Gen-Set Installation Guide

IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS

This guide contains important instructions for Blue Star Power Systems, Diesel and Gaseous Engine Driven Electric Generators.
It should be followed during installation and maintenance of the generator unit.

Blue Star Power Systems, Inc. | 52146 Ember Road, Lake Crystal, Minnesota 56055 | Phone + 1 507 726 2508 | bluestarps.com
 WARNING:

California Proposition 65 WARNING:

Engine exhaust produced by this product contains chemicals known to the state of California to cause
cancer, birth defects and other reproductive harm.

California Proposition 65 WARNING:

Battery Posts, Terminals and related accessories contain chemicals known to the state of California to
cause cancer, birth defects and other reproductive harm.

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Table of Contents
FOREWORD ................................................................................................................................................. 4
APPLICABLE CODES AND STANDARDS .................................................................................................... 4
PRODUCT IDENTIFICATION ........................................................................................................................ 5
SAFETY PRECAUTIONS AND WARNINGS ................................................................................................. 5
SITE PLANNING AND SELECTION .............................................................................................................. 6
UNIT LIFTING PROVISIONS ........................................................................................................................ 8
MOUNTING PAD CONSTRUCTION ............................................................................................................. 8
MOUNTING AND VIBRATION ISOLATION .................................................................................................. 9
COOLING SYSTEMS AND AIR REQUIREMENTS ..................................................................................... 10
EXHAUST SYSTEMS.................................................................................................................................. 12
FUEL SYSTEMS ......................................................................................................................................... 13
DIESEL FUEL SYSTEMS ........................................................................................................................ 13
GASEOUS FUEL SYSTEMS ................................................................................................................... 14
BATTERIES AND STARTING SYSTEMS .................................................................................................... 17
ELECTRICAL REQUIREMENTS ................................................................................................................. 21
AUTOMATIC TRANSFER SWITCHES ........................................................................................................ 23
THE APPENDICES ................................................................................................................................. 24

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FOREWORD
This installation guide is intended to provide general instructions for the safe and reliable installation of
your Blue Star engine generator set. It is of the utmost importance that each and every person who
performs work on this equipment is trained and familiar with the equipment and the contents of this
entire installation guide.

Each installation is unique in some ways and may require variance or modification from the suggestions
presented within this guide. If you are in doubt in any way during the installation process, please take a
moment to consult with your authorized Blue Star Power Systems representative. They are trained and
experienced in the installation and operation/maintenance of this equipment.

Note: The procedures presented in this guide are suggestions. They are not intended to address every
circumstance that can and will arise during the installation process. It is the responsibility of the
Owner/Operator to arrange for these to be performed by licensed individuals that regularly engage in this
type of work.

It is the responsibility of the Owner/Operator to ensure that all aspects of the installation are performed
in accordance with all Federal/State/county and local codes, and in accordance with the requirements of
the authorities having jurisdiction.

APPLICABLE CODES AND STANDARDS

Prior to installation, you should obtain and familiarize yourself with the following codes and standards
that are referenced within this guide and that may/will govern how the equipment is installed:

National Fire Protection Association (NFPA)

NFPA 30: Storage, handling and use of flammable liquids.

NFPA 37: Stationary combustion engines and gas turbines.

NFPA 54: National Fuel Gas Code.

NFPA 70: National Electrical Code.

NFPA 77E: Arc Flash Safety.

NFPA 99: Essential Electrical Systems for Health Care Facilities.

NFPA 101: Life Safety Code Number Systems.

NFPA 110 2010: Emergency and Standby Systems.

National Electrical Manufacturers Association (NEMA)

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Local codes enforced by the authority having jurisdiction.

The information presented within this guide is of the latest and up to date as of the publication date.
Blue Star Power Systems, Inc. reserves the right to change/update this publication and the information
contained within, without notice, obligation or liability whatsoever. Blue Star Power Systems does not
guarantee the satisfactory results of any installation performed using the information contained in this
guide. Nor will Blue Star Power Systems assume responsibility for any injury or damage to property as a
result of the use of this guide. Persons engaging in product installation do so at their own risk.

Once again, if you are in doubt in any way about the procedures for safe and proper installation of this
product, stop now and consult your authorized Blue Star Power Systems representative. They are
trained and experienced in the installation and operation/maintenance of this equipment.

PRODUCT IDENTIFICATION
Locate and record the unit model and serial numbers from the unit nameplate (usually affixed near the
controller) immediately after unpacking the equipment. Record the information in the space provided
below for future reference when requesting assistance or information regarding this equipment.

Unit Model Number:_____________________________________

Unit Serial Number:______________________________________

SAFETY PRECAUTIONS AND WARNINGS

Important safety Instructions: Electromechanical equipment, including generator sets, transfer switch
equipment and accessories can cause bodily harm and pose life threatening danger when improperly
installed, operated, maintained or accessed.

The terms DANGER, WARNING and CAUTION are used throughout this guide to alert the
installer/operator to special instructions concerning particular procedures that may be hazardous if
performed incorrectly. These safety alerts alone cannot eliminate the hazards that they signal. Strict
adherence to these special instructions and common sense operation of the equipment are the best
accident prevention measures.

