Installation Guidelines Spark-Ignited Stationary Emergency Generators Residential and Commercial 22 kW 2.4L 25 kW 1.5L 27 kW 2.4L 30 kW 1.5L 32 kW 2.4L 36 kW 2.4L 38 kW 2.4L 45 kW 2.4L 48 kW 5.4L 60 kW 2.4L NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS.
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Forward Purpose and Scope of This Manual 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 herein are not intended to replace or supersede, local, state, or national safety, electrical, and building codes pertaining to such installations.
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Table of Contents Section 4 Ventilation System 4.1 General ..........................15 4.2 Outdoor Installation Only ....................15 Section 5 Gaseous Fuel Systems 5.1 General ..........................17 5.1.1 Fuel System Conversion .......................... 17 5.2 Gaseous Fuel Properties ....................17 5.2.1 Natural Gas ..............................17 5.2.2 Propane Vapor (LPV) ..........................17 5.3 Gaseous Fuel Systems ......................17 5.3.1 Natural Gas System ..........................
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Table of Contents 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. (000004) 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.
Safety Section 1 1.1 — Introduction If any portion is not understood, contact the nearest Authorized Service Dealer for Read this manual thoroughly clarification. The manufacturer also requires having an Authorized Service Dealer oversee the installation of any standby generator set. Trained/qualified service technicians familiar with the control systems and available options have full access to drawings, publications, and other information required for a successful installation.
Safety Despite the safe design of this generator, 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. •...
Safety If it is necessary to stand on metal or concrete while installing, operating, servicing, or repairing this equipment, • lay down a dry wooden platform and cover with insulated mats before beginning. Verify that the generator is properly grounded. •...
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Safety NFPA 68: Standard on Explosion Protection by Deflagration Venting* NFPA 70E: Standard for Electrical Safety in the Workplace* NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances* NFPA 220: Standard on Types of Building Construction* NFPA 5000: Building Code* International Building Code** Agricultural Wiring Handbook*** ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power****...
Installation Planning Section 2 Connecting this generator to an electrical system normally supplied by an electric util- ity shall be by means of a transfer switch, so as to isolate the electric system from the utility distribution system when the generator is operating. Failure to isolate the elec- tric 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.
Installation Planning SERVICE ITEM 1.5L NOTES: OIL FILL CAP EITHER DOOR AIR INTAKE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1092 (43") WIDE X 1887 (74.3") LONG. OIL DIP STICK RIGHT DOOR (BOTH SIDES) REFERENCE INSTALLATION GUIDE SUPPLIED WITH UNIT FOR CONCRETE PAD GUIDELINES. RADIATOR/EXHAUST OIL FILTER RIGHT DOOR...
Installation Planning 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. If applicable, cover any exhaust system openings. •...
Installation Planning 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. •...
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Installation Planning Cellular Remote Monitoring System www.mobilelinkgen.com Figure 2-3. Product Accessories Installation Guidelines for Spark-Ignited Stationary Emergency Generators...
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Foundations & Mounting Section 3 3.1 — Generator Foundations 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.
Foundations & Mounting HIGH AND LOW VOLTAGE STUB-UP AREA (26.5) STUB-UP CIRCUIT BREAKER AREA NEUTRAL AND CUSTOMER CONNECTION OPENING 104.5 (4.1) (1.9) (.4) (2.0) (3.9) 226 (8.9) STUB-UP AREA DIMENSIONS: MM [INCH] 000382 Figure 3-1. Typical Installation Drawing Stub Up Detail 3.2 —...
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Foundations & Mounting Sheet Metal Generator Mounting Base Insulation 6 Inches 6 Inches Minimum Minimum Figure 3-2. Combustible Floor and Roof Protection. Since the entire bottom of the genset is now exposed, it should be covered with a sheet metal plate to keep out small animals and protect the integrity of the internal parts of the genset.
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Ventilation System Section 4 4.1 — General Adequate and unobstructed flow of cooling and ventilating air is critical to prevent buildup of explosive gases and to ensure safe generator operation. Do not alter 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.
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Gaseous Fuel Systems Section 5 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.
Gaseous Fuel Systems between the rigid supply piping and the gas connection at the generator, and must be installed straight without bends or kinks. The primary regulator outlet and the generator connection point must be sized correctly to provide the gener- ator with the required volume and pressure when it is operating at 100% of its rated load.
Gaseous Fuel Systems The piping system connecting the outlet of the first stage regulator to the First Stage Regulator with connection point on the second stage regulator must be properly sized to Relief Valve and Pressure Tap provide the fuel volume required by the unit at 100% load. The piping system between the outlet of the second stage regulator and Full Flow the generator connection point must be sized to provide the fuel volume...
