Industrial Generator Sets #1570...TP-5700 12/16 Safety Precautions and Instructions 7 Safety Precautions and Instructions IMPORTANTSAFETYINSTRUCTIONS. Electromechanical equipment,

Industrial Generator Sets

Models:

10--3250 kW

TP-5700 12/16t

Installation

Engine exhaust from this product containschemicals known to the State of Californiato cause cancer, birth defects, or otherreproductive harm.

WARNINGCalifornia Proposition 65

This product contains and/or emitschemicals known to the State of California tocause cancer, birth defects, or otherreproductive harm.


Breathing diesel engine exhaust exposesyou to chemicals known to the State ofCalifornia to cause cancer and birth defectsor other reproductive harm.S Always start and operate the engine ina well-ventilated area.S If in an enclosed area, vent the exhaustto the outside.S Do not modify or tamper with exhaustsystem.S Do not idle the engine except asnecessary.For more information go towww.P65warnings.ca.gov/diesel


Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Generator Set Identification Numbers

Record the product identification numbers from thegenerator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator setoperation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from theengine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

TP-5700 12/16 Table of Contents 3

Product Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abbreviations 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Related Materials 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 General 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Loading and Transporting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Lifting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 General Precautions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Weight and Center of Gravity 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.3 Lifting the Generator Set 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.4 Lifting the Subbase Fuel Tank 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.5 Lifting the Generator Set with Attached Enclosure 20. . . . . . . . . . . . . . . . . .2.1.6 Lifting the Generator Set, Enclosure, and

Subbase Fuel Tank Assembly 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.7 Lifting Single Point Lift Assemblies 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Generator Set Transporting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Location 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Location Factors 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Mounting Surface 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Single-Pad Mounting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Dual-Pad Mounting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 Four-Pad Mounting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.4 Mounting Pad Specifications 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 IBC Seismic Installation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Vibration Isolation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Dual-Bearing Alternator Alignment 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Air and Cooling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Air-Cooled Engines 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Liquid-Cooled Engines 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 System Features 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Installation Considerations 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.3 Recommended Coolant 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Unit-Mounted Radiator Cooling 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.1 System Features 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.2 Installation Considerations 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Remote Radiator Cooling 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.1 General 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.2 Vent Lines 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.3 Fill Lines (Balance or Static) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.4 Location Considerations 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.5 Installation Considerations 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator 36. . . . . . . . . .4.5.7 Procedure to Fill with Deaeration 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.8 Procedure to Fill without Deaeration 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.9 Checks after Initial Startup 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 City Water Cooling 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.1 System Features 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.2 Installation Considerations 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Cooling Tower 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8 Block Heaters 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-5700 12/16Table of Contents4

Section 5 Exhaust System 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Flexible Exhaust Line 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Condensation Trap 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Piping 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Double-Sleeved Thimbles 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Exhaust Outlet 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 Exhaust System Backpressure 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Fuel Systems 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Diesel Fuel Systems 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Main Tank 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.2 Day Tanks 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.3 Fuel Lines 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.4 Auxiliary Fuel Pumps 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Gas Fuel Systems, Common Components 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.1 Gas Lines 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.2 Gas Regulators 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 LP Fuel Systems 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.1 LP Gas Vapor-Withdrawal Systems 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.2 LP Gas Liquid-Withdrawal Systems 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Natural Gas Systems 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Combination Systems 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.1 Combination Natural Gas and LP Gas 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Pipe Size Requirements for Gas Fuel Systems 59. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7 Electrical System 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 Generator Set Voltage Reconnection 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Electrical Connections 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3 Load Lead Connections 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4 Grounding and Grounded Conductor (Neutral) Connections 63. . . . . . . . . . . . . . . . .7.5 Terminal Connector Torque 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6 Batteries 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7 Battery Chargers 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7 Component and Accessory Power Source Requirements 66. . . . . . . . . . . . . . . . . . .7.9 Optional Accessories 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9.1 Bus Bar Kits/Bus Lugs 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9.2 Gas Fuel Valve Kit 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9.3 Line Circuit Breaker 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9.4 Run Relay Kit 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9.5 Wireless Monitor 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Wiring Connections 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8 Decision-Makerr 550 Controller Accessories 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 Accessories and Connections 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Audiovisual Alarm Kit 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.2 Common Failure Relay Kit 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.3 Controller (Customer) Connection Kit 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.4 Float/Equalize Battery Charger Kit with Alarm Option 72. . . . . . . . . . . . . . .8.1.5 Ground Fault Annunciation 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.6 Idle (Speed) Mode Feature 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.7 Low Fuel (Level/Pressure) Switch 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.8 Prime Power Switch Kit 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.9 Remote Emergency Stop Kit 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.10 Remote Reset Feature 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.11 Remote Serial Annunciator (RSA III) 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.12 Shunt-Trip Line Circuit Breaker 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.13 Single-Relay Dry Contact Kit 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


TP-5700 12/16 Table of Contents 5

8.1.14 Ten-Relay Dry Contact Kit 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.15 Twenty-Relay Dry Contact Kit 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Accessory Connections 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 9 Decision-Makerr 3000 Controller Accessories 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 Accessories and Connections 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Common Fault/Failure (32A) Relay 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.2 Float/Equalize Battery Charger Kit with Alarm Option 88. . . . . . . . . . . . . . .9.1.3 Input/Output (I/O) Module Board 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.4 Low Fuel (Level/Pressure) Switch 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.5 Prime Power Switch Kit 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.6 Remote Emergency Stop Kit 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.7 Remote Reset Feature 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.8 Remote Serial Annunciator (RSA III) 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.9 Shunt-Trip Line Circuit Breaker 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Section 10 Decision-Makerr 3500 Controller Accessories 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1 Accessories and Connections 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1.1 Fifteen-Relay Dry Contact 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1.2 Remote Emergency Stop Kit 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1.3 Remote Serial Annunciator (RSA III) 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Section 11 Decision-Makerr 6000 Controller Accessories 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1 Accessories and Connections 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.1 Audiovisual Alarm Kit 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.2 Common Failure Relay Kit 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.3 Float/Equalize Battery Charger Kit with Alarm Option 104. . . . . . . . . . . . . . .11.1.4 Ground Fault Annunciation 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.5 Idle (Speed) Mode Feature 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.6 Low Fuel (Level/Pressure) Switch 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.7 Prime Power Switch Kit 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.8 Remote Emergency Stop Kit 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.9 Remote Reset Feature 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.10 Remote Serial Annunciator (RSA III) 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.11 Shunt-Trip Line Circuit Breaker 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.12 Single-Relay Dry Contact Kit 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.13 Ten-Relay Dry Contact Kit 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1.14 Twenty-Relay Dry Contact Kit 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Section 12 Remote Adjustment/Control Systems 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.1 Automatic Transfer Switches 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2 Decision-Makerr 550 Controller, Voltage Regulator and

