HomeMy WebLinkAboutINSTALLATION GUIDELINES FOR GENERATORSI
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IMAN GENERAC®
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Installation Guidelines
For
Stationary Industrial Generators
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This manual should remain with the unit.
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READ THIS MANUAL THOROUGHLY. This manual has been prepared to familiarize personnel involved with the
installation of generator sets with the manufacturer's installation requirements. Information and instructions contained
Only authorized dealers or qualified, competent installation contractors or electricians thoroughly familiar with applica-
ble codes, standards, and regulations should install this standby electric power system. The installation must be in strict
compliance with all codes, standards, and regulations. Start-up procedures must be performed by an Authorized Gen-
erac Industrial'Service Dealer.
It is not intended that this manual be used by any unqualified person for the purpose of installing a generator set. Instal-
lation, inspection, and testing of the system must be attempted only by competent, qualified electricians or installation
contractors who are familiar with the equipment and with all installation codes and requirements.
It would be impossible to provide details for every installation configuration. For this reason, much of the information in
this manual is general in nature. Illustrations of typical installations are not intended to serve as specific installation
plans, but may be used in the planning and design process when considering the selection and purchase of a genera-
tor set for standby power applications. Always have the unit specific drawings and manuals on hand before beginning
any installation.
Sources of Information
Installation information and recommendations contained herein are derived from the following sources:
Knowledgeable engineers, service technicians, and service representatives.
The National Electric Code (NEC).
National Fire Protection Association (I)IFPA) codes and standards.
Other sources as listed in Subsection 1.7.
Various manufacturing standards and hest practices.
QIf 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 electrical system from the utility distribution system when the generator is
operating. Failure to isolate anlelectrical system by such means may result 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
If an open bottom is used, the engine -generator is to be installed over non-combustible
materials and should be located such that combustible materials are not capable of
accumulating under the generator set.
After the system has been installed, do nothing that might render the installation in non-
compliance with such codes, standards, and regulations.
Every effort was made to ensure that the information in this manual was both accurate and complete at the time it was
released. However, the manufacturer reserves the right to change, alter, or otherwise improve this product at any time
without notice. i
WARNING!
California Proposition 65
Engine exhaust and some of its constituents are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
WARNING!
California Proposition 65
This product contains or emits chemicals known to the state of California to cause cancer,
birth defects, and other reproductive harm.
Installation Guidelines for Stationary Standby Industrial Generators
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Table of Contents
Section 1 Safety
1.1 Introduction................................I.......................................................................................................... I
1.2 Safety Rules................................1..........................................................................................................
1.3 General Hazards.................................................................................................................................2
1.4 Electrical Hazards ........................................................................................................................... 3
1.5 Fire Hazards ............................•I........................................................................................................... 3
1.6 Explosion Hazards ................... i............................................................................................................ 3
1.7 Standards Index
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Section 2 Installation Planning
2.1 Unit Drawings .......................... ........................................................................................................... 5
2.1.1 Installation Drawings........................................................... 5
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2.1.2 Wiring Diagrams............
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2.2 Receiving ............................,
2.2.1 Receiving and Unpack
2.2.2 Inspection ....................
23 Storage Before Installation
2.3.1 Long Term Storage ...,
2.3.2 Short Term Storage ..,
2.4 Lifting ..................................
2.5 Generator Location ...........
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2.5.1 General Location Guidelines....................................................................................................... 7
2.5.2 Weather Considerations............................................................................................................... 8
Section 3 Foundations & MoluntingI
3.1 Generator Foundations.....!.................................................................................................................. 9
3.1.1 Concrete Pad.............!................................................................................................................... 9
3.1.2 Dimensions.................!................................................................................................................... 9
3.1.3 Unit Clearance..........s................................................................................................................... 9
3.1.4 Roof Installation and Protection.................................................................................................. 9
3.1.5 Combustible Floor Protection....................................................................................................10
3.1.6 Stub Up Area............:..................................................................................................................10
3.2 Mounting .........................................................................................................................................10
3.2.1 Fixed Foundation ........................................ .........................10
3.2.2 Spring Isolators .......i...................................................................................................................11
3.2.3 Bottom Enclosure
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3.2.4 Connections.................................................................................................................................11
3.2.5 Tie Down Holes .......................................................................................................................12
Installation Guidelines for Stationary Standby Industrial Generators iii
Table of Contents
Section 4 Ventilation System
4.1 General................................................................................................................................................ 13
4.2 Outdoor Installations.......................................................................................................................13
4.2.1 Clearance.....................................................................................................................................13
4.3 Indoor Installations........................i................................................................................................... 13
4.3.1 Ventilation ............................... ...................................................................................................13
4.3.2 Ventilation Practices................................................................................................................... 13
4.3.3 Air Flow..................................1.................................................................................................... 14
4.3.4 Louvers
4.3.5 Motorized Louvers ................ !.............. ........................................................................................ 15
Section S Exhaust System I5.1 Best Practices...................................................................................................................................... 17
5.1.1 Emissions Compliance ........ ...................................................................................................... 18
5.2 System Components.........................................................................................................................18
5.2.1 Exhaust Manifold...............I.......................................................................................................18
5.3 Heat Shields....................................................................................................................................... 18
5.3.1 Blankets (Soft Manifold Sh elds).:............................................................................................. 18
5.3.2 Guards and Shields..................................................................................................................... 19
5.4 Turbochargers................................................................................................................................... 19
