREM OONDURS. REVISION: H-7539-C DATE: 9/24/10 PAGE 1 OF 2 GROUP G RTS TRANSFER SWITCH "dmw A FW NEUTRAL BLOCK GROUND CUSTOMER LOAD (DISTRIBUTION PANEL) EXPLODED VIEW: RTS INTERCONNECTION DIAGRAM DRAWING #: OH7453 EXPLODED VIEW: RTS INTERCONNECTION DIAGRAM DRAWING #: OH7453 APPLICABLE TO: GROUP G THIS PAGE IS LEFT INTENTIONALLY BLANK l REVISION: H-7539-C DATE: 9/24/10 PAGE 2 OF 2