Paralleling Applications 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3 Decision-Makerr 3000 Controller Voltage Regulator 118. . . . . . . . . . . . . . . . . . . . . . . .12.4 Decision-Makerr 3500 Controller Voltage Regulator 118. . . . . . . . . . . . . . . . . . . . . . . .12.5 Decision-Makerr 6000 Controller Voltage Regulator and

Paralleling Applications 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6 Decision-Makerr 8000 Controller Voltage Regulator and

Paralleling Applications 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7 Remote Speed Adjustment 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8 Remote Voltage Adjustment 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9 Remote Wiring 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.10 Voltage Regulator DVR 2000/ Remote Voltage Regulator Kit,

350 kW and Above 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


TP-5700 12/16Table of Contents6

Appendix A Abbreviations 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Common Hardware Application Guidelines 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C General Torque Specifications 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D Fuel Physical Properties 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix E Gas Fuel Vapor Pressures 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix F Gas Fuel System Installation Planning 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-5700 12/16 7Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Move the generator set masterswitch to the OFF position.(2) Disconnect the power to the batterycharger. (3) Remove the batterycables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command fromaremote computer.

(Decision-Makerr 3+ and 550Controllers)

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

(Decision-Makerr 3000, 3500, and6000 Controllers)

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) If the controller is not already in theMAN (manual) mode, press theController Mode button and then pressthe MAN mode button. (2) If thegenerator set is running, press andholdthe Manual--Stop button for at least2 seconds to stop the generator set.(3) Press the Controller Mode buttonand then press the controller Off modebutton. (4) Disconnect the power to thebattery charger, if equipped.(5) Remove the battery cables,negative (--) lead first. Reconnect thenegative (--) lead last whenreconnecting the battery. Follow theseprecautions to prevent the starting ofthe generator set by the remotestart/stop switch.

(Decision-Makerr 8000 Controller)

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Shut down the generator set. (2)Place the controller in Out of Servicemode. (3) Press the emergency stopbutton. (4) Disconnect the power to thebattery charger, if equipped.(5) Remove the battery cables,negative (--) lead first. Reconnect thenegative (--) lead last whenreconnecting the battery. Follow theseprecautions to prevent the starting ofthe generator set by the remotestart/stop switch.

(APM802 Controller)

TP-5700 12/168 Safety Precautions and Instructions

Battery

Sulfuric acid in batteries.Can cause severe injury or death.

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Battery acid cancausesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as this may result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetal surface away from thebattery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Risk of fire.Can cause severe injury or death.

Do not smoke or permit flames orsparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the fuelmixer, fuel line, fuelfilter, or other potential sources of fuelvapors. When removing the fuel line orfuel system be aware that liquidpropanecan cause frostbite on contact.

(Gas-fueled Model)

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the fuel injection system,fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuelvapors. Catch fuels in an approvedcontainer when removing the fuel lineor fuel system.

(Diesel-fueled Model)

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.


Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding unless the exhaust gas ispiped safely outside. Never operatethe generator set where exhaust gascould accumulate and seep back insidea potentially occupied building.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

Avoid high pressure fluids.Can cause severe injury or death.

Do not work on high pressure fuel orhydraulic systems withoutprotective equipment to protecthands, eyes, and body. Avoid thehazard by relieving pressure beforedisconnecting fuel injectionpressure lines. Search for leaksusing a piece of cardboard. Alwaysprotect hands, eyes, and body fromhigh pressure fluids. If an accidentoccurs, seek medical attentionimmediately.

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Explosive fuel vapors can causesevere injury or death. Takeadditional precautions when using thefollowing fuels:

Gasoline—Store gasoline only inapproved red containers clearlymarked GASOLINE.

Propane (LPG)—Adequate ventilationis mandatory. Because propane isheavier than air, install propane gasdetectors low in a room. Inspect thedetectors per the manufacturer’sinstructions.

Natural Gas—Adequate ventilation ismandatory. Because natural gas rises,install natural gas detectors high in aroom. Inspect the detectors per themanufacturer’s instructions.

Fuel tanks. Explosive fuel vaporscan cause severe injury or death.Gasoline and other volatile fuels storedin day tanks or subbase fuel tanks cancause an explosion. Store only dieselfuel in tanks.

Draining the fuel system. Explosivefuel vapors can cause severe injuryor death. Spilled fuel can cause anexplosion. Usea container to catch fuelwhendraining the fuel system. Wipeupspilled fuel after draining the system.

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LPG vapor ornatural gas fuel system for leakage byusing a soap and water solution withthe fuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

LPG liquid withdrawal fuel leaks.Explosive fuel vapors can causesevere injury or death. Fuel leakagecan cause an explosion. Check theLPG liquid withdrawal fuel system forleakage by using a soap and watersolution with the fuel system testpressurized to at least 90 psi(621 kPa). Do not use a soap solutioncontaining either ammonia or chlorinebecause both prevent bubbleformation. A successful test dependson the ability of the solution to bubble.


Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

Welding the generator set.Can cause severe electricalequipment damage.

Never weld components of thegenerator set without firstdisconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM).

CAUTION

Servicing the generator set when itis operating. Exposedmoving partscan cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on thegenerator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) connectors. (3) Disconnect allgenerator set controller and voltageregulator circuit board connectors.(4) Disconnect the engine battery-charging alternator connections.(5) Attach the weld ground connectionclose to the weld location.

Installing the battery charger.Hazardous voltage can causesevere injury or death. Anungrounded battery charger maycause electrical shock. Connect thebattery charger enclosure to thegroundof a permanent wiring system. As analternative, install an equipmentgrounding conductor with circuitconductors and connect it to theequipment grounding terminal or thelead on the battery charger. Install thebattery charger as prescribed in theequipment manual. Install the batterycharger in compliance with local codesand ordinances.

Connecting the battery and thebattery charger. Hazardous voltagecan cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Engine block heater. Hazardousvoltage can cause severe injury ordeath. The engine block heater cancause electrical shock. Remove theengine block heater plug from theelectrical outlet before working on theblock heater electrical connections.


Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Testing live electrical circuits.Hazardous voltage or current cancause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

Unbalanced and elevated weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not lift the generator set from theengine or alternator eyes. Neverstand under a unit being lifted.Always maintain a safe distance fromthe unit being lifted.See the lifting instructions in theinstallation manual that was providedwith the unit.