5.4.1 Wastegate......................................................................................... _...................................... 20
5.4.2 Flexible Exhaust Connections.................................................................................................... 20
5.4.3 Flexible Metal Hose and Bellows............................................................................................... 20
5.4.4 Installing Flexible Connections ................................................................................................. 21
5.4.5 Slip Joints.................................................................................................................................... 21
5.4.6 Silencer : ................................................................................................................................ 23
5.4.7 Silencer Rating ................i........................................................................................................... 23
5.4.8 Silencer Selection...........!............................................................................................................ 23
5.5 Exhaust System Piping....................................................................................................................... 24
5.5.1 Exhaust System Design, ............................................................................................................ 24
5.5.2 Other Considerations...!............................................................................................................ 24
5.5.3 Condensate Traps ......... :............................................................................................................. 25
5.5.4 Exhaust Thimbles....................................................................................................................... 26
5.5.5 Exhaust Pipe Insulation: ............................................................................................................. 26
5.5.6 Water Ingress Prevention.......................................................................................................... 26
Installation Guidelines for Stationary Standby Industrial Generators
Table of Contents
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5.6 Exhaust System Backpressure ... !....................................................................................................... 26
5.6.1 Measuring Backpressure ........................................................................................................... 27
5.6.2 Backpressure Tap Installation................................................................................................... 27
5.6.3 Calculating Backpressure I........................................................................................................ 28
5.6.4 Equivalent Length of Straight Pipe........................................................................................... 29
5.6.5 Combined Exhaust Systems....................................................................................................... 29
5.7 Pipe Support Considerations ... .......................................................................................................... 30
5.7.1 Thermal Growth........................................................................................................................ 30
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5.7.2 Turbocharger Loading .... ........................................................................................................... 30
5.7.3 Vibration Transmission .......................................................................................................... 30
5.7.4 Exhaust Discharge ........ !.......................................................................................................... 31
5.7.5 Exhaust Louvers............!............................................................................................................ 31
5.7.6 Common Exhaust Stack i............................................................................................................ 31
5.7.7 Power Module or Drop -Over Enclosure................................................................................... 33
5.7.8 Cleanliness During Installation................................................................................................. 33
5.7.9 Slobber or Wet Stackin............................................................................................................ 33
Section 6 Gaseous Fuel Sys
6.1 General.................................!.............................................................................................................. 35
6.1.1 Fuel Svstem Conversion............................................................................................................. 35
6.2 Gaseous Fuel Properties ................................................................................................................ 35
6.2.1 Natural Gas................................................................................................................................ 35
6.2.2 Propane Vapor (LPV) and Propane Liquid (LPL)................................................................. 35
6.3 Gaseous Fuel Systems .........!............................................................................................................... 36
366.3.1 Natural Gas System ...................................
6.3.2 LP -Vapor Withdrawal System.................................................................................................. 37
6.3.3 LP -Liquid Withdrawal System................................................................................................. 37
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6.3.4 Dual Fuel NG-LP System........................................................................................................... 38
6.3.5 Drin Lei
6.4 Fuel Pressure Regulators i.................................................................................................................. 39
6.4.1 General.....................:................................................................................................................... 39
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6.4.2 Definitions.................................................................................................................................... 39
6.4.3 Best Practices.............................................................................................................................. 40
6.4.4 Operating Fuel Pressure............................................................................................................ 40
6.4.5 Engine Fuel Consumption.......................................................................................................... 40
6.4.6 Fuel Pressure Regulator Sizing................................................................................................. 41
6.4.7 Recommended Fuel'Pressure Regulators................................................................................. 41
6.4.8 Primary Fuel Pressure Regulator............................................................................................. 41
Installation Guidelines for Stationary Standby Industrial Generators
Table of Contents
6.5 Pipe Sizing Considerations ........................................................................................................... 42
6.5.1 General.....................................
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6.5.2 Minimum Recommended Pipe Length ..................................................................................... 42
6.6 Pipe Sizing Practices........................................................................................................................ 43
6.6.1 Short Runs with Few or No Bends ............................................................................................ 43
6.6.2 Long Runs with Multiple Bends................................................................................................ 43
6.6.3 Natural Gas and LP -Vapor Pipe Sizing.................................................................................... 43
6.6.4 LP -Liquid Pipe Sizing ............................................................................................................ 47
6.6.5 Sizing LP Tanks for Vapor Withdrawal 48
6.7 Final Operating Test ...................................................................................................................... 50
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6.7.1 Gas Pressure Test Port Location 50
6.7.2 Final Test Procedure ................................................................................................................. 51
Section 7 Diesel Fuel Systems
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7.1 General Information ................... ..................................................................................................... 53
7.2 Diesel Fuel Base Tank....................................................................................................................... 53
7.3 Diesel Fuel Recommendations ......................................................................................................... 53
7.4 Day Tanks ................................... I...............................................:........................................................ 55
7.5 Other Options and Considerations................................................................................................... 55
Section 8 Electrical System
8.1 General Information .............. r.......................................................................................................
