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HomeMy WebLinkAboutINSTALLATION MANUALNED n StLaltin,. ao n ,au.a. StatioriaryEmer- ercy Generator g , r mum - INS - HUM WHO ; y C a _1 E"I I Z- Not intended for use in critical life support applications. -a - ,7,;OUTDOORINSTALLATION ONLY INTRODUCTION.......................................................................1 Read this Manual Thoroughly........................................1 How to Obtain Service...................................................1 SAFETY RULES....................................................................... 2 GENERAL INFORMATION........................................................ 4 1.1 Generator Installation..................................................... 4 1.2 Before Installation..........................................................4 1.3 Generator Location........................................................ 5 1.4 Generator Mounting and Support ................................... 5 1.5 Unpacking.....................................................................6 1.6 Lifting the Generator...................................................... 6 1.7 Generator Placement.....................................................6 1.8 Fuel Systems................................................................ 7 1.9 Calculating Volumetric Flow Rate and Pipe Size ...........16 1.10 Electrical Connections.................................................13 1.11 Battery Installation.......................................................13 1.12 Generator Activation....................................................14 INSTALLATION......................................................................16 2.1 Transfer Switch...........................................................16 2.2 Unpacking...................................................................16 2.3 Mounting.....................................................................16 i IOPERATION...........................................................................16 3.1 Basic Standby Electric System....................................16 3.2 Standby Circuit Isolation Method.................................16 3.3 i Total Circuit Isolation Method.......................................17 3.4 All Transfer Switch Installations...................................17 3.5 Nexus Transfer Switches.............................................18 3.6 Connection Diagrams..................................................18 3.7 Wire Recommendations/Sizing....................................20 INTRODUCTION Thank you for purchasing this model of the standby generator set. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the, manual was written. However, the manufacturer reserves the right to change, alter or otherwise improve this product(s) at any time without prior notice. READ IN MANUAL THOROUGHLY If any portion of this manual is not understood, contact the nearest Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incor- rectly or carelessly. Observe them carefully. Their definitions are as follows: INDICATES A HAZARDOUS SITUATION OR ACTION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury. A CAUTION I Indicates a hazardous situation or action which, if not avoided, could result in minor or moderate injury. NOTE: Notes contain additional information important to a procedure and will be found within the regular text body of this manual. i These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each I indicates is as follows: This symbol points out important safety information that, If not followed, could endanger personal safety and/or property of others. AThis symbol points out potential explosion hazard. ®This symbol points out potential fire hazard. AThis symbol points out potential electrical shock hazard. HOW TO OBTAIN SERVICE When the generator requires servicing or repairs, contact a Dealer for assistance. Service technicians are factory -trained and are capable of handling all service needs. When contacting a Dealer about parts and service, always supply the complete Model number, Serial number and Type Code (where applicable), of the unit as given on the Data Label affixed to the unit. i CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Save These instructions — The manufacturer suggests that these rules for safe operation be copied and ARLposted in potential hazard areas. Safety should be stressed to all operators, potential operators, and ser- vice and repair technicians for this equipment. I Save These Instructions — This manual contains Important instructions that should be followed during Aft installation of the generator and batteries. Study these SAFETY RULES carefully before installing, operating or servicing this equipment Become familiar with this Owner's Manuaf and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions. 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. If using a procedure, work method or operating technique that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe. ®Despite the safe design of this generator, operating this equipment imprudently, neglect- ing its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate or maintain this equipment. QPotentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator. AParts of the generator are rotating and/or hot during operation. Exercise care near running generators. ®Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed, can cause headaches, fatigue, diz- ziness, vomiting, confusion, seizures, nausea, fainting, unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available. GENERAL HAZARDS • For safety reasons, the manufacturer recommends that this equipment be installed, serviced and repaired by an authorized dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. • Installation, operation, servicing and repair of this (and related) equipment must always comply with applicable codes, stan- dards, 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, operat- ed and serviced in accordance with the manufacturer's instruc- tions and recommendations. Following installation, do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes, standards, laws and regulations. • 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. • When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. • Inspect the generator regularly, and promptly repair or replace all worn, damaged or defective parts using only factory - approved parts. • Before