Observe all warning labels found on the equipment. Ensure that all warning labels remain affixed and
intact, and are not obstructed with dirt, grease or other equipment.

Blue Star Power Systems Inc. cannot anticipate every possible circumstance that may involve a
hazardous situation. The warnings contained in this guide as well as the tags and labels affixed to the
equipment, are therefore not to be considered all inclusive.

Definitions:

DANGER: Indicates the presence of a hazard that WILL cause severe personal injury, death or
substantial property damage.

WARNING: Indicates the presence of a hazard that CAN cause severe personal injury, death or
substantial property damage.

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CAUTION: Indicates the presence of a hazard that CAN or WILL cause minor personal injury or property
damage.

HIGH VOLTAGE: Indicates that high voltage may be present in this vicinity or while performing this
procedure.

Additional Safety Precautions:

DANGER: Risk of Electrical Shock. The equipment ground connection on this equipment must be
suitably connected to earth ground in accordance with NFPA 70. This equipment shall not be used in
“floating neutral” applications.

WARNING: Be aware that once the engine starting batteries are connected, this equipment can and will
start automatically. Use extreme caution or disconnect the engine starting batteries prior to servicing or
making adjustments.

CAUTION: Prior to servicing the unit, remove power to all energized circuits, such as a battery charger,
coolant heaters, or any device that remains energized during servicing functions.

CAUTION: Wear eye protection when operating or servicing this equipment. Flying debris and/or
acid/gases from the engine starting batteries could be present during equipment operation and normal
battery charging.

SITE PLANNING AND SELECTION

Outdoor, enclosed units:

Choose a site that allows adequate clearance around the unit for ancillary equipment, fuel
storage/supply and routine servicing. The site should be level, not subject to flooding and in compliance
with local codes and ordinances.

The Unit is to be installed in a location that minimizes the risk of people coming in contact with hot
surfaces. Unless specified otherwise, the maximum ambient operating temperature rating of the unit is
50° C/ 122°F.

Allow adequate clearance for engine radiator air discharge so as not to restrict cooling air flow.

CAUTION: Allow adequate clearance for engine exhaust discharge, keeping in mind the high
temperatures and fumes associated with engine exhaust. Do not direct engine exhaust toward other
structures or their air intake means.

CAUTION: Internal combustion engines can produce high noise levels. Choose a location where sound
levels during operation will not be objectionable.

CAUTION: In northern climates, provide a suitable means to prevent the accumulation and penetration
of blowing snow.

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WARNING: Open bottomed stationary engine generator sets must be installed over/on non combustible
materials and shall be located such that it prevents the accumulation of combustible materials under or
inside the generator set. Provide a suitable means to prevent the accumulation of leaves and debris.

See the Mounting Pad Construction Section for typical foundation/inertia pad construction details. For
any other application, consult a structural engineering firm for proper design to meet the application
requirements.

Indoor Units:
Engine generator sets must be protected from the elements, and be provided with adequate ventilation
and cooling air.

Considerations when selecting a room size and location:

DO NOT USE THE GENERATOR ROOM FOR STORAGE OF ANY MATERIALS NOT ASSOCIATED WITH
THE GENERATOR SET.

The room should be sized to adequately accommodate the unit and all of the ancillary equipment such
as fuel supply/storage, starting batteries and charging equipment, cooling and exhaust system
components and automatic transfer switch equipment.

Allow a minimum of three feet of clearance on each side and radiator end, and five feet on the end
opposite the radiator for servicing

The fuel storage tank for diesel driven units should be located as close as possible to the unit.

Allow for clearance between hot components (such as exhaust system) and combustible materials.

Consult local building/safety codes for specific applicable requirements. Fire rating codes and
requirements must be adhered to.

Utilizing a generator set with a unit mounted radiator/cooling system is the most cost effective solution
when allowable. However, the room must be situated such that sufficient cooling air can be brought into
and exhausted to allow proper cooling of the equipment. Utilizing opposing exterior walls for radiator
cooling air supply and radiator discharge is the most effective and cost efficient when possible. Avoid
utilizing the same wall for air intake and discharge.

Consult your Blue Star Power Systems representative for installation guidance for remote cooled unit
applications.

Verify the load carrying capacity of the floor. Involve a structural engineering firm if in doubt or for
applications where an inertia pad similar in Figure 2 in the Appendices cannot be utilized.

See the exhaust system section for pertinent information regarding exhaust system considerations.

Utility Power: Make sure there is an adequate source of utility power available to supply the ancillary
equipment necessary for support while the gen-set is not in operation (Heaters, Chargers, Etc).

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WARNING: Open bottomed stationary engine generator sets must be installed over/on non combustible
materials and shall be located such that it prevents the accumulation of combustible materials from
accumulating under or inside the generator set.