57
8.2 Wiring Installation -Connection) Safety............................................................................................. 57
8.3 General Wiring Requirements I.......................................................................................................... 57
8.4 High Voltage Customer Connections................................................................................................ 57
8.5 Field Wiring Connections to Buss Bars............................................................................................ 61
8.6 Low Voltage Customer Connections................................................................................................ 61
8.7 Transfer Switch Location................................................................................................................ 63
8.8 Battery....................................:I...........................................................................................................
64
8.8.1 General Information ............................................................................................................... 64
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8.8.2 Battery Location ............!............................................................................................................ 65
8.8.3 Battery Size ............................................................................................................................. 65
8.8.4 Battery Charger............:............................................................................................................. 66
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8.8.5 Battery Cables............................................................................................................................. 66
8.8.6 Battery Installation andlReplacement...................................................................................... 66
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vi Installation Guidelines for Stationary Standby Industrial Generators
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Table of Contents
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Section 9Installation Checklists
9.1 Safety Checklist.........................!........................................................................................................ 69
9.2 Installation Planning Checklist i........................................................................................................ 69
9.3 Foundations & Mounting Checklist .................................................................................................. 70
9.4 Ventilation System Checklist............................................................................................................. 70
9.5 Exhaust System Checklist ........
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9.6 Gaseous Fuel System Checklist......................................................................................................... 73
9.7 Diesel Fuel System Checklist........................................................................................................... 74
9.8 Electrical System Checklist............................................................................................................... 74
Installation Guidelines for Stationa i Standby Industrial Generators vii
Section 1 Safety
1.1 — Introduction !
Read this manual thoroughly. If any portion is not understood, contact the nearest Authorized Generac Industrial
Service Dealer for clarification. The manufacturer also requires that the dealer oversee the installation of the standby
generator set. These individuals are trained/qualified service technicians familiar with the control systems and available
options, and also have full access to drawings, publications, and other information required for a successful installation.
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1.2 — Safety Rules
Throughout this publication, and on tags 'and decals affixed to the generator, DANGER, WARNING, CAUTION, and
NOTE boxes are'used to alert personnel, to special instructions about a particular operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully. They indicate:
I - -
Indicates a hazardous situatio i or action that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation or action that, if not avoided, could result in death or seri-
ous injury.
ACAUTION!
Indicates a hazardous situation or action that, if not avoided, could result in minor or mod-
erate injury.
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NOTE: Notes provide additional information important to a procedure or component.
These safety warnings cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance
with the special instructions while performing the action or service are essential to preventing accidents.
Four commonly used safety symbol
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accompany DANGER, WARNING, and CAUTION boxes and the type of informa-
tion each indicates:
This symbol points out important safety information that, if not followed, could
endanger personnel and/or property.
This symbol represents the potential for an Explosion Hazard.
This symbol represents the potential for a Fire Hazard.
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QThis symbol represenI
ts
the potential for an Electrical Shock Hazard. SAVE
THESE INSTRUCTIONS. This manual contains important instructions that should be followed
during installation of the generator set and batteries. The manufacturer suggests that
these safety rules be copied and posted in potential hazard areas. Safety should be
stressed to all installers, operators, potential operators, and service and repair technicians
for this equipment. Installation
Guidelines for Stationary Standby Industrial Generators
Safety
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 not all-inclusive. If using a procedure, work method, or operating
technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the pro-
cedure, work method, or operating technique dJ ed does not render the generator unsafe.
Despite the safe design of this generat&, operating this equipment imprudently, neglecting its maintenance, or
being careless can cause possible injury or death. Permit only responsible and capable persons to install, oper-
ate, and maintain this equipment.
Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
If this generator is used to power electrical load circuits normally powered by a utility power source, install a
transfer switch. The transfer switch must effectively isolate the electrical system from the utility distribution sys-
tem when the generator is operating. Failure to isolate an electrical system by such means will result in damage
to the generator and also may result in' injury or death to utility power workers due to backfeed of electrical
energy.
Generators produce potentially!lethal voltages. Ensure all steps are taken to make the genera-
tor safe before operation or service.