Gaseous Fuel Systems 5.4.2— Definitions The following definitions are provided for use in this manual. Table 5-1. Definitions Term Description The design pressure loss in the system under maximum probable flow conditions, from the point of deliv- Allowable Pressure ery to the inlet connection of the generator set, shall be such that the supply pressure at the generator is Drop greater than or equal to the minimum pressure required by the generator at its full load capacity.
Gaseous Fuel Systems The required fuel pressure to the unit is measured before the fuel shutoff solenoids at the inlet to the unit • mounted regulator. A 1/8 inch pipe port in the pressure regulator body, or in the piping just before the pressure regulator, is provided for this purpose.
Gaseous Fuel Systems 5.4.7— Recommended Fuel Pressure Regulators Use only direct acting fuel pressure regulators, such as those made by Fisher® or Maxitrol® or any other listed regu- lator manufacturer. 5.4.8— Primary Fuel Pressure Regulator The following are the recommended “best practices” with regard to specifying, sizing, and installing the primary fuel pressure regulator.
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Gaseous Fuel Systems There are several pipe sizing programs available for use on the Internet and from various manufacturers. If used it is highly recommended that the minimum pressure drop value always be used (0.5 inches w.c or less). This will ensure that the piping system is sized correctly to handle the generator set volume at full load, and during cranking and load transients, while also remaining above the minimum operating pressure.
Gaseous Fuel Systems Table 5-3. Fuel Pipe Sizing for Natural Gas (NG) LP Vapor (LPV) 11" to 14" of Water Column Table values are maximum pipe run in feet. Pipe Size (inches) 1 in 1.25 in 1.5 in 2 in 2.5 in LPG: 8.55 ft 3/lb., 4.24 lbs./gal., 2500 btu/ft LPG: 36.3 ft3 = 1 gal.
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Gaseous Fuel Systems To size an LP tank for a desired run time the following information is required: The maximum vapor consumption of the generator (in BTU/hr) at 100% load. The specification sheet for the gen- • erator will list the fuel consumption rate, usually in cubic feet per hour. To convert CFH to BTU/hr, multiply by 2520.
Gaseous Fuel Systems Length Height Propane Diameter Figure 5-3. Typical Propane Tank Dimensions NOTE: The minimum LP tank size is 250 gallons, unless unit calculations dictate use of a larger tank. Vertical tanks, which are measured in pounds, will not usually meet the minimum tank size (250 Gallons x 4.20 Pounds = approximately a 1050 pound vertical tank minimum).
Gaseous Fuel Systems NOTE: Below 45º F. the neoprene core of the plug does not recover it's original shape as rapidly as it would at higher temperatures. Therefore, upon removal of the gauge adapter probe, the valves may not close fully and immediately, or they may remain slightly open until the operating temperature is above 45º...
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Gaseous Fuel Systems Cranking Pressure. Pressure when the unit is cranking. Must not drop more than 1 in. w.c. below Static Pres- sure or below the minimum pressure listed in the unit specification sheet. If it does, it may indicate that fuel sup- ply piping is not correctly sized, or that primary regulator is improperly sized or mounted too close to the generator connection point.
Electrical System Section 6 6.1 — General Information All wiring must be properly sized, routed, supported, and connected. All wiring must comply with NEC and local codes. The generator uses Customer Connection Interface (CCI) panels to separate the high voltage and customer control wiring connections.
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Electrical System NOTE: The following tables are provided for references purposes only. Refer to the latest NEC, state and local AHJ requirements for proper sizing of power and control wires. Table 6-1. Frame Breakers Wire Lug AWG Range Torque Frame Breaker Range Wire Type Temperature...
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Electrical System Load Wiring Connections Neutral Ground Knock Out Plug (Cold Weather Kit) NOTE: Single phase shown. NOTE: See Figure 6-4 for typical control wiring connections. Figure 6-3. Typical High Voltage Connections Customer load wiring consists of single-phase or three-phase connections between the generator Main Line Circuit Breaker (MLCB) and the transfer switch.
Electrical System 6.6 — Control Wiring Connections The Control Wire Customer Connection block is where all of the control wiring is connected. Depending on the type of system, this wiring includes the following: 6.6.1— RTS Series Transfer Switch With T1 Fuse/Connection NOTE: The control wire customer connections typically use Class 1 Wiring Methods (verify with AHJ).
Electrical System 6.6.2— RTS Series Transfer Switch Without T1 Fuse/Connection Use a 120 volt generator protected circuit from the panel board to power the battery charger circuit (dedicated 15/20 amp circuit). 6.6.3— Two-Wire Start To convert transfer switches to 2 wire start mode of operation, see dealer for panel conversion and connection of termi- nals 178 and 183 in TB3.