UNIT LIFTING PROVISIONS

For safety and convenience, all Blue Star generator sets are provided with a means to lift the unit from
the skid base. There are two basic types of lifting devices (See Figure 1 in the Appendices). Smaller units
are provided with holes in the skid base by which to attach chain hooks. Larger units are provided with
removable lifting brackets for chain attachment. In both instances, the use of chain spreader bars or
equipment to suit the particular situation is required to prevent the lifting chains from damaging the unit
during lifting. Due to the vast amount of variation in units, lifting equipment and circumstances; the
safest means to lift the equipment without damage is at the sole discretion of the lifting equipment
operator.

The use of the individual engine and generator lifting devices shown on the diagrams are NOT to be
used to lift the entire engine generator set. These devices were designed to lift only their respective
component and not the complete unit. Lifting a complete unit by means of the engine and generator
lifting devices will be done solely at the lifting equipment operator’s discretion and assumed risk.

See Figure 1 in the Appendices for typical lifting devices drawing.

MOUNTING PAD CONSTRUCTION

Blue Star Engine Generator Sets should be installed on a concrete pad that is properly sized to support
the weight load of the unit and all associated accessories that will be installed with it as well as reduce
transmitted vibration to acceptable levels. The weight of your particular unit can be found on the unit
specification sheet provided in the operator’s manual provided with the unit. If your unit is equipped with
a sub-base fuel tank, you must include the weight of the fuel tank and fuel in your weight calculations.

CAUTION: The design criteria presented within this guide are general guidelines only. Check local
building codes and ordinances for proper composition, design criteria and clearances. Consult a
structural engineering firm for assistance with the design and certification of any supporting structure
that is not placed directly on the ground.

CAUTION: The unit dimensions listed on the model specification sheets provided in the operators
manuals are general dimensions for open type units. The overall dimensions of any particular unit can
vary greatly depending on the configuration and accessories ordered. If in doubt about the physical size
of any particular unit, contact your local Blue Star Power Systems Inc representative for unit specific
drawings prior to proceeding.

Common specifications require 2500 PSI concrete, reinforced with eight gauge wire mesh or #6
reinforcing bars on 12 inch centers. The minimum recommended thickness of the pad can be calculated
by using the formula below. If the weight per Ft³ of the specific concrete being used is unknown, use
145 pounds per Ft³, (which is a general average) for the calculations below.

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To reduce vibration transmission to the surrounding areas, a sub-surface layer of sand or gravel should
be used. Consult a qualified structural engineer for recommendations.

The overall width and length of the mounting pad should be a minimum of 12 inches longer and wider
than the skid base of the unit being mounted. It is normally desirable to extend the mounting pad three
to six inches above the surrounding concrete or grade for ease of service and cleaning.

Formula for calculating minimum mounting pad thickness:

See Figure 2 in the Appendices for Typical Indoor Genset Installation.

MOUNTING AND VIBRATION ISOLATION

Also see vibration isolation requirements in subsequent sections relative to fuel, exhaust and
electrical.

Noise and vibration are normal by-products of any internal combustion engine driven generator.

Vibration reducing mounts are generally used to secure the engine generator set to the concrete
mounting pad. The purpose of such mounts is to reduce the amount of noise and vibration that is
transmitted to the mounting pad during unit operation. Installations within buildings that have adjacent
areas designated for other uses should be reviewed by a structural engineer to ensure that transmitted
noise and vibration are reduced to unobjectionable levels.

There are typically two types of vibration reducing mounts used:

Pad type vibration mounts, which are simple and effective for most applications, are placed between the
engine generator set base frame and the concrete mounting pad. They are sized according to the weight
of the unit and accessories and should be placed at each mounting point designed into the generator
set skid base. To allow the vibration isolation pads to function properly, the nuts on the anchor bolts
holding the unit to the mounting pad should be left loose and “double-nutted” as opposed to being
tightened down. Refer to the illustration below.

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 .

Pad Type Vibration Mount Expanding Anchor Bolt

Spring type vibration mounts are designed for a higher level of vibration and noise isolation for critical
installations. If your particular generator set was provided with spring type mounts, please refer to the
operator’s manual provided with the unit for installation details for the particular mount that was
provided.

Spring Type Vibration Mount

COOLING SYSTEMS AND AIR REQUIREMENTS

CAUTION: In cold climate areas, the high volume of outside air that will be drawn into the generator
room can quickly reduce temperatures within the room to sub-freezing levels. All water piping and other
equipment subject to damage by freezing temperatures should be relocated or properly insulated to
prevent damage.

The cooling system is one of the most critical aspects of any generator set installation. Careful planning
must be exercised to insure that adequate ventilation will be available during operation under all possible
climatic conditions.

Cooling systems can range in complexity from the simplest and most common “unit mounted radiator”
to the most elaborate, remote mounted radiator, heat exchanger or heat recovery system. It would be
inconceivable to properly cover all possible cooling system applications in a guide of this type. For that
reason, only unit mounted radiator cooling systems will be described within. Please consult your local
Blue Star Power Systems representative for design, application and installation assistance for all cooling
system applications other than unit mounted radiator cooling.

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Installation considerations for unit mounted radiator cooling systems:
Prevailing wind: should be a key factor in deciding which direction to discharge the cooling air that will
be exhausted out through the unit mounted radiator. Wind pressure may reduce the amount of air the
engine mounted cooling fan can discharge through the unit mounted radiator, causing poor performance
or overheating. Consider which direction the wind is usually out of during the hottest days of the year,
when the cooling system will require the maximum amount of cooling airflow possible.