1.3 — General Hazards
For safety reasons, the manufacturer recommends that this equipment be installed, serviced, and repaired by an
Authorized Service Dealer or other competent, qualified electrician or installation technician who is familiar with
all applicable codes, standards, and iregulations.
Ensure that the generator is installed, operated, and serviced in accordance with the manufacturer's instructions
and recommendations. Following in do nothing that might render the unit unsafe or in noncompliance.
The engine exhaust fumes contain carbon monoxide, which can be DEADLY. If breathed in sufficient concentra-
tions, carbon monoxide can cause unconsciousness or even death. For this reason, adequate ventilation must
be provided. Exhaust gases must bie piped safely away from any building or enclosure that houses the generator
to an area where people, animals, ietc. will not be harmed.
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. Ensure that all guards, covers, and protective devices removed
during maintenance or service are' reinstalled.
Adequate, unobstructed flow of cooling and ventilating air is critical in any room or building housing the generator
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 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 men-
tally fatigued.
Inspect the generator regularly, and promptly repair or replace any worn or damaged components using only fac-
tory approved parts and proced l res.
Before performing any maintenance on the generator, always disconnect the battery cables to prevent accidental
startup. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG, or (—) first, then remove the
POSITIVE, POS, or (+) cable. When reconnecting the cables, connect the POSITIVE cable first, the NEGATIVE
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 exhaust, fuel, oil or coolant leaks.
2 i Installation Guidelines for Stationary Standby Industrial Generators
Safety
1.4 — Electrical Hazards
All generators 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 generator when it is in operation.
Avoid contact with bare wires, terminals and other connections. Ensure all covers, guards, and barriers are in
place, and that they are properly secured and/or locked before operation. If work must be done around an oper-
ating unit, stand on an insulated, dry, surface to reduce potential 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.
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If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment,
lay down a dry wooden platform acid cover with insulated mats before beginning.
Verify that the generator is properly grounded.
Wire gauge sizes of electrical wiring, cables, and cord sets must be adequate to handle the maximum electrical
current (ampacity) to which it will be subjected.
Before installing or servicing equipment, verify that all power voltage supplies are positively turned off at their
sources. Failure to do so can res l It in hazardous and possibly fatal electrical shock.
Connecting this unit to an electrical system normally supplied by an electric utility is 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 electri-
cal energy.
Generators installed with an auto matic transfer switch will crank and start automatically when NORMAL (UTIL-
ITY) source voltage is removed or is below an acceptable preset level. To prevent automatic startup and possible
injury, disable the automatic start circuit (battery cables, etc.) before working on or around the unit. Place a "DO
NOT OPERATE" tag on the gel erator,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, s l ch 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.
Do not wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving parts resulting in injury.
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1.5 — Fire Hazards i
Keep a fire extinguisher near the generator at all times. Keep the extinguisher properly charged and be familiar
with its use. Direct any questions to the local fire department.
NOTE: DO NOT use any carbon tetra -chloride type fire extinguishers. These fire extinguishers emit toxic fumes
and the liquid can damage wiring insulation.
1.6 — Explosion Hazards
Properly ventilate the room or building housing the generator to prevent buildup of explosive gas.
Do not smoke around the generator. Immediately wipe up any fuel or oil spills. Ensure that no combustible mate-
rials 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 of debris.
All types of fuels are potentially FLAMMABLE and/or EXPLOSIVE and must be handled with care. Inspect the
fuel system frequently and correct any leaks immediately. Be sure fuel supply lines are properly installed, purged,
and leak tested before placing the generator set into service.
Installation Guidelines for Stationary Standby Industrial Generators 3
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Safety I
1.7 — Standards Index
Be sure the generator set is in strict compliance with all applicable local, state, and federal laws, codes, and regulations
pertaining to such installations. Always use the current version or edition of the applicable law, code, and regulation as
it applies to the local jurisdiction. In the absence of pertinent local laws and standards, use the following published
materials as a guide. I
i. National Fire Protection Association (NFPA) 70: The National Electric Code (NEC)*
2. NFPA10: Standard for Portable Fire Extinguishers*
3. NFPA 30: Flammable and Combustible Liquids Code*
4. NFPA 37: Standard for Stationary Combustion Engines and Gas Turbines*
5. NFPA 54: National Fuel Gas Code*
s. NFPA 58: Standard for Storage and Handling of Liquefied Petroleum Gases*
7. NFPA 68: Standard on Explosion Protection by Deflagration Venting*
a. NFPA 70E: Standard for Electrical Safety in the Workplace*
9. NFPA 99: Health Care Facilities Code*
io. NFPA 101: Life Safety Code*
a. NFPA 110: Standard for Emergency land Standby Power Systems*
12. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances*
13. NFPA 220: Standard on Types of Building Construction*
14. NFPA 5000: Building Code*
15. International Building Code**
is. Agricultural Wring Handbook***
17. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power****
This list is not all inclusive. Check with the Authority Having Local Jurisdiction (AHJ) for any local codes or standards
which may be applicable to the jurisdiction where the generator is installed. The above listed standards are available
from the following internet sources:
www.nfpa.org
www.iccsafe.org
www.rerc.org Rural Electricity Resource Council; P.O. Box 309; Wilmington, OH 45177-0309
www.asabe.org American Society of Agricultural & Biological Engineers; 2950 Niles Road; St. Joseph, MI 49085
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4 Installation Guidelines for Stationary Standby Industrial Generators
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Section 2 Installation Planning
2.1 — Unit Drawings
2.1.1— Installation Drawings
Installation drawings show weights, dimensions, clearances, exhaust details, connection locations, wiring stub -ups, lift-
ing locations, and other information. Use the unit specific installation drawings when designing a site installation plan.