WARNING

Hot Parts

Hot coolant and steam.Can cause severe injury or death.

Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure.

WARNING

Hot engine and exhaust system.Can cause severe injury or death.

Do not work on the generator set untilit cools.

WARNING

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Servicing the engine heater. Hotparts can cause minor personalinjury or property damage. Install theheater before connecting it to power.Operating the heater before installationcan cause burns and componentdamage. Disconnect power to theheater and allow it to cool beforeservicing the heater or nearby parts.

Notice

NOTICE

This generator set has beenrewired from its nameplate voltageto

246242

NOTICEVoltage reconnection. Affix a noticeto the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Ordervoltage reconnection decal 246242from an authorized servicedistributor/dealer.

NOTICEParallel Operation. This productincludes features intended to supportoperation in parallel with the utility grid,but these features have not beenevaluated for compliance with specificutility interconnection protectionstandards or requirements.

NOTICECanadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

NOTICEElectrostatic discharge damage.Electrostatic discharge (ESD)damages electronic circuit boards.Prevent electrostatic dischargedamage by wearing an approvedgrounding wrist strap when handlingelectronic circuit boards or integratedcircuits. An approved grounding wriststrap provides a high resistance (about1 megohm), not a direct short, toground.


Notes

TP-5700 12/16 13Introduction

Introduction

This manual provides installation instructions forindustrial generator sets. Operationmanuals andwiringdiagram manuals are available separately.

Some additional model-specific installation informationmay be included in the respective generator setcontroller operation manual.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

Abbreviations

This publicationmakes use of numerous abbreviations.Typically, the word(s) are spelled out along with theabbreviation in parentheses when shown for the firsttime in a section. Appendix A, Abbreviations, alsoincludes many abbreviation definitions.

List of Related Materials

Separate literature contains, communication, firmware,and other additional information not provided in thismanual. Figure 1 lists the available literature partnumbers.

Manual Description Literature Part No.

Generator Set/ControllerWiring Diagram Manual

Multiple Part NumbersContact your

Distributor/Dealer

Monitor III Converters, Connections,and Controller Setup TT-1405

Monitor III Software Spec Sheet G6-76

Monitor III Converter, Modbusr/EthernetSpec Sheet G6-79

Monitor III Software Operation Manual TP-6347

Modbusr Communications ProtocolOperation Manual TP-6113

Program Loader Software Installation TT-1285

SiteTecht Software Operation Manual TP-6701

Remote Serial Annunciator (RSA) TT-1625

Decision-Makerr Paralleling System(DPS) Spec Sheet

G6-110

Decision-Makerr Paralleling System(DPS) Operation Manual

TP-6747

Battery Charger, 10 amp float/equalize TT-680

Battery Charger, 6 amp float/equalize TT-1342

Battery Charger, ESCR II TP-7025

500--1000REZK Engine InstallationManual TP-6995

1000REZCK Engine Installation Manual TP-7022

1300REZCK Engine Installation Manual TP-7023

Decision-Makerr 8000 OperationManual TP-6990

KD Model Operation Manual TP-7070

Figure 1 Related Literature

Modbusr is a registered trademark of Schneider Electric.

TP-5700 12/1614 Service Assistance

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Look at the labels and decals on your Kohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

TP-5700 12/16 15Section 1 General

Section 1 General

Industrial power systems give years of dependableservice if installed using the guidelines provided in thismanual and in applicable codes. Incorrect installationcan cause continuing problems. Figure 1-1 illustrates atypical installation.

Your authorized generator set distributor/dealer mayalso provide advice about or assistance with yourinstallation.

TP-5700-1

1. Exhaust thimble (for wall or ceiling)2. Silencer3. Supports4. Flexible sections5. Duct work for cooling air outlet

6. Mounting base7. Controller8. Electrical conduit9. Water trap with drain10. Fresh air intake

1

2 3

4

5

6

7

8

9

10

Figure 1-1 Typical Stationary-Duty Generator Set Installation

TP-5700 12/1616 Section 1 General

This manual references several organizations and theircodes that provide installation requirements andguidelines such as the National Fire ProtectionAssociation (NFPA) andUnderwriter’s Laboratories Inc.(UL).

D NFPA 54 National Fuel Gas Code

D NFPA 70 National Electrical Coder; the NationalElectrical Code is a registered trademark of theNFPA

D NFPA 99 Standard for Health Care Facilities

D NFPA 101 Life Safety Code

D NFPA 110 Emergency and Standby Power Systems

D UL 486A--486B Wire Connectors

D UL 486E Equipment Wiring Terminals for Use withAluminum and/or Copper Conductors

D UL 2200 Stationary Engine Generator Assemblies

These organizations provide information specifically forUS installations. Installers must comply with allapplicable national and local codes.

Before beginning generator set installation, record thefollowing data from the generator set’s specificationsheet and keep this data accessible for referenceduringinstallation:

D Dimensions and weight (verify dimensions andweight using the submittal data)

D Exhaust outlet size and maximum allowablebackpressure

D Battery CCA rating and quantity

D Fuel supply line size and fuel pressure requirement(gas models)

D Air requirements

TP-5700 12/16 17Section 2 Loading and Transporting

Section 2 Loading and Transporting

The loading and transporting processes expose thegenerator set to many stresses and the possibility ofimproper handling. Therefore, after transportingindustrial generator sets:

D Check the alignment of the radiator and supports toensure that the radiator is evenly spaced from thegenerator and that supports are square and of evenlength. Check the radiator fan for uniform alignmentand equal clearance within the radiator shroud.Adjust if necessary.

D After confirming the correct alignment, tighten thehardware to its specified torque. ReferenceAppendix C, General Torque Specifications.

2.1 Lifting

Unbalanced and elevated weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not lift the generator set from theengine or alternator eyes. Neverstand under a unit being lifted.Always maintain a safe distance fromthe unit being lifted.See the lifting instructions in theinstallation manual that was providedwith the unit.

WARNING

2.1.1 General Precautions

Follow these general precautions when lifting allgenerator sets and related equipment.

D Install proper size rigging at the skid lifting eyesproviding a direct pull on the skid lifting eye. Makesure the rigging does not work as a pry bar leveragainst the lifting eye.

D Do not lift the generator set using the lifting eyesattached to the engine and/or alternator as theselifting eyes can not support the total weight of thegenerator set.

D Always protect cables, chains, and straps from sharpedges.

