Kohler Generator Mounting Instructions

Installation
Industrial Generator Sets
Models:
20--2800 kW
TP-5700 12/07h
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that
operation manual, spec sheet, or sales invoice.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Generator Set Identification Numbers Engine Identification
Record the product identification numbers from the Record the product identification information from the
generator set nameplate(s). engine nameplate.
Model Designation Manufacturer

Specification Number Model Designation
Serial Number Serial Number
Accessory Number Accessory Description

Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2 Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Generator Set Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Determining Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.3 Lifting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.4 Lifting Subbase Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.5 Lifting Weather Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.6 Lifting Sound Shield Installed on Mounting Base (Concrete Slab) . . . . 19
2.1.7 Lifting Sound Shield with Integral Structural Steel Mounting to
Generator Set Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Generator Set Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.1 Single-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.2 Dual-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.3 Four-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.4 Mounting Pad Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Vibration Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4 Dual-Bearing Alternator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 4 Air and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Air-Cooled Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Liquid-Cooled Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.3 Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Unit-Mounted Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Remote Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.2 Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5.3 Fill Lines (Balance or Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5.4 Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator . . . . . . . . . . 33
4.5.7 Procedure to Fill with Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.8 Procedure to Fill without Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.9 Checks after Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6 City Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.7 Cooling Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.8 Block Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TP-5700 12/07 Table of Contents 3

Table of Contents, continued
Section 5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1 Flexible Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Condensation Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Double-Sleeved Thimbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.5 Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6 Exhaust System Backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 6 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.1 Main Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.2 Day Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1.3 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1.4 Auxiliary Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.2 Gasoline Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2.1 Fuel Storage Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2.3 Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3 Gas Fuel Systems, Common Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3.1 Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.3.2 Gas Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4 LP Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4.1 LP Gas Vapor-Withdrawal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.4.2 LP Gas Liquid-Withdrawal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5 Natural Gas Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6 Combination Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6.1 Combination Natural Gas and LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.6.2 Combination LP Gas or Natural Gas and Gasoline . . . . . . . . . . . . . . . . . 55
6.7 Pipe Size Requirements for Gas Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Section 7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Generator Set Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.3 Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.4 Grounding and Grounded Conductor (Neutral) Connections . . . . . . . . . . . . . . . . . 65
7.5 Terminal Connector Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.7 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.8 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.1 Audiovisual Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.2 Bus Bar Kits/Bus Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.3 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.8.4 Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.8.5 Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . 69
7.8.6 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.8.7 Low Fuel (Level or Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.8.8 Remote Annunciator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.8.9 Remote Serial Annunciator (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.8.10 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.8.11 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.8.12 Safeguard Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.8.13 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.8.14 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.9 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 Table of Contents TP-5700 12/07

Table of Contents, continued
Section 8 Paralleling and Remote Start/Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

8.1 Automatic Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.2 550 Controller, Menu 15 Paralleling Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.3 550 Controller, Menu 11 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.4 Reactive Droop Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.5 Remote Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.6 Remote Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.7 Remote Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.8 Remote Voltage Regulator Kit, 20--300 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.9 Voltage Regulator DVR 2000EC/Remote Voltage Regulator Kit,
350 kW and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.10 Voltage Regulator, PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.11 Voltage Regulator, Wound Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Appendix D Fuel Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Appendix E Gas Fuel Vapor Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Appendix F Gas Fuel System Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Appendix G Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
TP-5700 12/07 Table of Contents 5

Notes
6 TP-5700 12/07
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the case
Warning indicates the presence of a battery cables, negative (--) lead first. of eye contact. Never add acid to a
hazard that can cause severe Reconnect the negative (--) lead last battery after placing the battery in
personal injury, death, or substantial when reconnecting the battery. Follow service, as this may result in hazardous
property damage. these precautions to prevent starting of spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.
TP-5700 12/07 Safety Precautions and Instructions 7

Battery gases. Explosion can cause Servicing the fuel system. A flash Generator set operation. Carbon
severe injury or death. Battery gases fire can cause severe injury or death. monoxide can cause severe nausea,
can cause an explosion. Do not smoke Do not smoke or permit flames or fainting, or death. Carbon monoxide
or permit flames or sparks to occur near sparks near the carburetor, fuel line, is an odorless, colorless, tasteless,
a battery at any time, particularly when fuel filter, fuel pump, or other potential nonirritating gas that can cause death if
it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. inhaled for even a short time. Avoid
battery in a fire. To prevent burns and Catch fuels in an approved container breathing exhaust fumes when working
sparks that could cause an explosion, when removing the fuel line or on or near the generator set. Never
avoid touching the battery terminals carburetor. operate the generator set inside a
with tools or other metal objects. building unless the exhaust gas is
Remove all jewelry before servicing the Servicing the fuel system. A flash piped safely outside. Never operate
equipment. Discharge static electricity fire can cause severe injury or death. the generator set where exhaust gas
from your body before touching Do not smoke or permit flames or could accumulate and seep back inside
batteries by first touching a grounded sparks near the fuel injection system, a potentially occupied building.
metal surface away from the battery. To fuel line, fuel filter, fuel pump, or other
avoid sparks, do not disturb the battery potential sources of spilled fuels or fuel Carbon monoxide symptoms.
charger connections while the battery vapors. Catch fuels in an approved Carbon monoxide can cause severe
is charging. Always turn the battery container when removing the fuel line nausea, fainting, or death. Carbon
charger off before disconnecting the or fuel system. monoxide is a poisonous gas present in
battery connections. Ventilate the exhaust gases. Carbon monoxide is an
Servicing the air cleaner. A sudden odorless, colorless, tasteless,
compartments containing batteries to backfire can cause severe injury or
prevent accumulation of explosive nonirritating gas that can cause death if
death. Do not operate the generator inhaled for even a short time. Carbon
gases. set with the air cleaner removed. monoxide poisoning symptoms include
Battery short circuits. Explosion Combustible materials. A fire can but are not limited to the following:
can cause severe injury or death. cause severe injury or death. D Light-headedness, dizziness
Short circuits can cause bodily injury Generator set engine fuels and fuel D Physical fatigue, weakness in
and/or equipment damage. vapors are flammable and explosive. joints and muscles
Disconnect the battery before Handle these materials carefully to D Sleepiness, mental fatigue,
generator set installation or minimize the risk of fire or explosion. inability to concentrate
maintenance. Remove all jewelry Equip the compartment or nearby area or speak clearly, blurred vision
before servicing the equipment. Use with a fully charged fire extinguisher. D Stomachache, vomiting, nausea
tools with insulated handles. Remove Select a fire extinguisher rated ABC or If experiencing any of these symptoms
the negative (--) lead first when BC for electrical fires or as and carbon monoxide poisoning is
disconnecting the battery. Reconnect recommended by the local fire code or possible, seek fresh air immediately
the negative (--) lead last when an authorized agency. Train all and remain active. Do not sit, lie down,
reconnecting the battery. Never personnel on fire extinguisher or fall asleep. Alert others to the
connect the negative (--) battery cable operation and fire prevention possibility of carbon monoxide
to the positive (+) connection terminal procedures. poisoning. Seek medical attention if
of the starter solenoid. Do not test the the condition of affected persons does
battery condition by shorting the not improve within minutes of breathing
terminals together. Exhaust System fresh air.
Do not use copper tubing in diesel

Engine Backfire/Flash WARNING exhaust systems. Sulfur in diesel
exhaust causes rapid deterioration
Fire of copper tubing exhaust systems,
resulting in exhaust leakage.
WARNING
Carbon monoxide. Fuel System
Can cause severe nausea,
fainting, or death.
Fire. The exhaust system must be WARNING

Can cause severe injury or death. leakproof and routinely inspected.
Do not smoke or permit flames or

sparks near fuels or the fuel system.
Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
8 Safety Precautions and Instructions TP-5700 12/07

Fuel tanks. Explosive fuel vapors Engine noise. Hazardous noise can
WARNING can cause severe injury or death. cause hearing loss. Generator sets
Gasoline and other volatile fuels stored not equipped with sound enclosures
in day tanks or subbase fuel tanks can can produce noise levels greater than
cause an explosion. Store only diesel 105 dBA. Prolonged exposure to noise
fuel in tanks. levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
Avoid high pressure fluids. Draining the fuel system. Explosive protection when near an operating
Can cause severe injury or death. fuel vapors can cause severe injury generator set.
or death. Spilled fuel can cause an
Do not work on high pressure fuel or explosion. Use a container to catch fuel
hydraulic systems without when draining the fuel system. Wipe up
protective equipment to protect spilled fuel after draining the system.
Hazardous Voltage/
hands, eyes, and body. Avoid the Moving Parts
hazard by relieving pressure before Gas fuel leaks. Explosive fuel
disconnecting fuel injection vapors can cause severe injury or
pressure lines. Search for leaks death. Fuel leakage can cause an DANGER
using a piece of cardboard. Always explosion. Check the LP vapor gas or
protect hands, eyes, and body from natural gas fuel system for leakage by
high pressure fluids. If an accident using a soap and water solution with
occurs, seek medical attention the fuel system test pressurized to
immediately. 6--8 ounces per square inch
(10--14 inches water column). Do not Hazardous voltage.
The fuel system. Explosive fuel use a soap solution containing either Will cause severe injury or death.
vapors can cause severe injury or ammonia or chlorine because both
Disconnect all power sources before
death. Vaporized fuels are highly prevent bubble formation. A successful
opening the enclosure.
explosive. Use extreme care when test depends on the ability of the
handling and storing fuels. Store fuels solution to bubble.
in a well-ventilated area away from WARNING
LP liquid withdrawal fuel leaks.
spark-producing equipment and out of
Explosive fuel vapors can cause
the reach of children. Never add fuel to
severe injury or death. Fuel leakage
the tank while the engine is running
can cause an explosion. Check the LP
because spilled fuel may ignite on
liquid withdrawal gas fuel system for
contact with hot parts or from sparks.
leakage by using a soap and water
Do not smoke or permit flames or Hazardous voltage. Moving parts.
solution with the fuel system test
sparks to occur near sources of spilled Can cause severe injury or death.
pressurized to at least 90 psi
fuel or fuel vapors. Keep the fuel lines
(621 kPa). Do not use a soap solution
and connections tight and in good Operate the generator set only when
containing either ammonia or chlorine
condition. Do not replace flexible fuel all guards and electrical enclosures
because both prevent bubble
lines with rigid lines. Use flexible are in place.
formation. A successful test depends
sections to avoid fuel line breakage
on the ability of the solution to bubble.
caused by vibration. Do not operate the
generator set in the presence of fuel WARNING
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming Hazardous Noise
generator set operation.
Explosive fuel vapors can cause CAUTION
severe injury or death. Take
additional precautions when using the Hazardous voltage.
following fuels: Backfeed to the utility system can
cause property damage, severe
Gasoline—Store gasoline only in injury, or death.
approved red containers clearly
marked GASOLINE. Hazardous noise. If the generator set is used for
Can cause hearing loss. standby power, install an automatic
Propane (LP)—Adequate ventilation transfer switch to prevent inadvertent
is mandatory. Because propane is Never operate the generator set
interconnection of standby and
heavier than air, install propane gas without a muffler or with a faulty
normal sources of supply.
detectors low in a room. Inspect the exhaust system.
detectors per the manufacturer’s
instructions.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.