Thoroughly read the NOTES section of each drawing for important details.
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Figure 2-1. Typical Installation Drawing
2.1.2— Wiring Diagrams
Wiring and schematic diagramsishow the connection points for control wiring, load wiring, and any service power sup-
ply required for battery chargers, block heaters, etc. Always use the unit specific wiring diagrams during planning and
installation.
Installation Guidelines for Stationary Standby Industrial Generators 5
Installation Planning
2.2 — Receiving
2.2.1— Receiving and Unpacking
Handle shipping cartons and crates with care to avoid damage. Store and unpack cartons with the correct side up, as
noted by the label on the shipping carton. i
2.2.2— Inspection j
Carefully inspect the generator set and all contents of cartons for any damage that may have occurred during ship-
ment. See the shipping documentation for any provisions or guidance when damage is incurred. Correct all damage or
deficiencies before installation of the generator set.
2.3 — Storage Before Installation
2.3.1— Long Term Storage
If the unit is to be stored (or installed and not started -up) for six months or more, preserve in accordance with the man-
ufacturer's instructions. Contact the local Authorized Service Dealer to obtain the Long Term Preservation and Storage
Manual (Part No. OG4018) and the Preservation Checklist (Part No. OG4018A).
2.3.2— Short Term Storage
If the unit is to be stored (or installed and i of started -up) for less than six months, proceed as follows:
Place the unit on a smooth flat surface. Do not leave unit on the shipping pallet, as it leaves the bottom open for
entry of dirt, debris, insects, rodents, etc.
Leave exhaust system openings covered.
Leave plastic plugs in fuel connection points.
Use anti -rodent plugs and other enclosure features to prevent entry of birds, small animals, and foreign objects.
If it is an open unit exposed to the elements (stored outside or the surrounding structure is not completed), com-
pletely cover to prevent entry of water, dirt, dust, etc.
2.4 — Lifting
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To ensure personal safety and prevent damage to the unit, use only personnel experienced with rigging, lifting and
moving heavy machinery.
Use a spreader bar to prevent damage to the unit. Failure to use a spreader bar will result in scratches and dam-
age to painted surfaces on closed generator sets. Likely equipment or component damage may occur on open
generator sets.
Installation drawings show the lifting points and the CG (center of gravity) location for rigging and lifting purposes.
Always attach lifting and rigging devices at the designated points on the generator set. Do not use the lifting points of
the engine or alternator to move the'generator set. See Figure 2-2.
6 Installation Guidelines for Stationary Standby Industrial Generators
Installation Planning
DO NOT USE ENGINE OR ALTERNATOR LIFTING POINTS TO LIFrTHE COMPLETE GENERATOR SET
Figure 2-2. Lifting Points (Example)
2.5 — Generator LocationI
Locate the generator set so that it is readily accessible for maintenance, repair, and firefighting purposes. For outdoor
and rooftop installations, comply with code requirements for minimum distance from combustible walls and building
openings. For indoor installations, adhere to requirements for fuel supply, ventilation, exhaust ducting, proximity to
combustible materials, etc.
2.5.1— General Location Guidl lines
Consider the following: I
The supporting structure must be adequate for the generator set and its accessories.
For roof -mounted application, s, consideration should be given to the support strength of the structure and the
need for vibration isolation. Consult a structural engineer for recommendations.
Be sure the site is clean, dry, not subject to flooding, and provided with adequate drainage in the event of heavy
rains.
Be sure the location permits noise and vibration to be effectively isolated.
Verify that the site provides easy access to the generator set for maintenance, repair, and firefighting purposes.
Keep a minimum of five feet of clearance around each side of the generator set to facilitate the repair or replace-
ment of major components.
Be sure the location permits engine exhaust gases to be piped safely away from inhabited or occupied areas.
Consider the direction of prevailing winds to prevent exhaust gases from being carried back to the engine area or
to the fresh air intake vents of nearby buildings.