1

TP-5700-21. Reinforcing plate

Figure 2-1 Improper Lifting Hook Placement (above1000 kW)

D Generator sets typically above 1000 kW may havereinforcing plates on the skid. Do not attach liftinghooks to the reinforcing plate. See Figure 2-1.

D Lifting should only be conducted by those trained andexperienced in lifting and rigging to achieve a safeand effective lift. Consideration needs to be given to,but not necessarily limited to, the following items:

d Weight and center of gravity of the equipmentbeing lifted

d Weight and center of gravity of the lifting device

d Boom angles

d Selection of rated rigging

d Stability of lifting foundation

d Wind and weather conditions

d Local or regional codes that may require or restricttypes of rigging.

D Use a spreader bar to prevent lifting cables fromcontacting air cleaners, shrouds, and otherprotruding components. If the cables still do not clearthese components, remove the components.

2.1.2 Weight and Center of Gravity

Refer to the respective specification sheet and/or thesubmittal drawing for the weight and center of gravity ofall components being lifted. The total combined weightand center of gravitymust be known to select the properrigging. If the weight and center of gravity is not readilyavailable, contact your distributor/dealer.

As applicable, determine the weight and center ofgravity of the following components:

D Generator setD Enclosure system (includes silencer, inlet baffles,louvers, etc.)

D Subbase fuel tank (lift only empty fuel tanks).

TP-5700 12/1618 Section 2 Loading and Transporting

2.1.3 Lifting the Generator Set

The distributor/lifting contractor should choose one ofthe followingmethods to lift the generator set dependingupon the location circumstancesand the generator set’sweight and size. Remove cover plates as needed toaccess the generator set skid lifting eyes.

Single Spreader Bar and Hook Method

Refer to Figure 2-2.

Double Spreader Bar and Hook Method


Single Spreader Bar and Skid Lifting Bar Method


Double Spreader Bar and Skid Lifting Bar Method


TP-5700-2/L8

Figure 2-2 Single Spreader Bar and Hook Method

TP-5700-2/L9

Figure 2-3 Double Spreader Bar and Hook Method

TP-5700-2/L10

Figure 2-4 Single Spreader Bar and Skid Lifting BarMethod


TP-5700-2/L11

Figure 2-5 Double Spreader Bar and Skid LiftingBar Method

2.1.4 Lifting the Subbase Fuel Tank

This section deals with lifting the subbase fuel tank as asingle unit.

D The subbase fuel tankmust have lifting eyes in orderto use the following methods.

D The subbase fuel tank must be empty. Do not lift afuel tank containing fuel (or any liquid).

D Remove any vent piping longer than 1m (3.3 ft.) fromthe fuel tank. Do not lift a fuel tank with attached ventpiping longer than 1 m (3.3 ft.).

D Attach one or two spreader bars as shown.

Fuel Tank with Single Spreader Bar Method


Fuel Tank with Double Spreader Bar Method


TP-5700-2/L6

Figure 2-6 Fuel Tank with Single Spreader BarMethod

TP-5700-2/L7

Figure 2-7 Fuel Tank with Double Spreader BarMethod


2.1.5 Lifting the Generator Set withAttached Enclosure

Enclosure Attached Directly to the Generator SetSkid

Refer to Figure 2-8. Lift the assembly by lifting on theskid as shown in 2.1.3 Lifting Methods for GeneratorSet.

Do not attach hoisting equipment to the enclosure.

G6-109Generator Set Skid Skid Lifting Eyes

Figure 2-8 Typical Enclosure Attached Directly tothe Generator Set Skid

Enclosure Attached Directly to the Subbase FuelTank

Refer to Figure 2-9. Lift the assembly by lifting on thesubbase fuel tank lifting eyes. Lift using all of the liftingeyes provided on the subbase fuel tank. Select theprocedure from the following illustrations based on thematching number of available subbase fuel tank liftingeyes.

Do not attach hoisting equipment to the enclosure.

Enclosure Attached to the Enclosure Base andAssembled to the Subbase Fuel Tank


With the subbase fuel tank detached from the enclosurebase, lift only the enclosure and generator set using theenclosure base lifting eyes. Lift using all of the liftingeyes provided on the enclosure base. Select theprocedure from the following illustrations based on thematching number of available enclosure base liftingeyes.

G6-99Subbase Fuel Tank Lifting Eyes

Subbase Fuel Tank Lifting EyesG6-102

Figure 2-9 Typical Enclosure Attached Directly tothe Subbase Fuel Tank

Lift the entire enclosure, generator set, and subbasefuel tank assembly by lifting on the subbase fuel tanklifting eyes. Lift using all of the lifting eyes provided onthe subbase fuel tank. Select the procedure from thefollowing illustrations based on the matching number ofavailable subbase fuel tank lifting eyes. Do not attachhoisting equipment to the enclosure base.

Subbase Fuel Tank Lifting Eyes G6-104

EnclosureBase Lifting

Eyes

Figure 2-10 Typical Enclosure Attached to theEnclosure Base and Assembled to theSubbase Fuel Tank


2.1.6 Lifting the Generator Set,Enclosure, and Subbase FuelTank Assembly

When using the subbase fuel tank to lift the generatorset and/or enclosure as a package, use ALL of the liftingeyes on the subbase fuel tank.

Hoisting using Four Eye Lifting Method

Apply the same lifting methods using single or doublespreader bars as shown in 2.1.3 Lifting the GeneratorSet.

Hoisting using Six Eye Lifting Method

Apply onespreader bar and twochain falls (Figure 2-11)or three spreader bars and two chain falls (Figure 2-12)for six eye lifting.

D Install a pair of outer slings to the maximum angle asshown in Figure 2-11 and Figure 2-12.

D Remove the slack from the slings in the systembut donot lift the unit.

D Install adjustable chain falls and strap or cable themfrom the spreader bar to the middle lifting eyes.Adjust to remove the slack.

D Check and remove any slack that has developed inthe primary slings and check that all chains/straps/cables are carrying load.

TP-5700/L1

Figure 2-11 Six Eyes, Single Spreader Bar, and TwoChain Falls Lifting Method

TP-5700/L2

Figure 2-12 Six Eyes, Three Spreader Bars, and TwoChain Falls Lifting Method

Hoisting using Eight Eye Lifting Method

Apply two spreader bars and four chain falls(Figure 2-13) for eight eye lifting.

D Install a pair of outer slings up to the maximum angleas shown in Figure 2-13.




TP-5700/L3

Figure 2-13 Eight Eyes, Two Spreader Bars, andFour Chain Falls Lifting Method


Hoisting using Ten Eye Lifting Method

Apply three spreader bars and six chain falls(Figure 2-14) for ten eye lifting.