Connecting the battery and the Testing live electrical circuits.
CAUTION battery charger. Hazardous voltage Hazardous voltage or current can
can cause severe injury or death. cause severe injury or death. Have
Reconnect the battery correctly, trained and qualified personnel take
positive to positive and negative to diagnostic measurements of live
negative, to avoid electrical shock and circuits. Use adequately rated test
damage to the battery charger and equipment with electrically insulated
battery(ies). Have a qualified probes and follow the instructions of the
Welding the generator set.
electrician install the battery(ies). test equipment manufacturer when
Can cause severe electrical performing voltage tests. Observe the
equipment damage. Servicing the day tank. Hazardous following precautions when performing
voltage can cause severe injury or voltage tests: (1) Remove all jewelry.
Never weld components of the death. Service the day tank electrical
generator set without first (2) Stand on a dry, approved electrically
control module (ECM) as prescribed in insulated mat. (3) Do not touch the
disconnecting the battery, controller the equipment manual. Disconnect the
wiring harness, and engine electronic enclosure or components inside the
power to the day tank before servicing. enclosure. (4) Be prepared for the
control module (ECM). Press the day tank ECM OFF system to operate automatically.
pushbutton to disconnect the power. (600 volts and under)
Grounding electrical equipment. Notice that line voltage is still present
Hazardous voltage can cause within the ECM when the POWER ON Servicing the generator set when it
severe injury or death. Electrocution light is lit. Ensure that the generator set is operating. Exposed moving parts
is possible whenever electricity is and day tank are electrically grounded. can cause severe injury or death.
present. Ensure you comply with all Do not operate the day tank when Keep hands, feet, hair, clothing, and
applicable codes and standards. standing in water or on wet ground test leads away from the belts and
Electrically ground the generator set, because these conditions increase the pulleys when the generator set is
transfer switch, and related equipment risk of electrocution. running. Replace guards, screens, and
and electrical circuits. Turn off the main covers before operating the generator
circuit breakers of all power sources Short circuits. Hazardous set.
before servicing the equipment. Never voltage/current can cause severe
contact electrical leads or appliances injury or death. Short circuits can
cause bodily injury and/or equipment WARNING
when standing in water or on wet
ground because these conditions damage. Do not contact electrical
increase the risk of electrocution. connections with tools or jewelry while
making adjustments or repairs.
Welding on the generator set. Can Remove all jewelry before servicing the
cause severe electrical equipment equipment.
damage. Before welding on the Airborne particles.
generator set perform the following Engine block heater. Hazardous
voltage can cause severe injury or Can cause severe injury or
steps: (1) Remove the battery cables,
death. The engine block heater can blindness.
negative (--) lead first. (2) Disconnect
all engine electronic control module cause electrical shock. Remove the
Wear protective goggles and clothing
(ECM) connectors. (3) Disconnect all engine block heater plug from the
when using power tools, hand tools,
generator set controller and voltage electrical outlet before working on the
or compressed air.
regulator circuit board connectors. block heater electrical connections.
(4) Disconnect the engine battery- Electrical backfeed to the utility.
charging alternator connections. Hazardous backfeed voltage can
(5) Attach the weld ground connection cause severe injury or death. Install Heavy Equipment
close to the weld location. a transfer switch in standby power
Installing the battery charger. installations to prevent the connection WARNING
Hazardous voltage can cause of standby and other sources of power.
severe injury or death. An Electrical backfeed into a utility
ungrounded battery charger may electrical system can cause severe
cause electrical shock. Connect the injury or death to utility personnel
battery charger enclosure to the ground working on power lines.
of a permanent wiring system. As an
alternative, install an equipment Unbalanced weight.
grounding conductor with circuit Improper lifting can cause severe
conductors and connect it to the injury or death and equipment
equipment grounding terminal or the damage.
lead on the battery charger. Install the
battery charger as prescribed in the Do not use lifting eyes.
equipment manual. Install the battery Lift the generator set using lifting bars
charger in compliance with local codes inserted through the lifting holes on
and ordinances. the skid.

Hot Parts Notice
WARNING NOTICE
This generator set has been
rewired from its nameplate voltage
to
Hot coolant and steam.
Before removing the pressure cap, 246242
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure. NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
WARNING the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
Hot engine and exhaust system. NOTICE

Can cause severe injury or death. Canadian installations only. For
Do not work on the generator set until standby service connect the output of
it cools. the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Servicing the exhaust system. Hot
parts can cause severe injury or NOTICE
death. Do not touch hot engine parts.
Electrostatic discharge damage.
The engine and exhaust system
Electrostatic discharge (ESD)
components become extremely hot
damages electronic circuit boards.
during operation.
Prevent electrostatic discharge
Servicing the engine heater. Hot damage by wearing an approved
parts can cause minor personal grounding wrist strap when handling
injury or property damage. Install the electronic circuit boards or integrated
heater before connecting it to power. circuits. An approved grounding wrist
Operating the heater before installation strap provides a high resistance (about
can cause burns and component 1 megohm), not a direct short, to
damage. Disconnect power to the ground.
heater and allow it to cool before
servicing the heater or nearby parts.

Notes

Introduction
This manual provides installation instructions for Read this manual and carefully follow all procedures
industrial generator sets. Operation manuals and wiring and safety precautions to ensure proper equipment
diagram manuals are available separately. operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
Some additional model-specific installation information beginning of this manual. Keep this manual with the
may be included in the respective generator set equipment for future reference.
controller operation manual.
Information in this publication represents data available

at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
TP-5700 12/07 Introduction 13

Notes
14 Service Assistance TP-5700 12/07

Section 1 General
Industrial power systems give years of dependable Your authorized generator set distributor/dealer may
service if installed using the guidelines provided in this also provide advice about or assistance with your
manual and in applicable codes. Incorrect installation installation.
can cause continuing problems. Figure 1-1 illustrates a
typical installation.
2 3
1
9 5
4
10 8
TP-5700-1
1. Exhaust thimble (for wall or ceiling) 5. Duct work for cooling air outlet 8. Electrical conduit
2. Silencer 6. Mounting base 9. Water trap with drain
3. Supports 7. Controller 10. Fresh air intake
4. Flexible sections
Figure 1-1 Typical Stationary-Duty Generator Set Installation
TP-5700 12/07 Section 1 General 15

This manual references several organizations and their These organizations provide information specifically for
codes that provide installation requirements and US installations. Installers must comply with their
guidelines such as the National Fire Protection respective national and local codes.
Association (NFPA) and Underwriter’s Laboratories Inc.
(UL). Before beginning generator set installation, record the
following data from the generator set’s specification
D NFPA 54 National Fuel Gas Code sheet and keep this data accessible for reference during
installation:
D NFPA 70 National Electrical Coder; the National
Electrical Code is a registered trademark of the NFPA D Dimensions and weight (verify dimensions and
weight using the submittal data)
D NFPA 99 Standard for Health Care Facilities
D Exhaust outlet size and maximum allowable
D NFPA 101 Life Safety Code backpressure
D NFPA 110 Emergency and Standby Power Systems D Battery CCA rating and quantity
D UL 486A--486B Wire Connectors D Fuel supply line size and fuel pressure requirement
(gas models)
D UL 486E Equipment Wiring Terminals for Use with
Aluminum and/or Copper Conductors D Air requirements
D UL 2200 Stationary Engine Generator Assemblies
16 Section 1 General TP-5700 12/07

Section 2 Loading and Transporting
The loading and transporting processes expose the Do not attach lifting hooks to the outside reinforcing
generator set to many stresses and the possibility of plate of the skid. Attach lifting hooks as shown in
improper handling. Therefore, after transporting Figure 2-1 to use the strongest portion of the
industrial generator sets: mounting skid and prevent the lifting hooks from
slipping. To raise generator sets not equipped with
D Check the alignment of the radiator and supports to skid reinforcing plates, attach lifting hooks to either
ensure that the radiator is evenly spaced from the the inside or outside of the skid.
generator and that supports are square and of even
length. Check the radiator fan for uniform alignment
and equal clearance within the radiator shroud. 2.1.2 Determining Weights
Adjust if necessary. Refer to the respective specification sheet and/or the
submittal drawing for the weight of the generator set and
D After confirming the correct alignment, tighten the
hardware to its specified torque. Reference accessories. Contact your distributor/dealer if weights
are not shown. Specification sheets typically show
Appendix C, General Torque Specifications.
weights for the following components:
D Generator set
2.1 Generator Set Lifting
D Weather housing
D Sound shield
2.1.1 General Precautions
D Subbase fuel tank
Follow these general precautions when lifting all
generator sets. When the subbase fuel tank contains fuel, use the
following formula to determine the weight of the diesel
D Do not lift the generator set using the lifting eyes fuel:
attached to the engine and/or alternator. These eyes
cannot support the generator set’s weight. Instead, Fuel in liters x 0.848 = fuel weight in kilograms
use the four holes in the mounting skid of each Fuel in gallons x 7.08 = fuel weight in pounds
generator set that are intended for attaching lifting
hooks. The placement of the holes prevents the lifting
cables from damaging the generator set components
and maintains balance during lifting. 2.1.3 Lifting Methods
The distributor/lifting contractor should choose one of
D If the lifting cables contact air cleaners, shrouds, or
the following methods to lift the generator set depending
other protruding components, use spreader bars on
upon the location circumstances and the generator set’s
the cables as outlined in subsequent sections. If the
weight and size. The hook and cable apparatus method
cables still do not clear the protruding component(s),
may not be appropriate for heavier or bulkier generator
remove the component(s).
sets; therefore, choose the lifting fixture method if there
D Generator sets above 1000 kW may have reinforcing is any doubt regarding the ability of the hook and cable
plates on the skid. See Figure 2-1. apparatus method to support the generator set’s weight
or to accommodate its size.
1
TP-5700-2
1. Reinforcing plate
Figure 2-1 Lifting Hook Placement (above 1000 kW)
TP-5700 12/07 Section 2 Loading and Transporting 17

Hook and Cable Apparatus Method
D Lift the generator set by inserting lifting hooks in the 1
skid’s lifting holes. Use an apparatus of hooks and
cables joined at a single rigging point. See Figure 2-2.
If the cables contact any component of the generator
set, use spreader bars slightly wider than the
generator set skid to avoid damage to the generator
set. Apply only vertical force to the skid while lifting.
TP-5700-2
1. Spreader bars may be necessary to protect generator set

2. Lifting bars
Figure 2-3 Generator Set with Lifting Bars in Skid
TP-5700-2
1
1. Spreader bars may be necessary to protect generator set
Figure 2-2 Generator Set with Lifting Hooks in Skid
D Lift the generator set by inserting bars that extend

through the skid’s lifting holes and then attaching
lifting hooks to the bars. See Figure 2-3. Choose
bars sized to support the weight of the generator set
and secure the lifting hooks to prevent them from
sliding off the ends of the bars. Use spreader bars if
the lifting cables contact the generator set
components.
Lifting Fixture Method