The site must allow for the provision of an adequate fuel supply. For gaseous units, consider the length and
diameter of pipe requiredlito provide adequate fuel volume and pressure for the unit to run at its full load capacity. For
diesel units, consider the ease of accessibility for refueling purposes. Be
sure the location permits sufficient air flow for cooling and ventilation. For indoor applications, keep supply air and
radiator outlet air ducting to a minimum. For outdoor applications, consider the proximity of any walls, fences,
or other noise abatement or security barriers. For outdoor units with enclosures, do NOT face the radiator discharge
end of the enclosure into the prevailing wind. Installation
Guidelines for Stationary Standby Industrial Generators
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Installation Planning
In cold weather locations, consider heating of the enclosure (which may be required by application). For indoor
units with supply air ventilation, considerla means'to control ambient air temperature in extreme cold conditions.
Verify that the unit is securely fastened to the mounting pad to prevent movement caused by vibration.
Verify that all fuel, coolant, exhaust, andIelectrical connections have flexible sections to isolate vibration. Exhaust
systems must also allow for thermal expansion and contraction. Cracks and fractures, with the resulting leakage,
can develop rapidly without proper vibration isolation.
2.5.2— Weather Considerations
Consider local weather conditions during installation. There are various accessories available to ensure fast, reliable
starting and operation regardless of local climatic conditions. Enclosed unit heaters, engine jacket water heaters, lube
oil heaters, and battery warmers make starting of the engine more dependable and reliable. Strip heaters for the alter-
nator and control cabinets eliminate condensation by maintaining the temperature above the dew -point.
NOTE: Failure to comply with the location guidelines can result in damage to the generator or surrounding area and
may cause the warranty to be suspended or voided. Extra repair labor or equipment may not be covered under the
warranty if service access is difficult or restricted.
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8 Installation Guidelines for Stationary Standby Industrial Generators
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Section 3 Foundation,' & Mounting
3.1 — Generator Foundatio Q
Install the generator set on a concrete pad or base slab able to support its weight and accessories. A proper foundation
is needed to resist dynamic loading and reduce transmitted noise and vibration. The exact composition of the mounting
pad must follow standard engineering practices for the required loading and application. Securely fasten the genera-
tor set to the foundation using suitable grade, size and style fasteners. Holes are provided in the steel frame rails
for this purpose.
3.1.1— Concrete Pad
Seat the concrete pad or base slab on a prepared solid subsurface and use appropriate reinforcing bar or expanded
wire mesh. A common specification calls for 2500 psi concrete reinforced with 8 gauge wire mesh or number 6 reinforc-
ing bars on 12 inch centers. I
3.1.2— Dimensions
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Extend the concrete pad beyond the frame of the unit at least 18 inches and above the surrounding surface by 3-8
inches. This provides a mounting surface for fuel line support, as well as space for maintenance and repair.
The base pad must be: i
Capable of supporting 125% of the unit wet weight for single unit applications. Wet weight is the dry weight plus
the weight of the fuel in the base tank.
Flat and level to within 1/2 inch.
Capable of withstanding severe torque reactions on those units that are part of a paralleling system.
3.1.3— Unit Clearance
Verify that the site provides easy access to the generator set for maintenance, repair, and firefighting purposes. Keep a
minimum of five feet of clearance around each side of the generator set to facilitate the repair or replacement of major
components. I
3.1.4— Roof Installation andlProtection
Consult a design engineer to ensure that the roof structure is capable of supporting the full weight of the generator and
of handling any vibration or movement produced by the application of load. Install a layer of non-combustible insulation
and a layer of sheet metal underiIthe unit. Extend both the layer of insulation and sheet metal beyond the generator
base at least 12 inches (30.5 cm) on all sides. See Figure 3-1.
A containment dike with specificI capacities for fuel and/or oil spillage is also required.
Installation Guidelines for Stationary Standby Industrial Generators
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Foundations & Mounting
3.1.5— Combustible Floor Protection
Install a layer of non-combustible insulation topped with a layer of sheet metal under the unit. Extend both the layer of
insulation and sheet metal beyond the generator base at least 12 inches (30.5 cm) on all sides. See Figure 3-1.
Sheet Metal
Generator
Mounting Base
Insulation
12 Inches
Minimum 121nchesKIMinimum
Figure 3-1. Combustible Floor and Roof Protection
3.1.6— Stub Up Area
For load conduit, auxiliary power conduit (high voltage), and control wiring conduit (low voltage), see the installation
drawings for the location and dimensions of the stub up areas. See Figure 3-2.
XXX XXX
OPEN AREA
PRIMARY HIGHVOLTAGE STUB&
UPAREA PRIMARYCB
CONNECTIONj)
p) BOX OPENING LOWVOLTAGE )
M )00( STUB-
UPAREA XM MOTE ))
Figure
3-2. Typical Installation Drawing Stub Up Detail 3.
2 — Mounting 3.