TP-5700/L4

Figure 2-14 Ten Eyes, Three Spreader Bars, and SixChain Falls Lifting Method

Hoisting using Twelve Eye Lifting Method

Apply three spreader bars and eight chain falls(Figure 2-15) for twelve eye lifting.





2.1.7 Lifting Single Point LiftAssemblies

Some units have an enclosure integral to the skid andattach a single point lifting eye located at the top andcenter of the enclosure. The entire assembly may belifted with this eye.

TP-5700/L5

Figure 2-15 Twelve Eyes, Three Spreader Bars, andEight Chain Falls Lifting Method

2.2 Generator Set Transporting

Follow these guidelines when transporting thegenerator set:

D Select the transporting vehicle/trailer based on thedimensions and weight of the generator set asspecified in the generator set dimension drawing orspecification sheet. Ensure that the grossweight andoverall height of the generator set and vehicle/trailerin transport does not exceed applicabletransportation codes.

D Use low boy-type trailers that meet clearancerequirements when transporting units larger than1000 kW. Load large (unboxed) radiator-equippedgenerator sets with the radiator facing the rear toreducewind resistance during transit. Secure fans toprevent fan rotation in transit.

D Securely fasten the generator set to the vehicle/trailer. Even the heaviest of generator sets canmoveduring shipment unless they are secured. Fasten thegenerator set to the vehicle/trailer bedwith a correctlysized chain routed through the mounting holes of thegenerator set skid (or tank, if equipped). Use chaintighteners to remove slack from the mounting chain.Do not use strapping over the top of an enclosedgenerator set as damage to the enclosuremay occur.

D Always cover a non-enclosed unit with a heavy-dutycanvas or tarpaulin secured to the generator set ortrailer.

TP-5700 12/16 23Section 3 Location

Section 3 Location

3.1 Location Factors

Ideally, the generator set should be mounted onconcrete at ground level. For above-ground installations,including roof installations, weight considerations areespecially important. The building engineer determineswhether the structure can support the weight of thegenerator set.

The location of the generator set must meet thefollowing criteria.

General:

D Mounting surface is square and horizontally level atall four edges.

D Support the weight of the generator set and relatedequipment such as fuel storage tanks, batteries,radiators, andmounting pad(s). Keep inmind that themounting pad weight may exceed the weight of thegenerator set.

D Mounting pad should be designed to prevent thevibration of a running unit from causingmounting paddistortion and affecting engine/alternator alignment.

D Meet applicable fire rating codes and standards.

D Install the unit so that the risk of contact by peoplewith the hot generator set surfaces is minimized.

D Position the generator set over a noncombustiblesurface. If themounting surfacedirectly under or nearthe generator set is porous or deteriorates fromexposure to engine fluids, construct a containmentpan for spilled fuel, oil, coolant, and batteryelectrolyte. Donot allowaccumulationof combustiblematerials under the generator set.

D Permit vibration isolation and dampening to reducenoise and prevent damage.

D Be clean, dry, and not subject to flooding.

D Provide easy access for service and repair.

Indoor Installations:

D Allowadequate ventilationwith aminimumamount ofductwork.

D Allow safe expulsion of exhaust.

D Allow for storage of sufficient fuel to sustainemergency operation. See the generator setspecification sheet for fuel consumption.

D Allow for locating the fuel tank within the vertical liftcapabilities of the fuel pumpand any auxiliary pumps.See Section 6, Fuel Systems.

D Minimize the risk of public or unauthorized access.

D Provide adequate protection to prevent injury in thestub-up area. If the stub-up area opening is exposed,provide a cover or fill in the area to avoid the risk oftripping or falling into the stub-up opening.

Outdoor Installations:

D Select a location that provides adequate air flow.Avoid locations next to tall buildings that block normalair flow and cause air vacuum pockets. Avoid areasthat are subject to high winds, excessive dust, or otherairborne contaminants. High dust areas may requiremore frequent air cleaner maintenance. Hightemperature conditions affect generator set efficiency.Select a shaded area away from direct sunlight and/orother heat-producing equipment when practical.

D Avoid areaswith combustiblematerials, including butnot limited to building materials as well as naturalsurroundings. Keep dry field grass, foliage, andcombustible landscaping materials a safe distancefrom the exhaust system.

D The subsoil location must have a bearing strengthcapableof supporting thegenerator set andmountingpad combined weight. Analysis by a qualifiedtechnician or engineer is recommended to determinethe proper excavation material required.

D If the generator set enclosure is mounted on multiplepads where it is elevated above the main surface itmay cause discharge air recirculation underneath theunit. A typical location could be a building roof wherethe main surface is uneven for a single pad. Refer to4.3.2 Installation Considerations for information tominimize discharge air recirculation.

D Select a location that provides adequate space toaccess and service the unit. Allow for adequateclearance to open and close access doors. Avoidlocations on a hill or steep embankment unlessprovision is made to include a servicing platform.

TP-5700 12/1624 Section 3 Location

3.2 Mounting Surface

Figure 3-1 shows typical mounting surface details forsizing the concrete surface beyond the generator setand allowing for clearances during generator setservice. Follow the dimensional details provided inFigure 3-2, Figure 3-3, or Figure 3-4 depending uponthe mounting method.

3

3

3

1 2 4

5

6

7TP-5700-3

1. Engine end2. Generator set skid3. Extend the concrete surface a minimum of 152 mm (6 in.)

beyond the generator set4. Battery rack5. Allow at least 457 mm (18 in.) between the generator set

and adjacent walls or other obstructions on all sides forease of servicing the generator set

6. Alternator end7. Building wall8. Mounting pad (concrete surface)

3

8

Figure 3-1 Mounting Surface Detail (top view)

3.2.1 Single-Pad Mounting

Themanufacturer recommends a single, level concretemounting pad as shown in Figure 3-2. This methodprovides maximum stability for the generator set;however, draining the oil and servicing the generator setmay require raising the set from the pad.

Use an oil drain pump if clearance below the oil drain orextension is insufficient for a pan largeenough to holdallthe engine’s oil.

TP-5700-3

Figure 3-2 Single-Pad Mounting

3.2.2 Dual-Pad Mounting

The two-padarrangement shown inFigure 3-3provideseasy access to conveniently drain the oil. Follow the oildraining considerations outlined in Section 3.2.1.

TP-5700-3

Figure 3-3 Dual-Pad Mounting

3.2.3 Four-Pad Mounting

The four-pad arrangement shown in Figure 3-4provides more room under the engine for service thanthe previous two methods. Follow the oil drainingconsiderations outlined in Section 3.2.1.