Use a lifting fixture with adjustable cables to adapt to
different size generator sets and to compensate for unit 1
imbalance. See Figure 2-4. Select equipment (cables,
chains, and bars) capable of handling the weight of the
generator set.
TP-5700-2
1. Lifting fixture
Figure 2-4 Generator Set with Lifting Fixture
18 Section 2 Loading and Transporting TP-5700 12/07

2.1.4 Lifting Subbase Fuel Tank 2.1.7 Lifting Sound Shield with Integral
Structural Steel Mounting to
The distributor and/or lifting contractor determines the
type of subbase fuel tank lifting device. Lift the subbase Generator Set Skid
fuel tank as one unit if the tank is not installed on the If the generator set has an installed sound shield that
generator set. When lifting the fuel tank, use the mounts directly to the generator set skid using structural
subbase fuel tank’s lifting eyes, if equipped; otherwise steel components, the assembly can be lifted as a unit.
use chains or cables wrapped around the subbase fuel This type of configuration typically provides a single top-
tank. If using lifting straps, protect the straps from the lifting eye for lifting the entire assembly.
sharp edges of the fuel tank.
Remove the generator set from the shipping pallet
Generator sets to 400 kW. If the fuel tank is empty and before lifting the generator set assembly using the
does not extend outside the perimeter of the generator single lifting eye.
set skid, lift the generator set and the subbase fuel tank
together. If the tank is not empty or extends outside the
perimeter of the skid, use the next procedure. 2.2 Generator Set Transporting
Generator sets 400 kW and above. Uninstall the Follow these guidelines when transporting the
subbase fuel tank by removing the mounting hardware generator set:
and wiring between the generator set and the subbase
fuel tank. Lift the generator set and subbase fuel tank D Select the transporting vehicle/trailer based on the
separately. It is not necessary to drain the fuel tank dimensions and weight of the generator set as
when lifting just the fuel tank. specified in the generator set dimension drawing or
specification sheet. Ensure that the gross weight and
overall height of the generator set and vehicle/trailer
2.1.5 Lifting Weather Housing in transport does not exceed applicable
Lift the weather housing and generator set together as transportation codes.
one unit while observing the general precautions in
D Use low boy-type trailers that meet clearance
Section 2.1.1.
requirements when transporting units larger than
1000 kW. Load large (unboxed) radiator-equipped
2.1.6 Lifting Sound Shield Installed on generator sets with the radiator facing the rear to
Mounting Base (Concrete Slab) reduce wind resistance during transit. Secure fans to
prevent fan rotation in transit.
If the generator set has an installed sound shield and
subbase fuel tank, lift the set as one unit only if the D Securely fasten the generator set to the vehicle/trailer
subbase fuel tank has lifting eyes installed, the fuel tank and cover. Even the heaviest of generator sets can
is empty, and the tank does not extend outside the move during shipment unless they are secured.
perimeter of the generator set skid. In all other cases, Fasten the generator set to the vehicle/trailer bed with
remove the sound shield. a correctly sized chain routed through the mounting
holes of the generator set skid. Use chain tighteners
Sound Shield Removal Procedure to remove slack from the mounting chain. Cover the
entire unit with a heavy-duty canvas or tarpaulin
Refer to the sound shield’s installation instructions for secured to the generator set or trailer.
general considerations and reference figures.
1. Remove the sound shield‘s attaching bolts. These

bolts may be hidden by the sound shield insulation;
if so, carefully lift the insulation near the skid to
locate the bolts.
2. Lift the sound shield by the eyebolts to remove it

from the wood skid. Use the sound shield eyebolts
to lift only the sound shield.
3. Reinstall the sound shield after installing the

generator set.
TP-5700 12/07 Section 2 Loading and Transporting 19

Notes
20 Section 2 Loading and Transporting TP-5700 12/07

Section 3 Location
3.1 Location Factors D Provide adequate protection to prevent injury in the

stub-up area. If the stub-up area opening is exposed,
Ideally, the generator set should be mounted on provide a cover or fill in the area to avoid the risk of
concrete at ground level. For above-ground installations, tripping or falling into the stub-up opening.
including roof installations, weight considerations are
especially important. The building engineer determines D Minimize the risk of public or unauthorized access.
whether the structure can support the weight of the
generator set. Outdoor Installations:
The location of the generator set must meet the D Select a location that provides adequate air flow.
following criteria. Avoid locations next to tall buildings that block normal
air flow and cause air vacuum pockets. Avoid areas
General: that are subject to high winds, excessive dust, or other
airborne contaminants. High dust areas may require
D Support the weight of the generator set and related more frequent air cleaner maintenance. High
equipment such as fuel storage tanks, batteries, temperature conditions affect generator set efficiency.
radiators, and mounting pad(s). Keep in mind that the Select a shaded area away from direct sunlight and/or
mounting pad weight may exceed the weight of the other heat-producing equipment when practical.
generator set.
D Meet applicable fire rating codes and standards. 3.2 Mounting Surface
D Position the generator set over a noncombustible Figure 3-1 shows typical mounting surface details for
surface. If the mounting surface directly under or near sizing the concrete surface beyond the generator set
the generator set is porous or deteriorates from and allowing for clearances during generator set
exposure to engine fluids, construct a containment service. Follow the dimensional details provided in
pan for spilled fuel, oil, coolant, and battery Figure 3-2, Figure 3-3, or Figure 3-4 depending upon
electrolyte. Do not allow accumulation of combustible the mounting method.
materials under the generator set.
1 2 4
D Permit vibration isolation and dampening to reduce
noise and prevent damage.
3
D Be clean, dry, and not subject to flooding. 5
D Provide easy access for service and repair. 3 6
Indoor Installations:
3
D Allow adequate ventilation with a minimum amount of TP-5700-3
ductwork. 7
1. Engine end
D Allow safe expulsion of exhaust. 2. Generator set skid
3. Extend the concrete surface a minimum of 152 mm (6 in.)
beyond the generator set
D Allow for storage of sufficient fuel to sustain 4. Battery rack
emergency operation. See the generator set 5. Allow at least 457 mm (18 in.) between the generator set
specification sheet for fuel consumption. and adjacent walls or other obstructions on all sides for
ease of servicing the generator set
6. Alternator end
D Allow for locating the fuel tank within the vertical lift
7. Mounting pad (concrete surface)
capabilities of the fuel pump and any auxiliary pumps.
See Section 6, Fuel Systems. Figure 3-1 Mounting Surface Detail (top view)
TP-5700 12/07 Section 3 Location 21

3.2.1 Single-Pad Mounting 3.2.3 Four-Pad Mounting
The manufacturer recommends a single, level concrete The four-pad arrangement shown in Figure 3-4
mounting pad as shown in Figure 3-2. This method provides more room under the engine for service than
provides maximum stability for the generator set; the previous two methods. Follow the oil draining
however, draining the oil and servicing the generator set considerations outlined in Section 3.2.1.
may require raising the set from the pad.
Use an oil drain pump if clearance below the oil drain or

extension is insufficient for a pan large enough to hold all
the engine’s oil.
TP-5700-3
Figure 3-4 Four-Pad Mounting
3.2.4 Mounting Pad Specifications

TP-5700-3
Mounting pad weight. The weight of the single

Figure 3-2 Single-Pad Mounting
mounting pad or combined weight of multiple mounting
pads should equal or exceed the combined weight of the
3.2.2 Dual-Pad Mounting generator set and attached accessories.
The two-pad arrangement shown in Figure 3-3 provides To determine the weight of the mounting pad(s),
easy access to conveniently drain the oil. Follow the oil determine the volume (length x width x height) of each
draining considerations outlined in Section 3.2.1. pad in cubic meters (cubic feet). Multiply this result by
2400 kg (150 lb.) to determine a pad’s weight. In
multiple-pad installations, add the weights of all pads to
determine the total mounting pad weight.
Mounting pad specifications. Mounting pad

composition should follow standard practice for the
required loading. Typical specifications call for 17238--
20685 kPa (2500--3000 psi) concrete reinforced with
eight-gauge wire mesh or No. 6 reinforcing bars on
305 mm (12 in.) centers.
The recommended concrete mixture by volume is

TP-5700-3
1:2:3 parts of cement, sand, and aggregate,
Figure 3-3 Dual-Pad Mounting respectively. Surround the pad with a 200--250 mm
(8--10 in.) layer of sand or gravel for proper support and
isolation of a pad located at or below grade. Anchor the
generator set to the concrete using bolts cast into the
surface of the pad. Do not use expansion-type anchors.
Note: Refer to the generator set and accessory

dimension drawings for conduit and fuel-line
placement. The drawings give dimensions for
electrical and fuel connection roughins and
stubups.
22 Section 3 Location TP-5700 12/07

3.3 Vibration Isolation
Use one of the vibration isolation types detailed in the
following paragraphs. Also, connections between the
generator set or its skid and any conduits, fuel lines, or
exhaust piping must include flexible sections to prevent
breakage and to isolate vibration. These connections
are detailed in subsequent sections.
Isolator types. The two primary types of isolators are

neoprene and spring-type. Figure 3-5 shows neoprene
isolators between the engine-generator and the skid,
referred to as integral vibration isolation mounting.
Integral vibration isolation units come from the factory GM41122
with neoprene vibration isolation. Neoprene isolators
provide 90% vibration isolation efficiency and are
sufficient for installations at or below grade.
GM39515
2 Note: Dimensions are inches; in. x 25.4 = mm
CX-272000A-C
TP-5700-3 Figure 3-6 Vibration Spring Isolators
1. To engine-generator Generator sets with integral vibration isolation.