Electrical System NOTE: The following table is provided for references purposes only. Refer to the latest NEC, state and local AHJ requirements for proper sizing. Table 6-3. Control Wire Length/Size Maximum Recommended Wire Length Wire Size 1-115 ft (1-35m) No. 18 AWG 116-185 ft (36-56m) No.
Electrical System 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 explo- sion. An explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated.
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Electrical System Red Lead From Starter A = Protective Cover Black Lead B = Battery Strap To Frame Battery Figure 6-6. Installation Guidelines for Spark-Ignited Stationary Emergency Generators...
Electrical System 6.11 — Activate Unit Display Reads: Generator Active is displayed on the If the wrong language is selected, it may be changed LCD screen when the unit is first later using the Edit menu. Up Arrow = (+) powered up.
Electrical System Display Reads: Use UP ARROW or DOWN ARROW to Select YES to perform exercise at low speed. Select select either Yes or No. NO to perform exercise at normal operating speed. Quiet Test Mode? Press ENTER. Yes No Display Reads: Set Exercise Time.
Electrical System 6.12.3— Electrical Checks NOTE: Verify that all power and control wiring is properly terminated in the generator and corresponding location in transfer switch. For three phase applications, verify that generator phase rotation matches utility phase rotation. Complete electrical checks as follows: Verify that the generator is OFF.
Electrical System Press MANUAL on the control panel keypad. The engine should crank and start immediately. Allow the engine to warm up for a few minutes. Move the Main Circuit Breaker switch on the generator control panel up to the ON (Closed) position. Loads are now powered by the standby generator.
Lube Oil Maintainer System Section 7 7.1 — Lube Oil Maintainer System 7.1.1— Description NOTE: Oil reservoir is empty when shipped from factory. Fill with clean engine oil to activate the system. Oil reservoir capacity: 2.5 gallons (9.46 liters) The 36 kW, 45 kW, and 60 kW models are equipped with a Lube Oil Maintainer System. The system is installed at the factory and calibrated at the factory to the correct engine-running crankcase oil level.
Lube Oil Maintainer System NOTE: When changing engine oil, always close the shutoff valve to avoid draining the clean oil in the oil supply tank with the crankcase oil. See Figure 7-3 7.1.2— Fill Oil Supply Tank Rotate plastic cover counter-clockwise and remove from top of enclosure.
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Lube Oil Maintainer System FILL CAP Oil Supply Oil Inlet Tank Hose Test Button 2 1/2 GALLON OIL SUPPLY TANK Viewing Running Lens Engine Crankcase Level Center of SHUTOFF VALVE Green Bar Crankcase TEST BUTTON Hose REGULATOR ENGINE CRANKCASE OIL PAN REGULATOR VIEWING OIL DRAIN LENS...
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Installation Checklists Section 8 8.1 — Safety Checklist NOTE: See Chapter 1 for more information. Are manuals, wiring diagrams and other documentation readily available? Is there any evidence of freight damage? Does the enclosure have scratches or damage to painted surfaces (which would indicate lifting without a spreader bar)? ...
Installation Checklists Does the concrete pad extend beyond the frame rails at least six (6) inches (15.24 cm) on all sides? Is the concrete pad flat and level to within 1/2 inch? Are plugs installed in the tie-down holes of the frame rail? ...
Installation Checklists 8.6 — Gaseous Fuel System Checklist NOTE: See Chapter 5 for more information. Are fuel supply lines properly sized and installed? Were fuel supply lines purged and leak tested? Are sediment traps and drip legs installed to remove water and condensate from the gas flow? ...
Installation Checklists Are batteries correctly installed? Are the battery fluid levels correct? Are battery cables and connections clean and free of corrosion? Are the battery cables correctly connected? Are the terminal lugs correctly tightened? Is the battery condition and state of charge acceptable? ...
Installation Drawings Section 9 9.1 — 0K8420-A 25/30 kW (1.5 L) Page 1 of 2 SERVICE ITEM 1.5L NOTES: OIL FILL CAP EITHER DOOR AIR INTAKE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1092 (43") WIDE X 1887 (74.3") LONG. OIL DIP STICK...
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Installation Drawings 0K8420-A 25/30 kW (1.5 L) Page 2 of 2 45 (1.8) TYP 1380 (54.3) TYP MOUNTING SLOT CENTERS 13.5 X 29.5 MOUNTING SLOTS HIGH AND LOW VOLTAGE STUB-UP AREA (26.5) STUB-UP CIRCUIT BREAKER AREA NEUTRAL AND CUSTOMER CONNECTION OPENING 104.5...