TP-5700-3

Figure 3-4 Four-Pad Mounting

3.2.4 Mounting Pad Specifications

Mounting pad weight. The weight of the singlemounting pad or combined weight of multiple mountingpadsshould equal or exceed the combinedweight of thegenerator set and attached accessories.

To determine the weight of the mounting pad(s),determine the volume (length x width x height) of eachpad in cubic meters (cubic feet). Multiply this result by2400 kg (150 lb.) to determine a pad’s weight. Inmultiple-pad installations, add the weights of all pads todetermine the total mounting pad weight.


Mounting pad specifications. Mounting padcomposition should follow standard practice for therequired loading. Typical specifications call for 17238--20685 kPa (2500--3000 psi) concrete reinforced witheight-gauge wire mesh or No. 6 reinforcing bars on305 mm(12 in.) centers. The top surfaceof themountingpadonwhich thegenerator setmounts should bewithin aflatness of 3 mm (1/8 in.).

The recommended concrete mixture by volume is1:2:3 parts of cement, sand, and aggregate,respectively. Surround the pad with a 200--250 mm(8--10 in.) layer of sand or gravel for proper support andisolation of a pad located at or below grade.

Anchor thegenerator set to the concreteusingbolts castinto the surface of the pad. Otherwise, drill holes in themounting pad prior to generator set placement and useexpansion anchor bolts. Anchor the generator set skidor fuel tank (if equipped) using all of the provided anchorholes on the bottom of the skid.

Note: Refer to the generator set and accessorydimension drawings for conduit and fuel-lineplacement. The drawings give dimensions forelectrical and fuel connection roughins andstubups including model specific clearances.

3.3 IBC Seismic Installation

International Building Code (IBC) seismic installationsinvolve additional mounting and installationconsiderations. Refer to respective seismic installationADV drawing(s) for seismic isolator requirements.

3.4 Vibration Isolation

Use one of the vibration isolation types detailed in thefollowing paragraphs. Also, connections between thegenerator set or its skid and any conduits, fuel lines, orexhaust piping must include flexible sections to preventbreakage and to isolate vibration. These connectionsare detailed in subsequent sections.

Isolator types. The two primary types of isolators areneoprene and spring-type. Figure 3-5 shows neopreneisolators between the engine-generator and the skid,referred to as integral vibration isolation mounting.Integral vibration isolation units come from the factorywith neoprene vibration isolation. Neoprene isolatorsprovide 90% vibration isolation efficiency and are oftensufficient for installations at or below grade.

3

1

2

TP-5700-3

1. To engine-generator2. Skid crossmember

3. Neoprene vibration isolator

Figure 3-5 Neoprene-Type Integral VibrationIsolators

Figure 3-6 through Figure 3-10 shows the spring-typeisolator kit installed with direct-mounted units.Direct-mounted units haveno factory vibration isolation.Spring-type isolators provide 98% vibration efficiencyandare recommended for abovegrade installationsandother locations where vibration sensitivity could be anissue.

Generator sets with integral vibration isolation.Skids for generator sets 20 kW and larger use I or Csection-fabricated steel with a width of 52--76 mm(2--3 in.) per channel. The length varies with the size ofthe unit, resulting in a static load on the generator setskid of 69--172 kPa (10--25 psi) if the total bottomsurface of the channel is in contact with the mountingpad.

290173-V

Note: Dimensionsshown are mm (inches)

11(0.44)

51 (2)

11 (0.44) DIA.4-HOLES

191 (7.5)

203 (8)

16 (0.62)DIA.

127 (5)REF.

Figure 3-6 Vibration Isolators GM39515 andGM41122


GM66019-

Note: Dimensionsshown are in mm.1 mm equals0.039 inches.

Figure 3-7 Vibration Isolators GM66019, GM66304,and GM76149

GM66020-


Figure 3-8 Vibration Isolators GM66020, GM66022,GM66023, GM66024, and GM66313

GM66025-


Figure 3-9 Vibration Isolator GM66025

GM84038-

6X 21 (0.81) DIA HOLE FOR ATTACHMENT TO CONCRETE

4X (BASE PLATE) 19 (0.75) DIA HOLE FORATTACHMENT TO STEEL (VIEW CUT AWAY FORCLARITY)

Note: Dimensionsshown are mm (inches)

19 (0.75)REMOVABLEADJUSTING BOLT

156 (6.13)FREE &OPERATINGHEIGHT

29 (1.13)

159(6.25)

57(2.25)

22(0.88)

38(1.5)

286 (11.25)181 (7.13)

73(2.88)

305 (12)

Figure 3-10 Vibration Isolator GM84038


Generator sets with direct mounting. Largergenerator sets typically mount directly to a structuralsteel base. For these units, install the recommendedvibration isolators between the base and the mountingpad in the holes provided. Because of the reducedmounting surface area of these individual mounts, thestatic load on the mounting surface increases to therange of 345--690 kPa (50--100 psi).

Generator sets mounted on subbase fuel tanks. Donot install vibration spring isolators under the subbasefuel tank.

Dual isolation. For applications involving integralvibration isolators and where the factory does not offerspring-type isolators as a standard accessory, spring-type isolators may be installed under the skid provided

they equal the number of neoprene isolators, are inlinefront-to-back with the existing neoprene isolators, andadditional support plates are installed, as required. SeeFigure 3-11.

3.5 Dual-Bearing AlternatorAlignment

Generator sets equipped with dual-bearing alternatorsrequire alignment after mounting the generator set skidto a mounting pad. Refer to Service Bulletin SB-566 fordetails.

Note: Dual-bearing alternators used on REZCK modelgenerator sets do not require alignment.

GM31000

1. Generator set skid rail2. Generator set neoprene integral vibration isolators3. Skid rail gussets4. Support plate, 13 mm (1/2 in.) thick steel, of sufficient length to distribute loads directly to skid rail gussets.5. Locate accessory spring-type vibration isolators axially aligned with neoprene isolators6. Concrete mounting pad

1 2

456

3

Axial

Direction

Figure 3-11 Accessory Vibration Mount Location


Notes

TP-5700 12/16 29Section 4 Air and Cooling

Section 4 Air and Cooling

4.1 General

Combustion and heat dissipation require an ample flowof clean, cool air regardlessofwhether the generator setis air- or liquid-cooled. Approximately 70% of the heatvalue of fuel consumed by an engine is lost through thecooling and exhaust systems.