Noise: The fans required to move air through a unit mounted radiator cooling system will produce a fair
amount of noise. Consider positioning the radiator exhaust in a direction less subject to objectionable
noise levels.

Hot air discharge: At times, the cooling air discharged through a unit mounted radiator cooling system
can reach levels that could damage shrubs, bushes and plantings. This is of particular a concern if the
unit will be operated for extended periods of time during high ambient temperature periods. Choose the
placement direction accordingly.

Recirculation of cooling air: The most common cause of unit overheating is cooling air recirculation.
When hot air that’s discharged through the radiator is allowed to re-circulate back into the cooling air
intake means and through the radiator again, the cooling air can exceed the temperature capabilities of
the cooling system causing overheating. If at all possible, the cooling air intake and discharge means
should be located on opposing walls or be drawn from and exhausted to opposing directions.

Excessive external static pressure within the cooling system: The location of the unit relative to the
cooling air intake and exhaust should be such that the need for air ducting is kept to a minimum. For
proper operation, all extended air ducting should be sized to maintain the total cooling system external
restriction to less than 0.50 inches H₂O. Indoors, the radiator discharge must be ducted with flexible
material when installing to the wall opening.

See Figure 1 in the Appendices for Typical Unit Mounted Radiator Installation

Sizing cooling air inlet and exhaust openings for unit mounted radiator cooling systems:
Adequate cooling air flow is critical to the proper operation of any engine generator set. These
recommendations are presented in terms of “effective opening” which is the amount of open area of
which air is allowed to flow through a device.

Air intake: As a general rule, the “effective opening” of any device used as an air intake means to the
engine generator set should be a minimum of 75% larger in “effective opening” than the units’
radiator core . (See example)

Air exhaust: As a general rule, the “effective opening” of any device placed in front of the unit mounted
radiator as an air discharge device should be a minimum of 50% larger in “effective opening” than the
radiator core itself. The device and the radiator core duct adapter should be connected by ductwork of
minimal length, and shall be fitted with a flexible section installed at the radiator end.
FORMULA:

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Next, the louver dimensions (In2) can be converted to ft2 by dividing the ‘Required Louver Size’ by 144.
Louvers can then be chosen based on the physical layout of the room and what’s available for louver
sizes, so long as the length x width is equal to the ‘Required Louver Size’ in Ft².

See Figure 2 in the Appendices for drawing of typical fixed louver installation.

Various types of air intake and exhaust devices:

Fixed Blade Louvers: Generally used as air intake devices. The angled stationary blades allow cooling
air to flow into a room or enclosure while keeping out the elements and debris. A bird/rodent screen
should be installed on the back (inside) of the louver to prevent pest activity within the generator room.

Gravity Operated Louvers: Can only be used as air exhaust devices. The hinged louver blades are held
open by the discharge airflow during unit operation and fall shut by gravity when not in operation. The
use of ductwork to prevent cooling air recirculation is an absolute must when using gravity exhaust
louvers.

Motor Operated Intake Louvers: Perform the same basic function as fixed intake louvers except that
they close to keep out the elements when the unit is not in operation. The desired mode of operation is
such that the louver motor is “energized to close” and opens when power is removed.

Motor Operated Exhaust Louvers: Differ from motor operated intake louvers as the blades open to a
full 90° position to allow the higher velocity, exhausted air to flow with less restriction. The desired mode
of operation is such that the louver motor is “energized to close” and opens when power is removed.

CAUTION: Care should be taken to verify the mode of operation of the motorized louver being installed
(Either energize to close or energize to open) to insure that power is supplied or removed as needed in
all modes of operation. IE: During periods of test/exercise, actual power failure, simulated power failure
Etc. Improper control sequence/wiring could cause the louvers to remain closed while the unit is in
operation causing an overheat condition, shutdown or damage to the unit or accessories.

In some extreme cold climatic applications, the use of thermostatically controlled louvers may be used
to reduce problems associated with fuel system icing/gelling, engine overcooling Etc. Contact your Blue
Star Power Systems Representative for assistance in these applications.

EXHAUST SYSTEMS
The purpose of the exhaust system is to safely discharge the engine combustion exhaust gasses to a
safe area outside of the building or structure.

WARNING: Engine combustion exhaust fumes are deadly. Never allow the exhaust outlet termination to
be positioned such that exhaust gasses will be directed toward any air entry routes (doors, windows, air
intake vents, Etc) of an occupied building. When choosing the location for the discharge termination, do
not direct it towards anything that could catch fire or be damaged by high temperatures.