performing any maintenance on the generator, discon- nect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (—) first. Reconnect that cable last. • 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 dan- gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. ELECTRICAL HAZARDS • All generators covered by this manual produce dangerous elec- trical 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 stand- ing 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 ground- ing 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 (ampac- ity) 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 pos- sibly fatal electrical shock. • Connecting this unit 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 pos- sible, 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. • 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. • This generator 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 regulat- ing 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 fluids 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. LOCATION/EXHAUST HAZARDS • The 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. This should be considered prior to installing the generator. The unit should be positioned to direct exhaust gasses safely away from any building where people, animals, etc., will not be harmed. Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer's instruction, and in strict compliance with applicable codes and standards. Adequate, unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure cor- rect generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seri- ously affect safe operation of the generator. • Keep the area around the generator clean and uncluttered. Remove any materials that could become hazardous. 1.1 GENERATOR INSTALLATION This equipment is a liquid -cooled, engine -driven generator set. The generator is designed to supply electrical power that operates criti- cal electrical loads during utility power failure. The unit has been factory -installed in a weather resistant, all metal enclosure and is intended for outdoor installation only. ®If this generator is used to power electrical load circuits normally powered by a utility power source, it is required by code to install a transfer switch. The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating (NEC 701). Failure to isolate an elec- trical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy. 1.2 BEFORE INSTALLATION NOTE: Contact the local inspector or City Hall to make sure you are aware of all federal, state and local codes that could impact the installation. Secure all required permits before starting the job. Before installing this equipment, check the ratings of both the gen- erator and the transfer switch. Read "Emergency Isolation Method" and "Total Circuit Isolation Method". The generator's rated wattage/amperage capacity must be ade- quate 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. QConnecting this generator to an electrical sys- tem normally supplied by an electric utility shall be by means of a transfer switch, so as to iso- late the electric system from the utility distribu- tion system when the generator is operating. Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy. ®If an open bottom is used, the engine -generator is to be installed over non-combustible materi- als and should be located such that combus- tible materials are not capable of accumulating under the generator set. Only authorized dealers or qualified, competent installation con- tractors or electricians thoroughly familiar with applicable codes, standards and regulations should install this standby electric power system. The installation must comply strictly with all codes, standards and regulations pertaining to the installation. i A CAUT16NI AAfter the system has been installed, do nothing that might render the installation in noncompli- ance with such codes; standards and regula- tions. The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association (NFPA), Batterymarch Park, Quincy, MA 02269: • NFPA No. 37, STATIONARY COMBUSTION ENGINES AND GAS TURBINES • NFPA No. 54, NATIONAL FUEL GAS CODE • NFPA No. 58, LIQUEFIED PETROLEUM GAS CODE I • 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 appli- cable standards and local codes. 1.2.2 OTHER PUBLISHED STANDARDS !I In addition to NFPA standards, the following information pertaining to the installation and use of standby electric systems is avail- able: • Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y.10038. !i • 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. A52.1, AMERICAN NATIONAL STANDARD FOR CHIMNEYS, FIREPLACES AND VENTING SYSTEMS, available from the American National Standard Institute, 1430 Broadway, New York, N.Y. 10018. NOTE: It is essential to use the latest version of any standard to ensure that the generator and its accessories comply with all the appli- cable standards and local codes. The installer must comply with all applicable state and local codes. 1.3 GENERATOR LOCATION Install the generator set, in its protective enclosure outdoors, where adequate cooling and ventilating air always is available. Consider these factors: • Install the unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a wind- break to protect the unit. • Install the generator on high ground where water levels will not rise and endanger it. • This genset must be installed on a level surface. The base frame must be level within 1/2 inch all around. • Allow sufficient room on all sides of the generator for mainte- nance and servicing. This unit must be installed in accordance with current applicable NFPA 37 and NFPA 70 standards, as well as any other federal, state and local codes for minimum distances from other structures. • Where strong prevailing winds blow from one direction, face the generator air inlet openings into the prevailing winds. • Install the generator as close as possible to the transfer switch. This reduces the length of wiring and conduit. • Install the generator as close as possible to the fuel supply, to reduce the length of piping. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE. 1.4 GENERATOR MOUNTING AND SUPPORT When designing a concrete base slab, all federal, state and local codes should be followed. Special attention should be given to the concrete base slab which should exceed the length and width of the generator by a minimum of 6 inches on all sides. The mounting pad should be located as close as possible to the transfer switch and fuel supply. Make sure you leave adequate room around the generator for service access. Five feet is a good rule of thumb, but local codes vary. Place the pad high enough to keep rising water from reaching the generator. Make sure the generator will have adequate and unob- structed airflow by choosing an open space free of trees, shrubs, buildings or other obstructions (Figure 1.1). Figure 1.1— Mounting Pad The unit must be positioned so air vents won't become clogged with leaves, grass, snow or debris. Make sure that exhaust fumes will not enter the building through eaves, windows, ventilation fans or other air intakes. Never mount the unit under eves, under a deck or within three (3) feet of a window. Position the electrical conduit for power wiring, control wiring and the battery charger circuit so the generator can be placed correctly on the pad (Figure 1.2). Figure 1.2 — Position Conduit ,The concrete pad should be reinforced and deep enough so that the weight of the pad is equal to the weight of the generator (refer to the "Generator Mounting and Support' section in this manual). The length and width of the pad should exceed the length and width of the generator by at least 6 inches on all sides and the pad must be level within'/z inch all around. Refer to the installation diagram supplied with the owners manual for the correct stub up area location. If generator must be installed on any combustible floor or roof, comply with the following rules: • Place a layer of non-combustible insulation, followed by a layer of sheet metal beneath the unit's mounting base rails (Figure ,1.3). • Both the layer of insulation and the sheet metal must extend beyond the generator base to a distance of at least 6 inches 1(15.24 cm) on all sides. For, rooftop or building structure mounting, it is recommended that spring isolators be installed between the engine frame and the, mounting system. A minimum of six (6) isolators are required and must be located at the front and rear cross members and the center of the frame. Figure 1.3 — Combustible Floor and Roof Protection SHEET METAL GENERATOR INSULATION MOUNTING BASE 6INCHES r MINIMUM 6INCHES MINIMUM Since the entire bottom of the genset is now exposed, it should be covered with a metal plate to keep out small animals and protect the integrity of the internal parts of the genset. Genset movement is more intense with spring isolation, so flexible connections for the fuel and the electrical conduits are also required. NOTE: Consult the local building codes which may vary. 1.5 UNPACKING 1.5.1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care. Use care to avoid damage from dropping, bumping, collision, etc. Store and unpack cartons with the proper side up, as noted on the shipping carton. 1.5.2 INSPECTION After unpacking, carefully inspect the generator for any damage that may have occurred during shipment. If loss or damage is noted at the time of delivery, have the person(s) making delivery note all damage on the freight bill or affix their signature under the consignor's memo of loss or damage. 1.6 LIFTING THE GENERATOR When lifting or hoisting equipment is used, AL be careful not to touch overhead power lines. Generators that weigh more than 900 pounds require proper tools, equipment, and qualifled personnel to be used in all phases of handling and unpacking. 1.7 GENERATOR PLACEMENT Use a forklift, boom truck or similar equipment with sufficient I capacity to move the generator to the mounting pad area. The operator should be certified and experienced in generator instal- lation (Figure 1.4). Figure 1.4 — Lifting the Generator Before placing the generator on the pad, inspect for shipping dam- age and if necessary, file a claim with the shipper. After removing the bolts holding the generator base frame to the wooden pallet, use the lifting eyes on the base frame to lift the generator onto the pad. When properly positioned, secure the base frame to the pad with appropriately sized masonry bolts. Connect an approved ground strap to the grounding lug on the base frame and to an earth ground or grounding rod consistent with local regulations (Figure 1.5). ' Figure 1.5 — Connect Ground Wire 1.8 FUEL SYSTEMS 1.8.1 FUEL CONVERSION The generator shipped from the manufacturer configured to run on natural gas. Refer to the Owner's Manual for details on converting the generator to run on LP vapor. 1.8.2 INTRODUCTION TO GASEOUS FUEL SYSTEMS Gaseous fuels, such as LP and natural gas, are highly volatile and their vapors are explosive. LP gas is heavier than air and will settle in low areas. Natural gas is lighter than air and will settle in high areas. Even the slightest spark can ignite these fuels and cause an explosion. For safety, all codes, standards and regulations pertaining to the installation and use of gas- eous fuels must be strictly complied with. Local fuel gas codes may vary widely. For that reason, it is recom- mended that a local gas distributor or installer be consulted when installing a gaseous fuel supply system. In the absence of local fuel gas codes and regulations, booklets published by the National Fire Protection Association (NFPA) may be used as sources of information. Gaseous fuel systems should be installed by a licensed plumber who is experienced in generator installation and is familiar with local codes and regulations. When installing rigid natural gas lines, always use AGA approved black pipe. In most applications, a manual shutoff valve and a primary regula- tor must be a part of the installation (Figure 1.7). Figure 1.7 — Manual Shutoff Valve A section of UL or AGA approved flexible fuel line is required to protect the rigid fuel line connections against vibration from the generator. Installing the flexible fuel line with as few bends as possible will allow the flexible section to absorb and mitigate vibration. Never use a flexible fuel line to avoid an elbow in a rigid line and never attach gaseous fuel line supports to any part of the generator. Doing so defeats the purpose of the flexible. fuel line (Figure 1.8). Figure 1.8 — Flexible Fuel Line After checking all connections for leaks, check the static gas pressure at the secondary regulator to ensure there is sufficient pressure to operate the generator (see Owner's Manual). If the static pressure is too low, or is higher than 14 inches of water column, notify the local gas supplier. (Figure 1.9) Figure 1.9 — Water Column