2.1— Fixed Foundation Use
mounting holes in the base frame to fasten the unit to the foundation. Always use hardware of a suitable grade, size
and style. 10
iInstallation Guidelines for Stationary Standby Industrial Generators I
Foundations & Mounting
3.2.2— Spring Isolators
Always adjust spring isolators after installation following the manufacturer's instructions. The spring isolators are used
to level a unit within a reasonable distance. Typically, the mounting pad must be flat and level to within 1/2 inch. Secure
the spring isolator to both the generator base and foundation with appropriate grade, size and style fasteners. See Fig-
ure 3-3.
ILEVELING BOLT
I
LOCKING NUT
i
STABILIZER BOLT WELDED
TO BASE PLATE;NUT, METAL
TOP HOUSING /
WASHER & RUBBER WASHER
PRESSURE PLATE
ATTACHING NUTS
SLIGHTCLEARANCE
APPROX 1/8"
BASE PLATE I , -SPRING I
ASSEMBLY SOUND PAD OPERATING CLEARANCE
MAY VARY DUETO LOADING
LEVELING OF SEPARATE MOUNTS)
Figure 3-3. Typical Spring Isolator
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3.2.3— Bottom Enclosure
For generator sets with open bottoms using spring mounts between the frame rails and the mounting surface, or
mounted on an open bottom foundation (steel I -beams and/or grating surfaces, etc.), the bottom of the unit must be
enclosed to prevent entry of foreign objects and to prevent recirculation of hot radiator exhaust air. It must be covered
with a metal plate to keep out foreign objects (birds, rodents, insects, dirt and debris) and to protect internal compo-
nents and wiring. I
3.2.4— Connections
All fuel, coolant, exhaust, and electrical connections must have flexible sections where they connect to the unit to iso-
late vibration. Cracks, fractures, and leaks can develop without proper vibration isolation. Properly support and secure
all piping before installing the flexible connection.
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Installation Guidelines for Stationary Standby Industrial Generators 11
Foundations & Mounting
3.2.5— Tie Down Holes i
To protect internal components and wiring, and io prevent entry of dirt, debris and other foreign objects, plugs are pro-
vided (as applicable) to cover tie -down holes inithe frame rail. See Figure 3-4.
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Basi 3 Inch
Diameter Plug
7b
Figure 3-4. Frame Tie -Down Hole Plugs
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12 Installation Guidelines for Stationary Standby Industrial Generators
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Section 4 Ventilation System
4.1 — General
Adequate and unobstructed flow of cooliig and ventilating air is critical to prevent buildup of explosive gases and to
ensure safe generator operation. Do notialter the installation or permit even partial blockage of ventilation provisions.
Keep area around the generator clean and uncluttered, and remove any materials that may pose a hazard.
4.2 — Outdoor Installations
For units installed outdoors in their factory provided enclosures, the installation design must ensure that there are no
obstructions at any of the air intakes that may impede intake airflow.
4.2.1— Clearance
Keep a minimum of five feet of clearance around the unit to facilitate service and maintenance, and to ensure adequate
air circulation for air intakes and cooling of exhaust discharges.
4.3 — Indoor Installations
4.3.1— Ventilation
Adequate ventilation is a key consideration for indoor installations in order to meet cooling requirements and to supply
sufficient air for combustion. The unit specification sheets provide the cooling and combustion air requirements.
Cooling Air is required to remove heat generated by the unit during operation. It passes through the alternator,
over the engine, through the radiator and is then evacuated through appropriate ducting.
Combustion Air is requiredlby the engine for combustion. It flows through the air filter, the engine intake and
combustion chambers and then exits through the engine exhaust system.
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4.3.2— Ventilation Practices
Louvers have resistance to!air flow. Openings with louvers should be twice the area of an unobstructed opening
to provide proper air flow. At times duct work is necessary to provide cooling air for the room. Duct work must be
sized and installed accordiIng to acceptable standards.
Exercise care to be sure that any motorized louvers have power during all modes of operation.
In some extreme cold weather applications, the opening of louvers immediately upon startup can cause carbure-
tor icing and vaporizing problems with engines using gaseous fuels. Consider thermostatically controlled louvers
to reduce the problems ehcountered in cold weather applications.
Be sure the location permits sufficient air flow for cooling and ventilation. For indoor applications, keep supply air
ducting to a minimum. For outdoor applications, consider the proximity of any walls, fences, or other noise abate-
ment or security barriers that may inhibit air flow.
Installation Guidelines for Stationary Standby Industrial Generators 13
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Ventilation System
4.3.3— Air Flow
The intake and exhaust air inlets and outlets in an engine room or enclosure should be in -line to provide engine cooling
airflow parallel with the generator. Air flow travels through the alternator, across the engine, through the radiator and
then out through exhaust ducting. See Figure 4-1.
AIRF
OU1
A[W-LUIN
OUTLET
t
Figure 4-1. Generator Airflow
4.3.4— Louvers
Louvers prevent entry of wind driven rain, snow, and debris. Face intake louvers into the prevailing wind and angle all
louvers so that rain and snow do not pass directly through.