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 See Figure 3 in the Appendices for a Typical Exhaust Systems Drawing

Exhaust system consideration checklist:

A. Exhaust outlet terminations are not located upwind or near any building air intakes.
B. A flexible piping section of suitable design is used to prevent the transmission of vibration to the
exhaust piping which is extended beyond what was provided with the unit from the factory.
C. The exhaust piping materials are suitable for the temperatures expected and as published for
the particular unit. These temperatures can sometimes exceed 1200°F (649°C).
D. Extended piping is adequately sized to prevent excessive engine exhaust system back pressure
as published for the particular unit. Consult your Blue Star Power Systems representative for
assistance in the design of lengthy or elaborate exhaust system requirements.
E. Exhaust piping components are properly insulated to prevent operator exposure to excessive
temperatures.
F. Ventilated wall thimbles, piping sleeves or other suitable fire-proof materials are used where
piping passes through building materials as per all state and local codes.
G. Exhaust pipe termination includes a rain cap or other suitable means to prevent the entrance of
rain, debris and pests when not in operation.
H. All exhaust system components and extended piping beyond what was provided with the unit
from the factory is adequately supported to prevent damage to these components during
operation.
I. The overall exhaust system is oriented to provide a slight downward slope away from the engine
to prevent condensation from draining back into the engine.

FUEL SYSTEMS

General:
The fuel delivery system must be adequately sized and properly installed to provide an ample supply of
fuel for starting and running the unit throughout the duration of any emergency event. Prior to
connecting the fuel lines, ensure that the fuel connections are free of dirt, grease, water or other foreign
matter that could damage the engine.

The components required for a complete fuel system will vary depending on the fuel type, unit location
and applicable state and local codes. The aforementioned is to be used only as a guide. It is the fuel
system installers’ responsibility to ensure that the overall fuel delivery system is of a safe and code
compliant design.

DIESEL FUEL SYSTEMS

The following components comprise a typical diesel fuel delivery system:

A. Main fuel storage tank, sized for the desired length of run time.

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 B. Main fuel tank fill pipe with a suitable cap.
C. Main fuel tank vent line.
D. Fuel supply line with a foot/check valve.
E. Fuel return line.
F. Fuel storage “Day Tank” with transfer pump if required.
G. Fuel level switches as required for controls.

Main Fuel Storage Tank:

The ideal location for the main fuel storage tank is as close to the unit as possible. Provided that
applicable building and fire codes permit, the tank could be located within the same, or in an adjoining
room to the unit. If this is not feasible, the tank should be located in a suitable location according to
applicable state and local codes.

The fuel level in the main tank should be at the same height as the engines fuel transfer pump inlet. If
located within the generator room, the tank should be placed on the same general level as the unit, but
lower than the engine’s fuel injectors. If the tank must be placed at a level above or below this, a
separate priming or float tank may be required. When the main fuel storage tank can be located close to
the unit and the vertical “fuel lift” is five feet or less, the engines’ fuel pump may be adequate for
supplying fuel to the engine without additional means. If the horizontal run is excessive or the vertical lift
exceeds five feet, a fuel “Day Tank” and fuel transfer pump will be required.

All fuel storage tanks must be vented to a safe area to allow air and other gasses to escape to
atmosphere. The vent termination must be plumbed to a level above the highest point in the system to
prevent spillage in the event of an overfill situation. The vent pipe termination should be suitable to
prevent dust, dirt, moisture and pests from entering the tank.

GASEOUS FUEL SYSTEMS

Gaseous fuel systems should be sized and installed by qualified/authorized personnel only. Fuel
piping shall be rigidly supported along its entire length and protected against damage from
vibration. An AGA or UL approved flexible connector should be installed at the fuel inlet to the unit
to prevent the transmission of vibration to the fuel piping.

Gaseous fuel systems are grouped into four basic types.

1. Natural Gas
2. LP - Vapor Withdrawal
3. LP – Liquid Withdrawal
4. LP/NG Dual Fuel

Each fuel system type is covered below.

Natural Gas Fuel Systems: Natural gas is a vapor fuel that is supplied primarily by utilities. The BTU
content of the natural gas available in most locations is 1000 BTU/Ft³. If the BTU content at the site
location is below 1000 BTU/Ft³ the unit may have to be derated accordingly. The local gas utility will
provide fuel piping from the gas main to the site location. A primary gas regulator should be provided by

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the utility. It is the responsibility of the gas utility to ensure that adequate volume and gas pressure are
available at all times to insure proper operation. Consult the unit specification sheet located in the
Operation & Maintenance Manual provided with your particular unit for the required fuel type, volume,
and pressure requirements.

LP – Vapor Withdrawal Fuel Systems: Liquefied Petroleum Gas is a liquid fuel that is supplied primarily
by fuel distributors. Vapor Withdrawal is the most common type of LP fuel system. The LP fuel within the
tank is vaporized within the tank and is drawn under pressure from the top of the tank, above the level of
the fuel. The BTU content of LP Gas is 2500 BTU/Ft³. The local gas provider will provide fuel piping from
the storage tank to the site location. A primary gas regulator should be provided by the fuel provider. It is
the responsibility of the fuel provider to ensure that adequate volume and gas pressure are available at
all times to insure proper operation. Consult the unit specification sheet located in the Operation &
Maintenance Manual provided with your particular unit for the required fuel type, volume, and pressure
requirements.