Battery compartment ventilation. To prevent theaccumulation of explosive gases, ventilatecompartments containing batteries.

4.2 Air-Cooled Engines

Refer to the generator set specification sheet for airrequirements. Generally, airflow requirements do notpresent a problem since air-cooled models aredesigned for outside installation.

When planning outside installation, consider howbuildings and landscaping affect airflow. Also considerseasonal changes such as snow or foliageaccumulation and potential flooding conditions. Followa regular maintenance routine to remove snow andfoliage accumulations.

4.3 Liquid-Cooled Engines

4.3.1 System Features

Generator sets designed for interior installation featureliquid cooling systems. The three most common liquidcooling systems are unit-mounted radiator, remoteradiator, and city-water cooling. Observe the commoninstallation considerations outlined below as well as theinstallation considerations for your generator set’scooling system as detailed in subsequent sections.

4.3.2 Installation Considerations

Intake and outlet openings. Provide air intake and airoutlet openings for generator sets located in a buildingor enclosure. Keep air inlets and outlets clean andunobstructed. Position the air inlet into the prevailingwind and the air outlet in the opposite direction.

Elevated outdoor installations. If the generator setenclosure ismountedonmultiplepads, in caseswhereasingle pad is not practical such as an uneven buildingroof, it may cause discharge air recirculation under theunit. Enclosuresare constructedwith the intent of singlepad mounting where the unit is sealed to preventdischarge air recirculation. If multiple pad installation isunavoidable, use a single pad above the multiple pads

and fabricate flashing/skirting around the multiple padsto minimize unwanted discharge air recirculation.

Ventilating fans. Somebuildings tend to restrict airflowand may cause generator set overheating. Useventilating fans and/or ductwork to increase airflow inthe building if the generator set’s cooling fan does notprovide adequate cooling. See Figure 4-1. Remoteradiator and city-water cooled models requireventilating fans. When using ductwork and ventilatingfans, check the exhaust fan capacity in m3/min. (cfm). Ifusing exhaust fans, install fan-operated louvers withexhaust fans to regulate airflow. SeeFigure 4-2. Followthe fan manufacturer’s recommendations to determinethe size of the inlet and outlet openings.

TP-5700-4

Figure 4-1 Ventilating Fan

TP-5700-4

Figure 4-2 Exhaust Fan-Operated Louvers

TP-5700 12/1630 Section 4 Air and Cooling

Thermostatically-controlled louvers. Do not allowuncontrolled recirculation of air within an enclosure.The ventilation system must provide a temperaturedifferential sufficient to prevent high engine temperatureshutdown on even the hottest days.

In areas of great temperature variation, install movablelouvers to thermostatically regulate airflow and roomtemperature. See Figure 4-3 and Figure 4-4. Refer to4.4.2, InstallationConsiderations, Louver use for furtherinformation.

TP-5700-4

Figure 4-3 Stationary Air Inlet Louvers

TP-5700-4

Figure 4-4 Moveable Air Inlet Louvers

In cold climate interior installations using controlledrecirculation to recover heat, install thermostaticallyactivated louvers and fans to prevent the generator setand engine room from overheating.

Electric louvers are usually connected to the optionalgenerator set run relay. Typically, the louvers areenergized to open when the generator set is operating.However, some louvers are energized to close andwhen deenergized are spring-actuated to open whenthe generator set is operating.

Filters. Install a furnace-type or similar filter in the inletopening if the generator set operates in an atmospherehighly contaminated with impurities such as dust andchaff.

Air restrictions. Whenusing a filter, screen, or other airrestriction, increase the inlet opening size by thefollowing amounts to compensate for diminishedairflow:

D Louvers: Enlarge the opening 50%.D Window screening: Enlarge the opening 80%.D Furnace-type filters: Enlarge the opening 120%.

Some engines have maximum air intake restrictions.Refer to the respective generator set specification sheetfor specific requirements.

4.3.3 Recommended Coolant

All applications require antifreeze/coolant protection.Add antifreeze/coolant before starting the generator setor energizing the block heater(s). Most diesel enginemanufacturers require the use of an inhibitor additive tothe antifreeze/coolant.

Use a proper mixture of glycol (ethylene, propylene, orextended life organic acid), water, and supplementalcoolant additive (SCA) based on the enginemanufacturer’s recommendations. The antifreeze/coolant and additive mixture reduces corrosion, sludgeformation, and cavitation erosion and provides boil andfreeze protection.

Refer to theenginemanufacturer’soperationmanual forengine antifreeze/coolant specifications, concentrationlevels, and inhibitor selection recommendations.

4.4 Unit-Mounted Radiator Cooling

The unit-mounted radiator is the most common coolingsystem for engine-driven generator sets 20 kW andlarger.

4.4.1 System Features

The system’s major components include an engine-driven fan and circulating water pump, a radiator, and athermostat. The pump circulates water through theengine until it reaches operating temperature. Then theengine thermostat opens, allowing water circulationthrough the radiator. The thermostat restricts water flowas necessary to prevent overcooling. The fan blows airfrom the engine side of the radiator across the coolingsurface.


4.4.2 Installation Considerations

Figure 4-5 shows a typical unit-mounted radiatorinstallation. Note the direction of airflow and refer to thefigure as needed during installation.

1. Air inlet opening2. Ductwork mounting flange3. Air outlet duct4. Support legs5. Flexible section with radiator duct flange6. Pusher fan

TP-5700-4

1

2

3

456

Figure 4-5 Radiator-Cooled Generator SetInstallation

Avoid suction fan use. The alternator airflow shouldmove in the same direction as the engine’s standardpusher fan. Using a suction fan to reverse airflow is notrecommended because it may interfere with thealternator cooling airflow. This in turn reduces themaximum engine power available because highertemperature combustionair is drawn into the air cleaner.

Use ductwork to direct airflow. Direct the radiator airoutside the room or enclosure using sheet metalductwork with structural supports. Keep ductwork asshort, straight, and unobstructed as possible.Combined static pressure restrictions greater than0.12 kPaor 13 mm(0.5 in.)water columnon the radiatorinlet and outlet openings cause reduced airflow andcontribute to overheating especially in high ambient airtemperatures. Use heavy canvas, silicone rubber, orsimilar flexible material for the connection between theradiator duct flange and the ductwork to reduce noiseand vibration transmission.

Outlet and inlet location and sizing. Size the outletduct area 150% larger than the radiator duct flangearea. Size the inlet air opening at least as large butpreferably 50% larger than the outlet.

If screens, louvers, or filters are used on either the inletor outlet, increase the inlet or outlet size according to therecommendations given in Section 4.3.2, InstallationConsiderations.