2. Skid crossmember Skids for generator sets 20 kW and larger use I or C
3. Neoprene vibration isolator
section-fabricated steel with a width of 52--76 mm
Figure 3-5 Neoprene-Type Integral Vibration (2--3 in.) per channel. The length varies with the size of
Isolators the unit, resulting in a static load on the generator set
skid of 69--172 kPa (10--25 psi) if the total bottom
Figure 3-6 shows the spring-type isolator kit installed surface of the channel is in contact with the mounting
with direct-mounted units. Direct-mounted units have pad.
no factory vibration isolation. Spring-type isolators
provide 98% vibration efficiency, are suitable for any Generator sets with direct mounting. Larger
installation, and are required for above grade generator sets typically mount directly to a structural
installations. steel base. For these units, install the recommended
vibration isolators between the base and the mounting
pad in the holes provided. Because of the reduced
mounting surface area of these individual mounts, the
static load on the mounting surface increases to the
range of 345--690 kPa (50--100 psi).
TP-5700 12/07 Section 3 Location 23

Special requirements. If state or local codes require 3.4 Dual-Bearing Alternator
seismic or earthquake-proof mounts, or in critical
applications where the generator set is installed above Alignment
grade, it is also necessary to install spring-type vibration Generator sets equipped with dual-bearing alternators
isolators under the generator set skid. Accessory require alignment after mounting the generator set skid
vibration mounts used under formed sheet metal skids to a mounting pad. Refer to Service Bulletin SB-566 for
should equal the number of neoprene isolators and be details.
located in the skid rails vertically inline with the existing
neoprene isolators. See Figure 3-7.
1 2
GM31000
5 4 3
1. Generator set skid
2. Generator set neoprene integral vibration isolators
3. Accessory vibration mounts
4. Locate accessory vibration mounts vertically inline
5. Concrete mounting pad
Figure 3-7 Accessory Vibration Mount Location
24 Section 3 Location TP-5700 12/07

Section 4 Air and Cooling
4.1 General Ventilating fans. Some buildings tend to restrict airflow

and may cause generator set overheating. Use
Combustion and heat dissipation require an ample flow ventilating fans and/or ductwork to increase airflow in
of clean, cool air regardless of whether the generator set the building if the generator set’s cooling fan does not
is air- or liquid-cooled. Approximately 70% of the heat provide adequate cooling. See Figure 4-1. Remote
value of fuel consumed by an engine is lost through the radiator and city-water cooled models require
cooling and exhaust systems. ventilating fans. When using ductwork and ventilating
fans, check the exhaust fan capacity in m3/min. (cfm). If
Battery compartment ventilation. To prevent the using exhaust fans, install fan-operated louvers with
accumulation of explosive gases, ventilate exhaust fans to regulate airflow. See Figure 4-2. Follow
compartments containing batteries. the fan manufacturer’s recommendations to determine
the size of the inlet and outlet openings.
4.2 Air-Cooled Engines
Refer to the generator set specification sheet for air
requirements. Generally, airflow requirements do not
present a problem since air-cooled models are
designed for outside installation.
When planning outside installation, consider how

buildings and landscaping affect airflow. Also consider
seasonal changes such as snow or foliage
accumulation and potential flooding conditions. Follow
a regular maintenance routine to remove snow and
foliage accumulations.
4.3 Liquid-Cooled Engines

TP-5700-4
4.3.1 System Features
Figure 4-1 Ventilating Fan
Generator sets designed for interior installation feature
liquid cooling systems. The three most common liquid
cooling systems are unit-mounted radiator, remote
radiator, and city-water cooling. Observe the common
installation considerations outlined below as well as the
installation considerations for your generator set’s
cooling system as detailed in subsequent sections.
4.3.2 Installation Considerations

Intake and outlet openings. Provide air intake and air
outlet openings for generator sets located in a building
or enclosure. Keep air inlets and outlets clean and
unobstructed. Position the air inlet into the prevailing
wind and the air outlet in the opposite direction.
TP-5700-4
Figure 4-2 Exhaust Fan-Operated Louvers
TP-5700 12/07 Section 4 Air and Cooling 25

Thermostatically-controlled louvers. Do not allow Electric louvers are usually connected to the optional
uncontrolled recirculation of air within an enclosure. generator set run relay. Typically, the louvers are
The ventilation system must provide a temperature energized to open when the generator set is operating.
differential sufficient to prevent high engine temperature However, some louvers are energized to close and
shutdown on even the hottest days. when deenergized are spring-actuated to open when
the generator set is operating.
In areas of great temperature variation, install movable
louvers to thermostatically regulate airflow and room Filters. Install a furnace-type or similar filter in the inlet
temperature. See Figure 4-3 and Figure 4-4. Refer to opening if the generator set operates in an atmosphere
4.4.2, Installation Considerations, Louver use for further highly contaminated with impurities such as dust and
information. chaff.
Air restrictions. When using a filter, screen, or other air

restriction, increase the inlet opening size by the
following amounts to compensate for diminished
airflow:
D Louvers: Enlarge the opening 50%.
D Window screening: Enlarge the opening 80%.
D Furnace-type filters: Enlarge the opening 120%.
4.3.3 Recommended Coolant

All applications require antifreeze/coolant protection.
Add antifreeze/coolant before starting the generator set
TP-5700-4 or energizing the block heater(s). Most diesel engine
Figure 4-3 Stationary Air Inlet Louvers manufacturers require the use of an inhibitor additive to
the antifreeze/coolant.
Use a proper mixture of glycol (ethylene, propylene, or

extended life organic acid), water, and supplemental
coolant additive (SCA). The antifreeze/coolant and
additive mixture reduces corrosion, sludge formation,
and cavitation erosion and provides boil and freeze
protection.
The generator set manufacturer recommends a solution

of 50% ethylene glycol and 50% clean, softened water to
provide freezing protection to --37_C (--34_F) and
boiling protection to 129_C (256_F). A 50/50 solution
also inhibits corrosion.
Refer to the engine manufacturer’s operation manual for

engine antifreeze/coolant specifications, concentration
TP-5700-4 levels, and inhibitor selection recommendations.
Figure 4-4 Moveable Air Inlet Louvers
In cold climate interior installations using controlled

recirculation to recover heat, install thermostatically
activated louvers and fans to prevent the generator set
and engine room from overheating.
26 Section 4 Air and Cooling TP-5700 12/07

4.4 Unit-Mounted Radiator Cooling Avoid suction fan use. The alternator airflow should
move in the same direction as the engine’s standard
The unit-mounted radiator is the most common cooling pusher fan. Using a suction fan to reverse airflow is not
system for engine-driven generator sets 20 kW and recommended because it may interfere with the
larger. alternator cooling airflow. This in turn reduces the
maximum engine power available because higher
temperature combustion air is drawn into the air cleaner.
4.4.1 System Features
The system’s major components include an engine- Use ductwork to direct airflow. Direct the radiator air
outside the room or enclosure using sheet metal
driven fan and circulating water pump, a radiator, and a
thermostat. The pump circulates water through the ductwork with structural supports. Keep ductwork as
engine until it reaches operating temperature. Then the short, straight, and unobstructed as possible.
Combined static pressure restrictions greater than
engine thermostat opens, allowing water circulation
through the radiator. The thermostat restricts water flow 0.12 kPa or 13 mm (0.5 in.) water column on the radiator
inlet and outlet openings cause reduced airflow and
as necessary to prevent overcooling. The fan blows air
contribute to overheating especially in high ambient air
from the engine side of the radiator across the cooling
surface. temperatures. Use heavy canvas, silicone rubber, or
similar flexible material for the connection between the
radiator duct flange and the ductwork to reduce noise
4.4.2 Installation Considerations and vibration transmission.
Figure 4-5 shows a typical unit-mounted radiator Outlet and inlet location and sizing. Size the outlet
installation. Note the direction of airflow and refer to the duct area 150% larger than the radiator duct flange
figure as needed during installation. area. Size the inlet air opening at least as large but
preferably 50% larger than the outlet.
1
If screens, louvers, or filters are used on either the inlet
or outlet, increase the inlet or outlet size according to the
2 recommendations given in Section 4.3.2, Installation
Considerations.
3
Since the exhaust air of larger units is both high volume
and high velocity, direct the exhaust flow away from
areas occupied by people or animals.
TP-5700-4
6 5 4
1. Air inlet opening
2. Ductwork mounting flange
3. Air outlet duct
4. Support legs
5. Flexible section with radiator duct flange
6. Pusher fan
Figure 4-5 Radiator-Cooled Generator Set

Installation

Louver use. Design temperature-controlling louvers to In order to assess a remote radiator cooling system, the
prevent air inlet restrictions and air pressure reductions cooling system designer needs the following data. From
inside the building. Low building pressure can the respective generator set specification sheet, obtain
extinguish pilot lights on gas-fired appliances or cause the:
problems with the building ventilation system.
D Engine jacket water flow, Lpm (gpm)
Additionally, bringing large quantities of winter air into a
building wastes building heat and risks frozen water D Cooling air required for generator set based on 14°C
pipes in normally heated spaces. Use dampers and (25°F) rise and an ambient temperature of 29°C
controlled air outlet louvers as shown in Figure 4-6 to (85°F), m3/min. (cfm)
eliminate these problems and allow recovery of engine
heat to reduce building heat loss. Close the louvers to D Maximum static (vertical) head allowable above
the exterior and open the interior louvers when the engine, kPa (ft. H2O)
outdoor temperature is below 18°C--21°C (65°F--70°F).
From the engine and/or radiator data sheet, obtain the:
Reverse the louver settings when the outdoor
temperature is above 21°C--24°C (70°F--75°F). D Maximum water pump inlet restriction kPa (psi)
D Maximum allowable coolant pressure differential

1 2 3 4
external to engine kPa (psi)
The following subsections provide general design

guidelines for a remote radiator system.
4.5.1 General
6
TP-5700-4
System limitations. Cooling systems are limited by
5 radiator cap ratings. The maximum radiator operating
1. Exterior 4. Generator set pressure is 138 kPa (20 psi) and the maximum
2. Interior 5. Dampers operating temperature is 121°C (250°F). Radiators are
3. Air outlet duct 6. Controlled air outlet louvers available for vertical or horizontal discharge. See
Figure 4-7 and Figure 4-8.
Figure 4-6 Air Control Louvers
Air requirements. Refer to the generator set
specification sheet for radiator air and engine/alternator
4.5 Remote Radiator Cooling air requirements. Cooling air required for generator sets
A remote radiator system allows installation of equipped with a remote radiator is based on a 14°C
generator sets in locations where it would otherwise be (25°F) rise and an ambient temperature of 29°C (85°F).
difficult to bring the volume of air required to cool a unit- The amount of air required to ventilate the generator set
mounted radiator. In these systems, the engine water room or enclosure determines the size of the air inlet and
pump pushes coolant through a radiator mounted outlet. Configure the ventilation air inlet and outlet so
remotely from the generator set and, typically, in an that air flows across the generator set.
open area. An electric motor-driven fan mounted on the
Use a ventilating fan, if necessary, to dissipate alternator
radiator circulates air across the radiator’s cooling fins.
and engine heat loss.
Note: All remote radiators are sized for mounting in an

open area with no additional external devices
attached. Attached devices, confined installation,
louvers, dampers, ductwork, or other inlet or
outlet air restriction require resizing the radiator
to compensate for reduced airflow.