See Figure 4 in the Appendices for SINGLE FUEL NG/LP VAPOR WITHDRAWL
Drawing

LP – Liquid Withdrawal Fuel Systems: Liquefied Petroleum Gas is a liquid fuel that is supplied primarily
by fuel distributors. Liquid Withdrawal is the most commonly used type of LP fuel system when large
volumes of fuel are required. The LP fuel within the tank is drawn under pressure (in the liquid form) from
the bottom of the tank, below the level of the fuel and is converted to vapor by a fuel converted mounted
on the engine. The BTU content of LP Gas is 2500 BTU/Ft³. The local gas provider will provide fuel
piping from the storage tank to the site location. It is the responsibility of the fuel provider to ensure that
adequate volume and gas pressure are available at all times to insure proper operation. Consult the unit
specification sheet located in the Operation & Maintenance Manual provided with your particular unit for
the required fuel type, volume, and pressure requirements.

Fire regulations prohibit the installation or entrance of high pressure or liquid LP fuel piping into an
occupied building or enclosure.

See Figure 5 in the Appendices for SINGLE FUEL LP LIQUID WITHDRAWL

Drawing

LP/NG Dual Fuel Systems: Dual fuel systems allow for Natural gas to be used as the primary fuel and
LP gas to be used as a backup should the natural gas supply be interrupted. There are two types of dual
fuel systems available. Manual changeover systems which require qualified personnel to manually open
and close valves and switches to change fuels and automatic changeover systems which monitor the
primary fuel pressure and changeover automatically should the pressure be reduced to an unacceptable
level. Consult the operation and Maintenance Manual that was provided with your particular unit for
further instruction, system type, and volume and pressure requirements.

See Figure 6 in the Appendices for DUAL FUEL NG/LP VAPOR WITHDRAWL
AUTO CHANGEOVER Drawing

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 See Figure 7 in the Appendices for DUAL FUEL NG/LP LIQUID WITHDRAWL
AUTO CHANGEOVER Drawing

Gas Fuel System Design Considerations:

Gas piping shall not be used as a grounding means for electrical equipment.

The fuel system should incorporate a manual fuel lock-off valve to allow for maintenance of the system.

Refer to the typical installation drawings below for recommended fuel system components.

All gas piping should be sized to maintain adequate volume and pressure at the engine fuel inlet while
operating under full load. Overall length of run and number of elbows and fittings must be taken into
consideration.

General Guidelines for Determining Pipe Size for Gaseous Vapor Fuel Systems
1. Obtain the engine fuel consumption in cubic feet per hour at 100% load from the unit model
specification sheet for the type of fuel used.
2. Refer to the correction factor chart below to determine the proper correction factor for the type
of fuel being used.

Correction  Factors  For  Fuel  Specific  Gravity  

Fuel  Type   Specific  Gravity   Correction  Factor  
Natural  Gas   0.65   0.962  
Air   1.00   0.775  
Propane   1.50   0.633  
Butane   2.10   0.535  

3. Divide the fuel consumption from step 1 by the appropriate correction factor to obtain the
corrected flow rate.
4. Determine the “straight pipe equivalent length” for all of the fittings in the piping system from the
chart below.

Equivalent  Length  of  Straight  Pipe  for  Valves  and  Fittings  (in  Feet)  
Pipe  Size  (Nominal)  
Screwed  Fittings  
1/4   3/8   1/2   3/4   1   1  1/4   1  1/2   2   2  1/2   3   4  
Regular  90˚   2.3   3.1   3.6   4.4   5.2   6.6   7.4   8.5   9.3   11.0   13.0  
Elbows   Long  Radius  90˚   1.5   2.0   2.2   2.3   2.7   3.2   3.4   3.6   3.6   4.0   4.6  
Regular  45˚   0.3   0.5   0.7   0.9   1.3   1.7   2.1   2.7   3.2   4.0   5.5  
Line  Flow   0.8   1.2   1.7   2.4   3.2   4.6   5.6   7.7   9.3   12.0   17.0  
Tees  
Branch  Flow   2.4   3.5   4.2   5.3   6.6   8.7   9.9   12.0   13.0   17.0   21.0  

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 Globe   21.0   22.0   22.0   24.0   29.0   37.0   42.0   54.0   62.0   79.0   110.0  
Valves   Gate   0.3   0.5   0.6   0.7   0.8   1.1   1.2   1.5   1.7   1.9   2.5  
Angle   12.8   15.0   15.0   15.0   17.0   18.0   18.0   18.0   18.0   18.0   18.0  
Strainer       4.1   4.6   5.0   6.6   7.7   18.0   20.0   27.0   29.0   34.0   42.0  

5. Add the “equivalent length” to the total length of straight pipe within the system.
6. From the table below, choose the column with the nearest “total” pipe length.
7. Move down the column until the capacity figure in cubic feet per hour is encountered.
8. Move horizontally to the left to obtain the suggested pipe size.