Installation Drawings 9.2 — 0K8624-A 22/27 kW (2.4 L) Page 1 of 2 SERVICE ITEM 2.4L NOTES: OIL FILL CAP EITHER SIDE OIL DIP STICK RIGHT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1092 (43") WIDE X 1885 (74.2") LONG. RADIATOR/EXHAUST REFERENCE INSTALLATION GUIDE SUPPLIED WITH UNIT FOR CONCRETE PAD GUIDELINES.
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Installation Drawings 0K8624-A 22/27 kW (2.4 L) Page 2 of 2 13.5 X 29.5 MOUNTING SLOTS HIGH AND LOW VOLTAGE STUB-UP AREA CIRCUIT BREAKER [26.5] NEUTRAL AND CUSTOMER STUB-UP CONNECTION OPENING AREA 104.5 [4.11] [2.0] [1.1] [.4] [3.9] 1370 [54.0] 210 [8.3] STUB-UP REMOVABLE...
Installation Drawings 9.3 — 0K8636-A 36/45 kW (2.4 L) Page 1 of 2 SERVICE ITEM 2.4L NOTES: OIL FILL CAP EITHER SIDE OIL DIP STICK RIGHT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1194MM (47") WIDE X 2256MM (88.8") LONG. RADIATOR/EXHAUST OIL FILTER RIGHT SIDE...
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Installation Drawings 0K8636-A 36/45 kW (2.4 L) Page 2 of 2 13.5 X 29.5 HIGH AND LOW MOUNTING SLOTS VOLTAGE STUB-UP AREA CIRCUIT BREAKER [30.9] NEUTRAL AND CUSTOMER STUB-UP CONNECTION OPENING AREA [6.4] 12 [.5] [.4] [6.4] [2.0] 1733 [68.2] 217 [8.5] STUB-UP REMOVABLE...
Installation Drawings 9.4 — 0K9268-A 32/38 kW (2.4 L) Page 1 of 2 SERVICE ITEM 2.4L NOTES: RADIATOR/EXHAUST EITHER SIDE OIL FILL CAP DISCHARGE AIR AIR INTAKE OIL DIP STICK RIGHT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1194 (47") WIDE X 2255 (88.8") LONG. (BOTH SIDES) (BOTH SIDES) OIL FILTER...
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Installation Drawings 0K9268-A 32/38 kW (2.4 L) Page 2 of 2 13.5 X 29.5 MOUNTING SLOTS HIGH AND LOW VOLTAGE STUB-UP AREA [30.9] STUB-UP AREA 162 [6.4] 9 [.4] 12 [.5] 51 [2.0] 162 [6.4] CIRCUIT BREAKER 1733 [68.2] 217 [8.5] REMOVABLE STUB-UP ACCESS COVER NEUTRAL AND CUSTOMER STUB-UP...
9.5 — 0L2090-A 60 kW (2.4 L) Page 1 of 2 SERVICE ITEM 2.4L NOTES: OIL FILL CAP EITHER SIDE RADIATOR/EXHAUST OIL DIP STICK RIGHT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1194MM (47") WIDE X 2256MM (88.8") LONG. DISCHARGE AIR AIR INTAKE REFERENCE INSTALLATION GUIDE SUPPLIED WITH UNIT FOR CONCRETE PAD GUIDELINES.
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Installation Drawings 0L2090-A 60 kW (2.4 L) Page 2 of 2 13.5 X 29.5 HIGH AND LOW MOUNTING SLOTS VOLTAGE STUB-UP AREA CIRCUIT BREAKER [30.9] NEUTRAL AND CUSTOMER STUB-UP CONNECTION OPENING AREA [6.4] 12 [.5] [2.0] 162 [6.4] [.4] 1733 [68.2] 217 [8.5] STUB-UP AREA...
9.6 — 0K9243-A 48 kW (5.4 L) Page 1 of 2 SERVICE ITEM 5.4L NOTES: RADIATOR/EXHAUST OIL FILL CAP RIGHT SIDE DISCHARGE AIR AIR INTAKE OIL DIP STICK LEFT SIDE 1. MINIMUM RECOMMENDED CONCRETE PAD SIZE: 1194 (47") WIDE X 2256 (88.8") LONG. (BOTH SIDES) BATTERY 12V (BOTH SIDES)
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Installation Drawings 0K9243-A 48 kW (5.4 L) Page 1 of 2 HIGH AND LOW 13.5 X 29.5 MOUNTING SLOTS VOLTAGE STUB-UP AREA CIRCUIT BREAKER [30.9] NEUTRAL AND CUSTOMER STUB-UP CONNECTION OPENING AREA [6.4] [.4] [.5] [2.0] [6.4] 1733 [68.2] 217 [8.5] REMOVABLE STUB-UP STUB-UP COVER...
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