2 3 4 5
6
1
8
9
14
13
12 10
TT11863
11
1. Remote vertical radiator 8. Engine outlet
2. Pressure cap 9. Engine water pump
3. Surge tank/expansion tank 10. Suction side
4. Radiator inlet 11. Fill/drain (lowest point of engine
5. Fill line 12. Shutoff valve
6. Vent line 13. Radiator outlet
7. Shutoff Valve 14. Maximum allowable static (vertical) head (varies with engine)
Figure 4-7 Remote Vertical Radiator System
7 8
1 2 3 4 5 6
9
TT11864
12
11 10
1. Radiator inlet 5. Radiator outlet 8. Shutoff valve 11. Fill/drain (lowest point of
2. Pressure cap 6. Vent line(s) 9. Engine outlet engine)
3. Surge tank/expansion tank 7. Fill line 10. Engine inlet 12. Shutoff valve
4. Horizontal radiator
Figure 4-8 Remote Horizontal Radiator System

Static (vertical) head. If the vertical distance from the Note: The water in the hot well tank drains into the
engine water pump to the radiator (known as static radiator when the generator set is not running.
head) is within the engine manufacturer’s
recommendations, and the pressure drop through the Note: Determine the size requirements of the remote
piping and remote radiator does not exceed the engine radiator and hot well tank/heat exchanger for
manufacturer’s limits, use the engine water pump to each application. Do not use a standard remote
circulate water through the remote radiator. The radiator with a hot well tank/heat exchanger.
allowable static head ranges from 5.2 m--15.2 m
(17 ft.--50 ft.) and is listed on the generator set 4.5.2 Vent Lines
specification sheet. Exceeding the allowable static head
causes excessive pressure on engine components Route the vent lines at a continuous upward slope from
resulting in problems such as leaking water pump seals. the engine connection exit to the expansion tank. Port
all vent lines individually into the expansion tank above
Note: Size the pressure relief valve or cap to remain the coolant level.
under the engine pressure limit.
Locate the vent lines in the expansion tank to prevent
Hot well tank/heat exchanger. When the static splash on the coolant level sensor. Thoroughly vent the
(vertical) head exceeds the distance stated in the systems by installing vent lines to all the vent points on
specification sheet, use a hot well tank or heat the engine and the charge air cooler circuits including
exchanger and auxiliary circulating pump as shown in the radiator core. Refer to the installation drawings for
Figure 4-9 or Figure 4-10. Always wire the circulating vent points.
pump in parallel with the remote radiator fan so that both
operate whenever the generator set operates. Size the vent line the same as the connection point on
the engine. The vent lines may be slightly larger;
A partial baffle divides a hot well tank into two or more however, vent lines sized too large will increase fill line
compartments. The engine pump forces heated water flow and possibly reduce head pressure applied to the
into the hot side, and the auxiliary pump then draws the engine water pump inlets.
water off and forces it into the radiator. After circulating
through the radiator, coolant drains back to the cold side
of the well where the engine water pump removes it. A
hot well or heat exchanger also isolates head pressures
from the engine.

1
5 6
7
4
8
3
12
11
10 TT11865
1. Vacuum relief check valve 5. High volume breather 9. Generator set
2. Remote radiator 6. Expansion space 10. Fill/drain (lowest point of engine)
3. Auxiliary water pump 7. Vent line(s) 11. Shutoff valve
4. Baffles 8. Shutoff valve 12. Hot well tank
Figure 4-9 Compound Remote Radiator/Hot Well Tank Cooling System
3 4 5
2
6
10
11 9
12 TT11865
1. Expansion/surge tank 5. Vent line(s) 9. Fill/drain (lowest point of engine)

2. Remote radiator 6. Fill line 10. Shutoff valve
3. Vent line 7. Shutoff valve 11. Heat exchanger
4. Expansion/surge tank 8. Generator set 12. Auxiliary water pump
Figure 4-10 Compound Remote Radiator/Heat Exchanger Cooling System

4.5.3 Fill Lines (Balance or Static) 4.5.5 Installation Considerations
Connect the fill line(s) to the bottom of the expansion When installing the remote radiator:
tank. Make the lines as short as possible, continuously
descending, and connected directly before the engine D Use a remote radiator setup kit to aid installation. See
water pump(s). To provide a positive head pressure to Figure 4-11.
the engine water pump inlet, properly locate the fill line
(or makeup line). See the installation drawings for the fill D Wire the cooling fan motor to the generator set output
line connection points. so that the fan operates whenever the generator set
operates. There is no need for a thermostatic control
Connect the vent and fill lines to the expansion tank at of the fan motor because the engine thermostat
the greatest possible distance from each other to prevents overcooling as it does on generator set-
prevent aeration and preheating of the coolant returning mounted radiator systems. Follow all applicable
down the fill line. national and local codes when wiring the cooling fan.
The minimum fill line sizes cannot be smaller than the D Follow the wiring diagram on the remote radiator’s
connection point on the engine. Do not allow fittings on fan motor. The motor rotation must match the fan
the fill lines to reduce the effective size. If other cooling blade design. The manufacturer supplies most units
system components vent too much coolant to the with counterclockwise fan rotation as viewed from
expansion tank, larger diameter fill lines may be motor side. The fan is a blower type, moving air from
needed. the fan side of the radiator, through the core, and out
the front side.
4.5.4 Location Considerations D Preferably, connect no devices to either side of the

radiator. Resize the radiator if adding louvers or duct
When choosing the radiator’s location:
work to the radiator to compensate for reduced
D For economical installation and operation, locate the
airflow.
radiator as close as practical to the engine and at the D Ensure that the radiator is level and securely bolted to
same elevation to reduce piping, coolant, and wiring
a firm, solid foundation.
costs.
D Brace the radiator as needed, especially in areas with
D Locate the radiator surge tank fill opening and vent
strong winds.
line(s) at the highest point in the cooling system.
D Use isolators to keep area vibration from affecting the
D Position the radiator no closer than one fan diameter
radiator or to keep vibration produced by the radiator
from a wall, another radiator, or any other obstruction from affecting surrounding areas.
that would restrict air movement and future service
access. D Use hose clamps on all nonthreaded connections.
D Locate the radiator to prevent recirculation of the

heated exhaust air back into the intake stream.
D Mount the radiator in an area where prevailing winds

do not hamper free airflow.
D Locate the radiator where it is not subject to deep

snow or ice accumulation, flooding, industrial fallout,
leaf accumulation, heavy dust and chaff, or other
detrimental seasonal or environmental conditions.
D For rooftop installations, do not locate the radiator

near critical sound areas, building ventilation, or hood
exhausts.

1
2
10 9
3
4
GJ-273000-B
1. Drain valve 5. Front belt guard 8. Top belt guard
2. Belt guard bracket 6. Bottom belt guard 9. Upper radiator hose outlet
3. Right-hand belt guard 7. Lower radiator hose inlet 10. Top mounting bracket
4. Left-hand belt guard
Figure 4-11 Remote Radiator Setup Kit, Typical
4.5.6 Surge (Expansion) Tank for Use piping of ample size and with as few short sweep
Horizontal Discharge Radiator bends or elbows, tees, and couplings as possible. Use
long sweep elbows or long bends, if bends are required.
A horizontal discharge remote radiator requires the use
of a surge (expansion) tank as shown in Figure 4-8. Installation. Support piping externally, not from the
Locate the tank at the highest point in the cooling radiator or engine.
system. The surge tank provides venting, surge/
expansion protection, and filling/makeup functions. On standard remote radiators, connect radiator bottom
outlets only to the suction side of the pump. Plumb the
D Equip the surge tank with a sight-glass gauge, lines to prevent air from becoming trapped in the lines.
overflow tube, and pressure cap. Route piping in one general direction, either upward or
downward. A combination of both upward and
D Size the surge tank to handle at least 6%--10% of the
downward piping creates air pockets in the piping.
total cooling system volume. Follow the engine Route vent lines to the expansion/surge tank without
manufacturer’s recommendation when available. creating low spots in the lines.
D Connect the main line from the surge tank to the
Flexible connections. Provide flexible connections
highest point of the remote radiator. Most vertical when connecting piping to the radiator assembly. Use
core radiators have the surge tank as part of the hose clamps at all nonthreaded connections.
radiator top tank. The setup illustrated in Figure 4-8
provides for radiator and engine deaeration and a Shutoff valves. Locate shutoff valves between the
positive pressure at the pump suction inlet. engine and cooling system to allow for isolation of both
the radiator and the engine. A shutoff valve eliminates
D Use a strainer to filter dirt, scale, and core sand from
the need to drain the entire cooling system during
the coolant line. service.
Piping. Size water piping between the engine and the
remote radiator large enough to eliminate the need for a
booster pump. If the cooling system requires a booster
pump, contact your distributor/dealer.
4.5.7 Procedure to Fill with Deaeration 4.5.9 Checks after Initial Startup
For radiators designed for full deaeration, fill the radiator If any problems arise during startup, immediately shut
according to the following procedure. down the generator set. See Figure 4-12, Cooling
System Checklist. Even after a successful startup, shut
1. Fill the cooling system from the bottom when down the generator set after 5--10 minutes and recheck
possible. Otherwise, fill the radiator at the filler the belt tension to make sure no hardware has loosened
neck. during operation. Perform another recheck after
8--12 hours of operation.
2. Next, fill the radiator through one of the top tank or
expansion/surge tank inlets located before the final n Operation
hose connection.
Verify the cooling fan’s position in the fan shroud.
3. Continue filling the system to cover the filler neck Check the mounting hardware.
bottom until coolant appears in the sight glass Check the fan motor for free rotation.
located in the radiator top tank.
Check V-belts for alignment and tension.
4. Check and correct any leaks in the system. Fill the system with coolant and check all connections for
tightness and leaks.
4.5.8 Procedure to Fill without Verify that all electrical connections are secure and that the
power source matches the motor nameplate.
Deaeration
Verify that no loose foreign material is in the fan’s air stream.
For radiators designed without deaeration, fill the With the unit running, check for:
radiator according to the following procedure.
fan clearance
1. Initially, fill the radiator through one of the top tank excessive vibration
inlets located before the final hose connection for excessive noise
faster and more complete fillup.
coolant leaks
2. Fill the cooling system from the bottom when Figure 4-12 Cooling System Checklist
possible. Otherwise, fill the radiator at the filler
neck with coolant covering the filler neck bottom
until coolant appears in the sight glass located in
the radiator top tank.
3. Check for and correct any leaks in the system.