Gaseous  Fuel  Pipe  Capacities  in  Cubic  Feet  Per  Hour  

Pipe  Size   Total  Equivalent  Length  of  Pipe  in  Feet      
(Inches)   10   20   30   40   50   60   70   80   90   100   150   200  
1/4   43   29   24   20   18   16   15   14   13   12   10   8  
3/8   95   65   52   45   40   36   33   31   29   27   22   19  
1/2   175   120   97   82   73   66   61   57   53   50   40   35  
3/4   360   250   200   170   151   138   125   118   110   103   84   72  
1   680   465   375   320   385   260   240   220   205   195   160   135  
1  1/4   1400   950   770   660   580   490   460   460   430   400   325   280  
1  1/2   2100   1460   1180   990   900   810   750   690   650   620   500   430  
2   3950   2750   2200   1900   1680   1520   1400   1300   1220   1150   950   800  
2  1/2   6300   4350   3520   3000   2650   2400   2250   1050   1950   1850   1500   1280  
3   11000   7700   6250   5300   4750   4300   3900   3700   3450   3250   2650   2280  
4   23000   15800   12800   10900   9700   8800   8100   7500   7200   6700   5500   4600  

See following page for an example

Example:

Engine Generator set fuel consumption at 100% load running on natural gas equals 1600 Cubic feet per
hour.

The correction factor for natural gas is 0.962. Therefore 1600 ÷ 0.962 = 1633 (adjusted flow rate).

Reading down the 100 foot pipe length column in the capacity table until a capacity equal to or greater
than 1633 is obtained, which is 1850.

Reading across to the left, we see that 2 ½ inch piping will be required.

BATTERIES AND STARTING SYSTEMS

Engine starting batteries need to supply adequate current and voltage to the engine starter motor as
indicated on the specific model specification sheet located in the operation and maintenance manual

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provided with the unit. If the unit has one battery, the DC system voltage is 12VDC Nominal. If the unit
has two or four batteries, the DC system voltage is 24VDC Nominal.

When supplied, all lead acid batteries are shipped pre filled with electrolyte unless specified otherwise.

After installation, coat battery terminal connections with anti-corrosion compound to minimize corrosion.

Check battery electrolyte level and ensure all vent caps are in place and secure weekly.

 
Servicing of batteries are to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.

When replacing batteries, use the same number and the following type batteries: Vented Lead Acid
Engine Starting. Refer to the specific unit specification sheet provided in the operator manual with the
particular unit for the battery size.

CAUTION – Do not dispose of battery or batteries in a fire. The battery is capable of exploding.

CAUTION – Do not open or mutilate the battery or batteries. Released electrolyte has been known to be
harmful to the skin and eyes and to be toxic.

CAUTION – A battery presents a risk of electrical shock and high short circuit current. The following
precautions are to be observed when working on batteries:

1) Remove watches, rings, or other metal objects,

2) Use tools with insulated handles,

3) Wear rubber gloves and boots,

4) Do not lay tools or metal parts on top of batteries,

5) Disconnect charging source prior to connecting or disconnecting battery terminals,

and  
 
 
The installation of the engine generator shall provide enough ventilation to ensure that gases generated
by vented batteries during charging, or caused by equipment malfunction are removed.

CAUTION – The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically
conductive and corrosive. The following procedures are to be observed:

1) Wear full eye protection and protective clothing,

2) Where electrolyte contacts the skin, wash it off immediately with water,

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 3) Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek
medical attention.
 
4) Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice
is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (4 liters) of
water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming)
has ceased. The resulting liquid is to be flushed with water and the area dried.

CAUTION – Lead-acid batteries present a risk of fire because they generate hydrogen gas.

The following procedures are to be followed:

1) DO NOT SMOKE when near batteries,

2) DO NOT cause flame or spark in battery area, and

3) Discharge static electricity from body before touching batteries by first touching a grounded
metal surface.
 

CUSTOMER SUPPLIED BATTERY REQUIREMENTS

 
 Customer supplied engine starting batteries must meet the performance criteria listed below.
 
Diesel Gen-set Models No. of Batteries Battery Voltage Minimum CCA
JD30-XX 1 12 750
JD40-XX 1 12 640
JD50-XX 1 12 640
JD60-XX 1 12 640
JD60-XX 1 12 750
JD80-XX 1 12 800
JD100-XX 1 12 800
JD125-XX 1 12 800
JD150-XX 1 12 800
JD200-XX 1 12 800
JD250-XX 1 12 1100
JD275-XX 1 12 1100
JD300-XX 1 12 1100
CD300-XX 2 24 750
JD350-XX 2 24 925
JD415-XX 2 24 925
CD500-XX 2 24 1425
VD100-XX 2 24 680
VD150-XX 2 24 750
VD200-XX 2 24 750
VD250-XX 2 24 900
VD300-XX 2 24 900
VD350-XX 2 24 900