Since the exhaust air of larger units is both high volumeand high velocity, direct the exhaust flow away fromareas occupied by people or animals.

Louver use. Design temperature-controlling louvers toprevent air inlet restrictions and air pressure reductionsinside the building. Low building pressure canextinguish pilot lights on gas-fired appliances or causeproblems with the building ventilation system.

Additionally, bringing large quantities of winter air into abuilding wastes building heat and risks frozen waterpipes in normally heated spaces. Use dampers andcontrolled air outlet louvers as shown in Figure 4-6 toeliminate these problems and allow recovery of engineheat to reduce building heat loss. Close the louvers tothe exterior and open the interior louvers when theoutdoor temperature is below 18C--21C (65F--70F).Reverse the louver settings when the outdoortemperature is above 21C--24C (70F--75F).

31 2

5

6

4

TP-5700-4

1. Exterior2. Interior3. Air outlet duct

4. Generator set5. Dampers6. Controlled air outlet louvers

Figure 4-6 Air Control Louvers

4.5 Remote Radiator Cooling

A remote radiator system allows installation ofgenerator sets in locations where it would otherwise bedifficult to bring the volume of air required to cool a unit-mounted radiator. In these systems, the engine waterpump pushes coolant through a radiator mountedremotely from the generator set and, typically, in anopen area. An electricmotor-driven fanmounted on theradiator circulates air across the radiator’s cooling fins.

The remote radiators have a Secondary ExpansionDeaeration and Drawdown (SEDD) tank. This SEDDtank can be connected to the radiator either as an openor closed tank system. ClosedSEDD tanks are typicallyused when the remote radiator is in close proximity tothe generator set and open SEDD tanks are typicallyused when the remote radiator is located further away.

TP-5700 12/1632 Section 4 Air and Cooling

In order to assess a remote radiator cooling system, thecooling systemdesigner needs the followingdata. Fromthe respective generator set specification sheet, obtainthe:

D Engine jacket water flow, Lpm (gpm)

D Cooling air required for generator set based on 14C(25F) rise and an ambient temperature of 29C(85F), m3/min. (cfm)

D Maximum static (vertical) head allowable aboveengine, kPa (ft. H2O)

From the engine and/or radiator data sheet, obtain the:

D Maximum water pump inlet restriction kPa (psi)

D Maximum allowable coolant pressure differentialexternal to engine kPa (psi)

Note: The REZCK models are not equipped with anengine-driven water pump and primary/secondary thermostats. Selection, sourcing, andinstallation of the primary/secondary waterpumps and primary/secondary thermostatsmustbe provided by the design engineer based on theapplication requirements using the generator setspec sheet data and the water pumpmanufacturer’s specifications.

The following subsections provide general designguidelines for a remote radiator system.

4.5.1 General

System limitations. Cooling systems are limited byradiator cap ratings. The maximum radiator operatingpressure is138kPa (20psi) and themaximumoperatingtemperature is 121C (250F). Radiators are availablefor vertical or horizontal discharge. See Figure 4-7 andFigure 4-8.

Air requirements. Refer to the generator setspecification sheet for radiator air and engine/alternatorair requirements. Coolingair required for generator setsequipped with a remote radiator is based on a 14C(25F) rise and an ambient temperature of 29C (85F).The amount of air required to ventilate the generator setroomorenclosuredetermines thesizeof theair inlet andoutlet. Configure the ventilation air inlet and outlet sothat air flows across the generator set.

Useaventilating fan, if necessary, to dissipatealternatorand engine heat loss.

Note: All remote radiators are sized for mounting in anopen area with no additional external devicesattached. Attached devices, confined installation,louvers, dampers, ductwork, or other inlet oroutlet air restriction require resizing the radiatorto compensate for reduced airflow.

TT11863

1

11

9

8

32 4

10

6

7

1. Remote vertical radiator (horizontal discharge)2. Pressure cap3. Surge tank/expansion tank4. Radiator inlet5. Fill line6. Vent line7. Shutoff Valve

8. Engine outlet9. Engine water pump10. Suction side11. Fill/drain (lowest point of engine12. Shutoff valve13. Radiator outlet14. Maximum allowable static (vertical) head (varies with engine)

5

12

13

14

Figure 4-7 Remote Vertical Radiator (Horizontal Discharge) System


TT11864

1. Radiator inlet2. Pressure cap3. Surge tank/expansion tank

1 2 3 4 5 7

11 10

86 9

12

4. Horizontal radiator(vertical discharge)

5. Radiator outlet6. Vent line(s)

7. Fill line8. Shutoff valve9. Engine outlet

10. Engine inlet11. Fill/drain (lowest point of engine)12. Shutoff valve

Figure 4-8 Remote Horizontal Radiator (Vertical Discharge) System

Static (vertical) head. If the vertical distance from theengine water pump to the radiator (known as statichead) is within the engine manufacturer’srecommendations, and the pressure drop through thepiping and remote radiator does not exceed the enginemanufacturer’s limits, use the engine water pump tocirculate water through the remote radiator. Theallowable static head ranges from 5.2 m--15.2 m(17 ft.--50 ft.) and is listed on the generator setspecification sheet. Exceeding the allowable static headcauses excessive pressure on engine componentsresulting in problems such as leaking water pump seals.

Note: Size the pressure relief valve or cap to remainunder the engine pressure limit.

Hot well tank/heat exchanger. When the static(vertical) head exceeds the distance stated in thespecification sheet, use a hot well tank or heatexchanger and auxiliary circulating pump as shown inFigure 4-9 or Figure 4-10. Always wire the circulatingpump in parallel with the remote radiator fan so that bothoperate whenever the generator set operates.

A partial baffle divides a hot well tank into two or morecompartments. The engine pump forces heated waterinto the hot side, and the auxiliary pump then draws thewater off and forces it into the radiator. After circulatingthrough the radiator, coolant drains back to the cold sideof the well where the engine water pump removes it. Ahot well or heat exchanger also isolates head pressuresfrom the engine.

Note: The water in the hot well tank drains into theradiator when the generator set is not running.

Note: Determine the size requirements of the remoteradiator and hot well tank/heat exchanger foreach application. Do not use a standard remoteradiator with a hot well tank/heat exchanger.

4.5.2 Vent Lines

Route the ve

Documents

Industrial Generator Sets #1570...TP-5700 12/16 Safety Precautions and Instructions 7 Safety Precautions and Instructions IMPORTANTSAFETYINSTRUCTIONS. Electromechanical equipment,