4.6 City Water Cooling 4.6.2 Installation Considerations
Vibration isolation requirements. Water inlet and
4.6.1 System Features outlet connections are mounted on the generator set
skid and isolated from engine vibration by flexible
City water-cooling systems use city water and a heat
sections. If the generator set is vibration-mounted to the
exchanger for cooling. They are similar to remote skid and the skid is bolted directly to the mounting base,
radiator systems because they require less cooling air no additional flexible sections are needed between
than unit-mounted radiator systems. Figure 4-13 shows
connection points on the skid and city water lines. If the
some of the elements of a typical installation. generator set skid is mounted to the base with vibration
The heat exchanger limits the adverse effects of city isolators, use flexible sections between the connection
water chemistry to one side of a heat exchanger, which points on the skid and city water lines.
is relatively easy to clean or replace, while engine Shutoff valve location. A solenoid valve mounted at
coolant circulates in a closed system similar to the
the inlet connection point automatically opens when the
radiator system. The heat exchanger allows engine generator set starts, providing the engine cooling
temperature control, permits the use of antifreeze and system with pressurized water from city water mains.
coolant conditioners, and is suited to the use of an
This valve automatically closes when the unit shuts
engine block heater as a starting aid. down. Use an additional customer-supplied valve
ahead of the entire system to manually shut off city water
for generator set service.
1 2
6
5
7
Side View End View 10 8

11 9
HC-273000-E/TP-5700-4
1. Coolant expansion tank 7. City water supply
2. Coolant expansion tank pressure cap 8. Heated city water into floor drain
3. Ventilation fan (for heat rejected from exhaust and engine) 9. Connect heat exchanger outlet to floor drain
4. Connect heat exchanger inlet to city water supply 10. Heat exchanger
5. Flexible section 11. Solenoid valve
6. Manual shutoff valve
Figure 4-13 City-Water Cooling System with Heat Exchanger

4.7 Cooling Tower The engine cooling system circulates coolant through
the heat exchanger outer shell. Raw water circulates
A cooling tower system is a variation of a city water through the heat exchanger tubes absorbing heat from
cooling with heat exchanger system. In warm, dry the engine coolant. The heated raw water flows into a
climates, a cooling tower is a suitable source of pipe at the top of the cooling tower and sprays down into
generator set cooling water. the tower to cool by evaporation. Because some water
is constantly being lost through evaporation, the system
A cooling tower system consists of the engine cooling must provide makeup water.
system plus a raw-water system. The engine cooling
system usually includes the engine water pump, a heat
exchanger, a surge tank, and the engine water jacket.
The raw-water system consists of the cooling tower, a
raw-water pump, and the tube portion of the heat
exchanger. A typical system is shown in Figure 4-14.
4
3
1 2
TP-5700-4
8 7 6 5
1. Engine water pump 3. Cooling tower 5. Cooling tower drain 7. Heat exchanger
2. Surge tank 4. Makeup water connection 6. Heat exchanger drain 8. Auxiliary water pump
Figure 4-14 Cooling Tower System
4.8 Block Heaters The block heater thermostat is set to 43°C (110°F) on all
generator sets models except the 1750/2000REOZMB.
Block heaters are available as installed accessories on The 1750/2000REOZMB models have a thermostat
all generator sets. Generator sets installed in NFPA setting of 50°C (122°F) for optimum operation. This
applications generally require use of a block heater. adjustment is made by removing the thermostat cap.
Equip generator sets with block heaters on all standby
applications where the generator set is subject to Note: Block heater damage. The block heater will fail
temperatures below 0--20°C (32--68°F). See the if the energized heater element is not immersed
respective generator set spec sheet for specific in coolant. Fill the cooling system before turning
temperature recommendations. Connect the block on the block heater. Run the engine until it is
heater to a power source that is energized when the warm and refill the radiator to purge the air from
generator set is not running. the system before energizing the block heater.

Section 5 Exhaust System
Satisfactory generator set performance requires proper The flexible line limits stress on the engine exhaust
exhaust system installation. Figure 5-1 and Figure 5-2 manifold or turbocharger. Never allow the engine
show typical arrangements of recommended exhaust manifold or turbocharger to support the silencer or
systems. The following sections detail exhaust system exhausting piping.
components.
Note: Do not bend the flexible section or use it to
compensate for misalignment between the
5.1 Flexible Exhaust Line engine exhaust and the exhaust piping.
Install a section of seamless stainless steel flexible When using threaded flexible exhaust connectors,
exhaust line at least 305 mm (12 in.) long within 610 mm place a 152--203 mm (6--8 in.) length of pipe between
(2 ft.) of the engine exhaust outlet. See Figure 5-1 and the flexible exhaust connectors and the exhaust
Figure 5-2. manifold. See Figure 5-1. The pipe reduces the
temperature of the flexible connection, simplifies flexible
1 section removal, and reduces strain on the engine
exhaust manifold.
4 3 2
5.2 Condensation Trap
5 Some silencers are equipped with a drain pipe plug for
6 draining condensation; see Figure 5-3. Otherwise,
install a wye- or tee-type condensation trap with a drain
7 plug or petcock between the engine and the exhaust
silencer as shown in Figure 5-4. The trap prevents
8 TP-5700-5 condensed moisture in the engine exhaust from
draining into the engine after shutdown. Periodically
1. Supports 5. Drain petcock
drain collected moisture from the trap.
2. Pitch line downward 6. Flexible section
3. Silencer 7. Solid section 152--203 mm (6--8 in.)
4. Water trap 8. Manifold
Figure 5-1 Exhaust System, End Inlet Silencer
2 1
1. Pipe Plug TP-5700-5
9 3
Figure 5-3 Silencer Condensation Drain Plug
4
5
6
7
8
TP-5700-5
1. Exhaust wall thimble 6. Outer diameter adapter and clamp 1

2. Silencer 7. Flexible section
3. 45° Y fitting 8. Manifold
4. Water trap 9. 45° elbow
5. Drain petcock
1. Condensation trap TP-5700-5
Figure 5-2 Exhaust System, Side Inlet Silencer

Figure 5-4 Condensation Trap
TP-5700 12/07 Section 5 Exhaust System 37

5.3 Piping
2
1
Note: Select piping with a diameter that is the same size
as, or larger than, the manifold outlet’s inside
6
diameter.
3
D Keep exhaust lines as short and straight as possible.
9
D Use schedule 40 black-iron pipe.
8 4
D Use sweep elbows with a radius of at least three times
the pipe diameter.
7
D Use exhaust piping that conforms to applicable
codes.
6 5
D Support the exhaust piping securely, allowing for
thermal expansion.
D Insulate the exhaust piping with high-temperature 11

10
insulation to reduce the heat rejected by exhaust
piping and consequently the amount of ventilating air
required. 15
In general, exhaust temperatures measured at the 12

engine’s exhaust outlet are less than 538°C (1000°F),
except for infrequent brief periods; therefore, low-heat
appliance standards apply. Each generator set 14 13
specification sheet provides exhaust temperatures.
For units with exhaust temperatures below 538_C TP-5700-5
(1000_F), route the exhaust piping a minimum of

457 mm (18 in.) from combustible material, including
1. Rain cap (or gradual U bend)
building materials and natural surroundings. If exhaust 2. Rain shield
temperatures exceed 538_C (1000_F), the minimum 3. 254 mm (10 in.) minimum
distance is 914 mm (36 in.). 4. 25 mm (1 in.) minimum
5. Exhaust pipe
When planning exhaust silencer and piping placement, 6. Ventilation holes at both ends
7. 254 mm (10 in.) minimum
consider the location of combustible materials. If the 8. 25 mm (1 in.) minimum
proximity of the exhaust system to the combustible 9. Flashing
materials cannot be avoided, follow a regular 10. Inner sleeve
maintenance schedule to ensure that combustible 11. Outer sleeve
12. Thimble outer diameter
materials are kept away from the exhaust pipes after 13. 254 mm (10 in.) minimum outside
installation. Combustible materials include building 14. 254 mm (10 in.) minimum inside
materials as well as natural surroundings. Keep dry field 15. Exhaust pipe diameter
grass, foliage, and combustible landscaping material a
safe distance from the exhaust system. Figure 5-5 Double-Sleeved Thimbles and Rain Cap
Construct the thimble so it extends at least 254 mm

5.4 Double-Sleeved Thimbles (10 in.) both inside and outside the structure’s surface.
Openings at both ends of the thimble allow cooling air to
If the exhaust pipe passes through a wall or roof, use a circulate through the thimble. If screening is used on the
double-sleeved exhaust thimble to prevent the outer end to keep birds and animals from entering the
transmission of exhaust pipe heat to the combustible thimble, use a mesh large enough to allow unrestricted
material. Figure 5-5 shows construction details of a air circulation through the thimble. See Section 5.5 for
typical double-sleeved thimble in which exhaust piping additional exhaust outlet location and protection
passes through a combustible structure. Sheet metal considerations.
shops usually fabricate thimbles using installation
engineer’s specifications and drawings.
38 Section 5 Exhaust System TP-5700 12/07

5.5 Exhaust Outlet Exhaust System Backpressure Calculation
Procedure
Outlet location. Engine performance and efficiency
depend on the location of the exhaust outlet. Direct the Determine the total backpressure by calculating the
exhaust outlet away from the air inlet to prevent exhaust effects of the individual exhaust system components
gases from entering the air inlet and clogging the dry- and adding the results. Make calculations using either
type air filter elements. Hot exhaust drawn through the English or metric units. Exhaust pipe references are
radiator adversely affects engine cooling. Locate the nominal pipe NPT (in.) sizes. The procedure shows an
exhaust outlet to prevent exhaust fumes from entering a example with italic text. Calculations relate to end inlet
building or enclosure. silencers.
Noise reduction. The exhaust outlet configuration Note: When calculating backpressure drop for side inlet
affects the apparent noise level for people or animals in silencers, use the end inlet values shown and add
the vicinity. An upward-directed outlet seems quieter 0.75 kPa (0.25 in. of mercury or 3.4 in. of water) to
than one directed downward or horizontally. backpressure calculations.
Additionally, a 30- to 45-degree angled cut at the end of
1. Select the exhaust silencer type for the
a horizontal exhaust outlet pipe reduces turbulence at
application—hospital, critical, residential, or
the outlet, thereby reducing the noise level.
industrial. See the silencer specification sheet for
Rain cap. To prevent precipitation from entering the definitions for each exhaust silencer type. Confirm
exhaust pipe, install a rain cap on vertical outlets. See silencer type availability for your generator set with
Figure 5-5. In a climate where freezing is common, do your authorized distributor/dealer, as some
not use a rain cap. Instead, extend the exhaust piping at generator sets do not use all four types.
least 610 mm (24 in.) beyond the roof line and create a
Example: Determine the silencer backpressure for
gradual U bend at the end to direct the exhaust outlet
the recommended critical silencer on a 230 kW,
downward. Keep the pipe outlet at least 457 mm (18 in.)
60 Hz diesel generator set.
from the roof to prevent hot exhaust from igniting the
roof material. 2. Refer to the generator set specification sheet for:
Note: Do not use a rain cap in areas subject to freezing a. Engine exhaust flow at rated kW in m3/min.
temperatures. (cfm)
Example: 57.5 m 3/min. (2030 cfm)
5.6 Exhaust System Backpressure
b. Maximum allowable backpressure in kPa (in. of
Exhaust backpressure limits engine power and Hg)
excessive backpressure causes serious engine Example: 10.2 kPa (3.0 in. Hg)
damage. Excessive backpressure usually results from
one or more of the following reasons: 3. Refer to the submittal catalog for:
D The exhaust pipe diameter is too small. a. The recommended critical silencer part number
D The exhaust pipe is too long. Example: 343616
D The exhaust system has too many sharp bends.
b. Silencer inlet diameter in mm (in.)
D The exhaust silencer is too small.
Example: 152 mm (6 in.)
D The exhaust silencer is not the correct design for the
application. c. Silencer inlet position (end or side)
Example: end inlet
Use the following procedure to verify that the installed
exhaust system does not exceed the engine’s maximum d. The flexible exhaust adapter part number
exhaust backpressure limit as specified in the generator Example: 343605
set specification sheet.
e. Flexible exhaust adapter, flexible section length
Example: 857 mm (33.75 in.)