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Diesel Gen-set Models No. of Batteries Battery Voltage Minimum CCA
VD400-XX 2 24 900
VD450-XX 2 24 900
VD500-XX 2 24 900
VD550-XX 2 24 900
VD600-XX 2 24 900
VD100-XXFT4 2 24 680
VD125-XXFT4 2 24 680
VD150-XXFT4 2 24 750
VD200-XXFT4 2 24 800
VD250-XXFT4 2 24 900
VD300-XXFT4 2 24 900
VD350-XXFT4 2 24 900
VD400-XXFT4 2 24 900
VD550-XXFT4 2 24 900
VD600-XXFT4 2 24 900
TD250-XX 2 24 800
TD275-XX 2 24 800
TD300-XX 2 24 800
TD350-XX 2 24 800
TD400-XX 2 24 800
TD450-XX 2 24 800
TD500-XX 2 24 800
TD550-XX 2 24 800
TD600-XX 2 24 800
MD800-XX 4 24 1100
MD1000-XX 4 24 1100
MD1250-XX 4 24 1100
MD1600-XX 4 24 1100
MD2000-XX 4 24 1100
Gas Gen-set Models No. of Batteries Battery Voltage Minimum CCA
GM25-XX 1 12 650
PS40-XX 1 12 650
GM40-XX 1 12 650
GM50-XX 1 12 650
GM60-XX 1 12 650
GM100-XX 1 12 650
PS125-XX 1 12 650
PS130-XX 1 12 650
PS150-XX 1 12 650
NG150-XX 2 24 900
NG200-XX 2 24 900
NG265-XX 2 24 1000
NG300-XX 2 24 1000
NG350-XX 2 24 1000
NG400-XX 2 24 1000
NG425-XX 2 24 1000

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ELECTRICAL REQUIREMENTS

AC Output Connections:
Verify that the generator output voltage and phase as listed on the unit nameplate match the system
voltage and phase to which it is to be connected.

Note: If the gen-set was provided from the factory without a main line circuit breaker, a main line circuit
breaker must be provided by the installing contactor downstream of the gen-set load output terminals.
The maximum number of circuit breakers installed downstream of the load output terminals is limited to
six. The output load connection point on units supplied without a main line circuit breaker will be located
in an externally mounted terminal block within an enclosure and will be permanently marked as such.
The output load conductors must be connected to this connection point.

Note: The enclosures supplied with main line breakers in excess of 1200 amps are intended for bottom
conduit/connection access only.

All wiring must be sized and installed in accordance with all applicable electrical code requirements and
UL2200 requirements (See “Wire Sizing Guidelines” below). All conductors must be sized, insulated and
supported in an approved manner.

Wire  Sizing  Guidelines  (Based  on  UL2200  Requirements):  

(Reference  Section  12.1.3  &  Table  62.3  of  UL2200  Standard)  
 
Load  connection  wires  to  circuit  breaker  /  gen-­‐set  should  be  sized  based  on  UL2200  requirements.    The  
requirements  are  as  follows:  
 
Formula:  
Genset  rated  output      *        115%    
 0.88  (40C  ambient  correction)  
 
Example:  
100A  Rated  Output    *    115%  
0.88  (40C  ambient  correction)          =  130.68181  Amps  (Round  up  to  131  Amps)  
 
Note:  
• If mainline circuit breaker is rated below calculated amps of formula, use calculated
amps for wire sizing.
• If mainline circuit breaker is rated above calculated amps of formula, use circuit breaker
rating for wire sizing.

Wire Sizing Selection Pre UL2200:

• Use 75C column of NEC (Table 310-16) (Even when using 90C or greater wire)
• Wire selection must have amperage rating above calculated amps or circuit breaker,
whichever is greater.
 

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A suitable earth ground must be connected to the grounding terminal marked with the symbol shown
below:

All conduits terminating at the generator connection points must incorporate a flexible section to
eliminate the transmission of vibration.

Refer to output circuit breaker nameplate data for wire sizing/type and pressure terminal torque values.

The tightening torque tables shown below are to be used as a guide.  

 
Tightening  torque  for  pressure  wire  connectors  having  screws  
 

 
 
 
 
Tightening  torque  for  pressure  wire  connectors  having  internal  drive  socket  head  screws  
 

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Accessory Wiring:
It is recommended that all accessories requiring power be wired to a local panel being supplied by the
load side of the transfer switch. This ensures that the accessories will be powered by whichever
electrical source is available.

All accessory wiring should per Class 1 wiring methods and should be run in conduits separate of the
generator output conductors. AC and DC accessory circuits should also be run in separate conduits.

All accessory wiring is to be terminated within the interface connection box provided and labeled as
such.

Verify that the nameplate voltage of the accessories match the system voltage that will be supplying
them.

Refer to the electrical wiring diagrams provided in the Operation and Maintenance Manual provided with
the particular unit for further wiring details.

AUTOMATIC TRANSFER SWITCHES

Automatic transfer switch installation should be provided by a licensed electrician. Refer to the detailed
wiring diagrams and installation instructions that are provided with the equipment.

 
1) Unbalanced  load  capability  when  the  output  has  a  neutral  conductor.  
 
 

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The Appendices
 

Typical Lifting Devices

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Typical Indoor Genset Installation

  

Typical Exhaust Systems

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Single   Fuel NG/LP Vapor Withdrawl

 
 

Single Fuel LP Liquid Withdrawl

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Dual Fuel NG/LP Vapor Withdrawl Auto Changover

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 Gen-Set Installation Guide

Blue Star Power Systems, Inc.

52146 Ember Road
Lake Crystal, Minnesota 56055
Phone +1 507 726 2508
Fax + 1 507 726 2670 bluestarps.com