Size louvers to provide more than the' required air flow. Louvers have resistance to air flow, so openings with louvers
should be twice the area of an unobstructed opening. Louver manufacturers will provide flow rate capacities to match
size of louver openings to airflow requirements.
Use motor operated louvers or properly designed and sized gravity louvers to minimize static pressure drop. Be sure
louvers face inward for air intake. Exercise care to be sure that any motorized louvers have power during all modes of
operation.
Intake louvers in engine rooms are,usually located high on a wall, but the required quantity of air flow may necessitate
an entire wall of louvers. Use ducting to direct fresh intake air toward the generator to help promote the correct air flow.
EXHA
LO
MIN Min F I -I
ON
i T7 `TrS
Figure 4-2. Indoor Installation Example
14 Installation Guidelines for Stationary Standby Industrial Generators
Ventilation System
4.3.5— Motorized Louvers
Motorized louvers may be used in extremely cold climates to improve ambient temperature within the generator space
when the unit is not operating. The following requirements apply to the use of motorized louvers:
Be sure the louvers open automatically when the generator starts. This may be accomplished with a spring
loaded mechanism that does not require power. When the generator shuts down, the louvers "power" to a reset
or closed position. I
Connect the power circuit for the louvers to a circuit powered by the generator.
Wind blowing against intake openings can blow open gravity louvers causing low temperature and moisture
problems in bad weather. In cold climates, the high volume of outside air drawn into the room can quickly reduce
temperatures to freezing. Any water piping or other equipment susceptible to freeze damage should be properly
insulated or located elsewhere. Thermostatically controlled louvers can be used to help maintain stable engine
room temperatures in cold climate conditions. Again, connect the louver power circuit to a circuit powered by the
generator.
Installation Guidelines for Stationary Standby Industrial Generators 15
Section 5 Exhaust System
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5.1 — Best Practices
A well -designed exhaust system collects exhaust gases from the engine cylinders and discharges it safely and effi-
ciently. For optimal performance, the exhaust system must conform to the following.
Use flanged exhaust pipe rated for at least 15000 F and constructed of schedule 40 black iron, steel, or other
suitable materials having adequateIstrength and durability.
Minimize resistance to exhaust gas flow (backpressure) and keep it within the specified limits.
Reduce exhaust noise to meet local regulations.
Provide adequate clearance between exhaust system components and engine parts, machine structures, enclo-
sures and building structures to minimize the impact of high exhaust temperatures.
Use a flex joint between the engine connection point and the rigid piping.
Ensure the system does not stress engine components such as turbochargers and exhaust manifolds with
excess weight.
Use flexible bellows to allow for li I ear and/or axial movement of rigid piping due to thermal expansion/contrac-
tion.
Use sweep elbows with a radius at least three times the pipe diameter.
Ensure that exhaust system components are able to reject heat energy.
Properly support and connect exhaust piping and silencers. Verify that no strain or excessive weight,is placed on
the flex coupling connected to th'e engine. Flex couplings are only used to isolate vibration. Do not use flex cou-
plings to correct alignment probllems or carry the weight of a silencer/piping system.
Slope exhaust piping away from the engine outlet and install a water trap with drain at the lowest point. Installa-
tion of a water (condensate) drain at the outlet of the silencer is also recommended.
Properly terminate exhaust piping outside a structure housing a generator set, so that hot gases are harmlessly
discharged and do not come into contact with any combustible surface or material.
Do not terminate exhaust piping under loading platforms, structures, or near any opening in a building.
Provide at least nine inches (22.9 cm) of clearance between exhaust piping and any combustible surface.
Guard exhaust piping to prevent burns, where necessary.
Do not wrap or shield "dry" turbochargers and exhaust manifolds.
Keep exhaust piping well cleat of fuel tanks, fuel lines, etc.
Use a ventilated thimble to guard exhaust piping if routing through combustible walls or roofs.
Terminate piping on horizontal exhaust stacks with a 450 tailpipe.
Size the effective opening area of exhaust louvers 25% to 50% larger than the engine radiator core effective
opening.
Be sure the backpressure measured at the air -out side of the radiator never exceeds the maximum allowable
backpressure specified by the manufacturer.
Keep the ductwork from the radiator outlet flange to the exhaust vent opening as short and straight as possible.
Install the ductwork from the, radiator outlet flange to the exhaust vent opening in a manner that prevents any
recirculation of exhaust air back to the generator area.
Design extended exhaust ductwork with as few bends as possible. Where bends are necessary, they should be
in the form of gradual sweeps (large radius bends) to allow airflow with minimum restriction.
Exercise care to be sure that any motorized louvers have power during all modes of operation.
For outdoor units, ensure that there are no obstructions at the exhaust discharge that may cause exhaust gases
to circulate back to the air intakes. Recirculation of exhaust air will cause the unit to overheat.
Installation Guidelines for Stationary Standby Industrial Generators 17