4. Determine the exhaust gas velocity through the Note: When calculating backpressure drop for
silencer as follows: side inlet silencers, use the end inlet values
shown and add 0.75 kPa (0.25 in. of
a. Using the exhaust silencer inlet diameter mercury or 3.4 in. of water) to backpressure
determined in step 3, determine corresponding calculations.
inlet area using Figure 5-6.
Note: Refer to Figure 5-8 to calculate in inches of
Example: 0.0187m 2 (0.201 sq. ft.)
water and feet per minute.
b. Use this data to calculate the exhaust gas
velocity. Divide the engine exhaust flow from 6. Total the number of elbows and flexible sections in
the exhaust system between the engine and the
step 2 in m3/min. (cfm) by the silencer inlet area
m2 (sq. ft.) to get flow velocity in m (ft.) per exhaust system outlet. Compare the radius of the
minute. bend (R) to the pipe diameter where (D) is the
nominal pipe diameter in inches. Determine the
Example: equivalent length in m (ft.) of straight pipe for the
57.5 m 3/min. / 0.0187 m 2 = 3075 m/min. elbows and flexible sections from the following:
(2030 cfm / 0.201 sq. ft. = 10100 ft./min.)
Bend Bend
Nominal Pipe Size, Angle Type Radius Conversion Factor
in. NPT Inlet Area, m2 Inlet Area, ft2 90° Close R=D 32 x D* / 12
1 0.00056 0.0060 90° Medium R = 2D 10 x D* / 12
1 1/4 0.00097 0.0104
90° Sweep R = 4D 8 x D* / 12
1 1/2 0.00131 0.0141
45° Close R=D 15 x D* / 12
2 0.00216 0.0233
45° Sweep R = 4D 9 x D* / 12
2 1/2 0.00308 0.0332
3 0.00477 0.0513 Flex Sections 2 x Length[ / 12
4 0.00821 0.0884 * Use the diameter of the silencer inlet in inches from
step 3 for the initial calculation. If the results from step 9
5 0.0129 0.139
indicate excessive backpressure drop, then recalculate
6 0.0187 0.201 using the larger-diameter pipe size selected.
8 0.0322 0.347 [ Use the flexible exhaust adapter length from step 3 and
10 0.0509 0.548 add any additional flex sections in the exhaust system
expressed in inches.
12 0.0722 0.777
14 0.0872 0.939
Convert the equivalent pipe length calculated in
16 0.1140 1.227 feet to meters using ft. x 0.305 = m, as needed.
18 0.1442 1.553
Examples:
Figure 5-6 Cross Sectional Area for Standard
Silencer Sizes 45_ sweep elbows:
9 x 6.0 in. / 12 = 4.5 equiv. ft. or 1.4 equiv. m
5. Refer to Figure 5-7. Use the exhaust gas velocity
determined in step 4 and find the exhaust gas 90_ close elbows:
velocity value in thousands on the bottom scale. 32 x 6.0 in. / 12 = 16.0 equiv. ft. or 4.9 equiv. m
Move vertically up until this value intersects the
curve of the corresponding silencer type as Flexible sections:
determined in step 1. Move left on the horizontal 2 x 33.75 in. / 12 = 5.6 equiv. ft. or 1.7 equiv. m
axis and determine the backpressure drop value in
kPa (in. of Hg). Equivalent of straight pipe:
4.5 + 16.0 + 5.6 = 26.1 equiv. straight ft.
Example: Exhaust velocity, 3075 m/min. (10100 ft./ 1.4 + 4.9 + 1.7 = 8.0 equiv. straight m
min.) intersects with critical silencer curve B and
the corresponding backpressure value is
approximately 2.8 kPa (0.85 in. of mercury).
Silencer type is end inlet from step 3 information
with no additional backpressure drop value per the
following note.

kPa in. of Hg
A B
6.4 1.9
6.1 1.8
5.8 1.7
C
5.4 1.6
5.1 1.5
4.7 1.4
D
4.4 1.3
4.1 1.2
3.7 1.1
Pressure
3.4 1.0
Drop
3.0 0.9
2.7 0.8
2.4 0.7
2.0 0.6
1.7 0.5
1.4 0.4
1.0 0.3
0.7 0.2
0.3 0.1
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.1 3.4 3.6 4.0 4.3 5.8 4.9 (m/min.)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 (ft./min.)
Exhaust Gas Velocity in Thousands
A = Hospital Silencer
B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer
Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa
(0.25 in. of mercury or 3.4 in. of water) to the backpressure.
Figure 5-7 Silencer Backpressure Drop (in. of Hg)

mm of Water in. of Water
A B
660.4 26
609.6 24
558.8 22
508.0 20 C
457.2 18
406.4 16
Pressure D
Drop 355.6 14
304.8 12
254.0 10
203.2 8
152.4 6
101.6 4
50.8 2
0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.1 3.4 3.6 4.0 4.3 (m/min.)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (ft./min.)
Exhaust Gas Velocity in Thousands
A = Hospital Silencer
B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer
Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa
(86 mm of water or 3.4 in. of water) to the backpressure.
Figure 5-8 Silencer Backpressure Drop (in. of water)

7. Determine the total length of straight pipe used in 9. Add the backpressure of the piping determined in
the exhaust system. Add this calculation to the step 8 to the backpressure of the silencer
equivalent length for elbows and flexible sections determined in step 5. The total should not exceed
obtained in step 6. the engine manufacturer’s maximum allowable
Example: system backpressure determined in step 2 or on
the generator set’s specification sheet. If the total
Straight pipe = 3.0 m (10 ft.). exceeds the maximum, use a larger pipe size or
Equivalent straight pipe from step 6: 8.0 m (26.1 ft.) silencer or both. Repeat the calculation if new
components are selected to verify that the system
3.0 m + 8.0 m = 11.0 m or backpressure would not exceed the limit using the
10 ft. + 26.1 ft. = 36.1 ft. total larger component(s).
Example:
8. Refer to Figure 5-9 if the pipe size is 102 mm (4 in.)
or less or Figure 5-10 if the pipe size is 127 mm 0.4 kPa (step 8) + 2.8 kPa (step 5) = 3.2 kPa
(5 in.) or larger. Maximum allowable backpressure = 10.2 kPa
3.2<10.2 backpressure drop is acceptable
Place a straight edge across the chart with the
edge in line with the pipe size in inches (D) on the 0.14 in. Hg. (step 8) + 0.85 in. Hg. (step 5) =
right column from step 3 and the engine exhaust 0.99 in. Hg.
flow (Q) from step 2 on the left column. Maximum allowable backpressure = 3.0 in. of Hg.
0.99< 3.0 backpressure drop is acceptable
Read backpressure kPa/m or in. of Hg/ft. (∆P) from
the center column. Calculate the total piping
system backpressure by multiplying the total
equivalent straight pipe in m (ft.) from step 7 by the
kPa/m or in. of Hg/ft. of pipe from this step.
Example:
11.0 equiv. m x 0.04 kPa/m =

0.4 total system backpressure in kPa
36.1 equiv. ft. x 0.004 in. Hg/ft. =

0.14 total system backpressure in inches of Hg

Q Engine Exhaust Flow
m3/min. cfm
28.3 1000
25.5 900 D Pipe Diameter
mm inches
22.7 800
25.4 1.0
19.8 700
17.0 600
Δ P Backpressure
14.2 500 kPa per m in. Hg per foot 31.8 1.25
1.033 1.0
0.515 0.5
11.3 400
38.1 1.5
8.5 300
0.104 0.1
7.1 250 44.5 1.75
0.052 0.05
5.7 200 50.8 2.0
0.009 0.01
4.2 150 0.005 0.005
63.5 2.5
0.001 0.001
2.8 100
2.5 90 0.001 0.0005 76.2 3.0
2.3 80
2.0 70
0.000 0.0001 88.9 3.5
1.7 60
0.000 0.00005
1.4 50 101.6 4.0
1.1 40 114.3 4.5

0.000 0.00001
127.0 5.0
(cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)
Figure 5-9 Backpressure using Pipe Size 4 in. (102 mm) or Less

Q Engine Exhaust Flow D Pipe Diameter
m3/min. cfm mm inches
76.2 3
453.1 16000
Δ P Backpressure
339.8 12000 kPa per m in. Hg per foot
1.033 1.0 101.6 4

283.2 10000
0.515 0.5
254.9 9000
226.6 8000
198.2 7000 127.0 5

0.104 0.1
169.9 6000
0.052 0.05
141.6 5000
152.4 6
113.3 4000 0.009 0.01

177.8 7
0.005 0.005
85.0 3000
203.2 8
0.001 0.001
228.6 9
0.001 0.0005
56.6 2000
254.0 10
42.5 1500 0.000 0.0001
0.000 0.00005 304.8 12
330.2 13
28.3 1000
355.6 14
25.5 900 0.000 0.00001
22.7 800
406.4 16
(cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)
Figure 5-10 Backpressure using Pipe Size 5 in. (127 mm) or Larger

Notes

Section 6 Fuel Systems
Comply with applicable state and local codes when 6.1.1 Main Tank
installing any fuel system.
Storage. Because it is less volatile than gas or gasoline,
diesel fuel is safer to store and handle. Regulations for
6.1 Diesel Fuel Systems diesel storage tank placement are less stringent than
the regulations for gas or gasoline storage. In some
The main components of a typical diesel fuel system are locations, large main tanks are permitted inside the
a main fuel storage tank, a day tank, fuel lines, and an building or enclosure.
auxiliary fuel pump. See Figure 6-1.
1 2 3 4
13
12
11
8 7 6 5
TP-5700-6
10
1. Injector return line 8. Fuel supply line from main fuel tank to day tank
2. Day tank vent 9. Overflow line
3. Day tank 10. Foot valve
4. Auxiliary fuel pump 11. Main fuel storage tank
5. Tank drain 12. Fuel tank vent
6. Electric fuel level control switch 13. Tank filling inlet
7. Fuel supply line from day tank to engine connection
Figure 6-1 Diesel Fuel System
TP-5700 12/07 Section 6 Fuel Systems 47

Tank location. Locate fuel storage tanks above ground Provide easy access to fuel filters and sediment drains
or bury them underground in accordance with for regular and frequent service. Clean fuel is especially
applicable codes. Figure 6-2 shows a commonly used important to diesel engines, which have easily clogged
above-ground subbase tank contained in the generator fuel injectors and pumps.
set mounting base.
2 4
1 3
TP-5700-6
1. Generator set skid 3. Subbase fuel tank
2. Side view 4. End view
Figure 6-2 Subbase Fuel Tank
Tank size. Codes requiring standby power often specify Fuel alternatives. Most diesel engines operate
a minimum onsite fuel supply. Such requirements are satisfactorily on No. 2 domestic burner oil available in
included in NFPA 70, National Electrical Code, and most parts of the US. If the site heating system is oil-
NFPA 99, Standard for Health Care Facilities. Diesel fired, consider supplying the engine with fuel from the
fuel deteriorates if stored for more than one year; same tank used for heating oil to reduce costs and to
therefore, size the tank to ensure that regular generator ensure a continually fresh fuel supply for the engine.
set exercising will use the tank’s contents within one This practice necessitates that the fuel oil meets the
year. If there are no applicable code requirements, the engine manufacturer’s minimum requirements for wax
manufacturer recommends a tank sized for eight hours point, pour point, sulfur content, and cetane number as
of operation at rated load. Refer to the generator set these factors influence cold weather starting and
specification sheet for fuel consumption data. generator set power output. When supplying multiple
applications from the same main fuel tank, provide each
Tank venting. Vent the main fuel tanks to allow air and with a separate supply line.
other gases to escape to the atmosphere without
allowing dust, dirt, and moisture to enter the tank.
Fuel expansion. Never fill the tank more than 95% full
to allow for fuel expansion. On overhead main tanks,
use a fuel shutoff solenoid to prevent hydraulic lock or
tank overflow caused by excessive static head fuel
pressures.
48 Section 6 Fuel Systems TP-5700 12/07

6.1.2 Day Tanks (100_F) and are subject to damage if operated with fuel
temperatures above 60_C (140_F), a day tank providing
The terms day tank and transfer tank are at least four hours of fuel consumption should be used to
interchangeable. Having a day tank adjacent to the provide enough capacity to cool the fuel returning from
engine allows the engine fuel transfer pump to easily the engine. If smaller day tanks are used, the generator
draw fuel during startup and provides a convenient set manufacturer may recommend installing a fuel
location to connect fuel injector return lines. See cooler or routing engine fuel return lines to the main
Figure 6-3. storage tank. See Figure 6-3.
Connect a float-switch-controlled solenoid antisiphon Optional equipment includes fuel level gauges, manual
valve or a float valve to prevent siphoning fuel from the priming pumps, float switches for pump control, float
main storage tank if the main tank fuel level is above the valves, rupture basins, and low level alarms. Remove
day tank inlet. the plastic shipping plugs and install metallic pipe plugs
in all unused fuel tank ports to provide a liquid-tight seal.
Tank size. Standard tanks are available in sizes from
38--3952 L (10--1044 gal.) with or without integral
electric fuel transfer pumps. Because engines are
subject to fuel temperature deration above 38_C
1 2
12 11 10
9 8
TP-5700-6
1. Return line from fuel pump 7. Fuel shutoff solenoid

2. Return line from fuel injectors/fuel rack 8. Day tank
3. Vent (to outside) 9. Fuel supply line from day tank to engine connection
4. Overhead main tank 10. Filter
5. Maximum 76 m (25 ft.), minimum 25 mm (1 in.) 11. Flexible line
6. Fuel supply line from main fuel tank to day tank 12. Fuel pump
Figure 6-3 Diesel Fuel System with Overhead Main Tank and Day Tank

6.1.3 Fuel Lines 6.1.4 Auxiliary Fuel Pumps
The following items describe fuel line selection and Primary, engine-driven fuel pumps typically develop a
application. Never use the fuel piping or fuel line clamps maximum of 48 kPa (7 psi) pressure and draw fuel to
to ground any electrical equipment. approximately 1.2--1.4 m (4--5 ft.) vertically or 6 m
(20 ft.) horizontally. When the main tank is located a
Line type. Use Schedule 40 black-iron pipe, steel greater distance from the engine or for a more reliable
tubing, or copper tubing for diesel fuel systems. Diesel fuel system, use an auxiliary pump alone or in
fuel reacts adversely with galvanized tanks and piping, connection with a day tank. See Figure 6-3. Limit
producing flaking sediment that quickly clogs filters and auxiliary fuel pump pressure to approximately 35 kPa
causes fuel pump and fuel injector failure. Ensure that (5 psi).
any flexible fuel lines used are approved for diesel fuel.
Use a shutoff solenoid valve wired into the engine run
Line size. Use the smallest diameter fuel line that still circuit or a check valve to help keep the fuel line primed.
delivers enough fuel to the engine with an acceptable Install the check valve on the outlet side of the auxiliary
pressure drop of 6.9 kPa (1.0 psi). Using oversize piping fuel pump to minimize inlet restriction.
increases the chance of air introduction into the fuel
system during engine priming, which increases the Auxiliary fuel pump options. On engines using less
potential for fuel pump damage and hard starting. than 38 L (10 gal.) of fuel per hour (approximately
100 kW or less), connect an engine starting battery-
Flexible connectors. Use flexible connections powered electric fuel transfer pump in series with the
spanning a minimum of 152 mm (6 in.) between the engine-driven transfer pump. Locate the electric pump
stationary piping and the engine fuel inlet connection. nearer to the fuel tank than to the engine. An auxiliary
pump located at the fuel tank approximately doubles the
Return lines. A diesel system delivers more fuel to the horizontal and vertical distance limits of a single engine-
injectors than the engine uses; therefore, a system has driven pump.
one supply line from the fuel tank and at least one return
line from the fuel injectors. Size the fuel return lines no On engines using more than 38 L (10 gal.) of fuel per
smaller than the fuel supply lines. hour or when drawing fuel more than 1.8 m (6 ft.)
vertically or 12 m (40 ft.) horizontally, use an electric
Route the return fuel line to either the day tank or the motor-driven positive displacement pump with a day
main storage tank. Place the return lines as far away tank and float switch. Electrically connect the fuel pump
from the pickup or fuel diptube as possible to prevent air to the transfer switch load side for maximum reliability.
entry and to keep warm fuel from being reintroduced to This type of pump can typically lift fuel 5.5 m (18 ft.) or
the engine. If fuel lines are routed to the day tank, note draw it horizontally up to 61 m (200 ft.).
the day tank size requirements in Section 6.1.2, Day
Tanks. Where vertical runs exceed 5.5 m (18 ft.) or horizontal
runs exceed 61 m (200 ft.), remote-mount the pump
A properly designed fuel return line is unrestricted and adjacent to the fuel storage tank. This type of installation
as short as possible, and it allows gravity return of fuel to allows these pumps to push fuel over 305 m (1000 ft.)
the storage tanks. In installations where gravity return is horizontally or more than 31 m (100 ft.) vertically and
not possible, obtain approval of the design from the deliver adequate fuel for generator sets up to 2000 kW.
generator set supplier based upon the engine’s Always connect a positive-displacement pump directly
specifications before installing a fuel system with static to a day tank and float switch to protect the engine fuel
head pressure on the return lines. Fuel return line system from excessive fuel pressures.
restriction can cause engine hydraulic lock or
uncontrollable overspeed on some systems.

6.2 Gasoline Fuel Systems 6.2.3 Fuel Pumps
The main components of a typical gasoline fuel system Engine fuel pumps usually lift fuel up to 1.2 m (4 ft.) or
are a fuel storage tank, fuel lines, and a fuel pump. See draw it horizontally up to 6 m (20 ft.). Connect auxiliary
Figure 6-4. engine starting battery-powered electric pumps in
series with the engine-driven pump. See Figure 6-4. An
auxiliary pump located at the fuel tank approximately
3 4 doubles the horizontal and vertical distance limits of a
1 2 single engine-driven pump. Limit auxiliary fuel pump
pressure to approximately 35 kPa (5 psi).
6.3 Gas Fuel Systems, Common

TP-5700-6 Components
Gas fuel systems operate on either LP (liquefied
petroleum) or natural gas.
1. Fuel tank 3. Gasoline shut-off
2. Fuel pump 4. Gasoline carburetor Note: Design and install gas fuel systems in
accordance with NFPA 54, National Fuel Gas
Figure 6-4 Gasoline Fuel System Code, and applicable local codes.
6.2.1 Fuel Storage Tank All gas systems include a carburetor, secondary gas
regulator, electric gas fuel solenoid shutoff valve, and
Gasoline fuel systems are usually limited to outdoor or flexible fuel connector.
portable trailer-mounted generator sets because codes
typically restrict or prohibit storing more than 3.8 L
(1.0 gal.) of gasoline inside a building. 6.3.1 Gas Lines
Never use fuel piping to ground electrical equipment.
If a fuel storage tank is located higher than the engine,
The gas supplier is responsible for installation, repair,
install an antisiphon fuel solenoid valve or air bleed hole
and alteration to gas piping.
in the fuel tank diptube (near the top of the tube inside
the tank) to prevent siphoning. Line type. Use Schedule 40 black-iron pipe for gas
piping. Copper tubing may be used if the fuel does not
Gasoline deteriorates after six months; therefore, use
contain hydrogen sulfide or other ingredients that react
the smallest storage tank allowed by code.
chemically with copper.
6.2.2 Fuel Lines Line size. Size piping according to the requirements of
the equipment. Refer to the generator set specification
Never use fuel piping to ground electrical equipment. sheet or the dimension drawing for detailed information
on your system. In addition to the actual fuel
Line type. Use Schedule 40 black-iron pipe, steel consumption, consider the following pressure loss
tubing, or copper tubing for gasoline fuel systems. Do factors:
not use galvanized pipe and fittings.
D Pipe length
Line size. Use the smallest diameter fuel line that will D Other appliances on the same fuel supply
not restrict the required fuel flow. D Number of fittings
Flexible connectors. Use flexible connections Flexible connections. Rigid-mount the piping but
spanning a minimum of 152 mm (6 in.) between the protect it from vibration. Use flexible connections
stationary piping and the engine fuel inlet connection. spanning a minimum of 152 mm (6 in.) between the
stationary piping and the engine fuel inlet connection.

6.3.2 Gas Regulators gas. Refer to the appropriate generator set’s operation
manual and/or the decal attached to the generator set
Gas regulators reduce high incoming fuel pressures to for information regarding spring/adjustment screw
lower levels acceptable for engines. Refer to the usage for specific models. Some models may require
generator set spec sheet for fuel supply pressures. new diaphragm kits and/or inverting the gas regulator
Typical gas fuel pressures are shown in Figure 6-5. when changing fuel type.
Install a solenoid valve upstream from the gas regulator
and the flexible fuel connector to prevent the Installation position for fuel type. The gas regulator
accumulation of an explosive mixture of gas and air functions normally pointing downward for both natural
caused by leaks in the flexible connection or the gas gas and LP gas. If only natural gas fuel is used, the gas
regulator. The generator set installer normally wires the regulator may be installed pointing upward.
engine battery-powered solenoid valve to the engine
starting controls to open the valve when the engine Pressure testing. Some gas regulators provide for
cranks or runs. installation of a pressure gauge to test inlet and outlet
pressures. If no such provision is available, install pipe
For UL compliance, the fuel solenoid valves are needed tees in the fuel line to test pressure and use pipe plugs to
per UL 2200, Section 35.3.2.2.1. plug unused openings.
Fuel Supply Pressure

6.4 LP Fuel Systems
Generator Water Column,
Set Model Engine kPa (oz./in.2) cm (in.) Fuel characteristics. LP fuel exists as a vapor and a
20 kW Ford 1.7--2.74 (4--6) 18--28 (7--11) liquid in pressurized tanks. Since LP fuel does not
30--125 kW GM 1.7--2.74 (4--6) 18--28 (7--11) deteriorate in storage, a large supply of fuel can be kept
135--275 kW
Detroit Diesel
1.2--5 (2.9--11.6) 13--51 (5--20) onsite indefinitely for operation during emergency
Series 50/60
conditions. This makes LP gas ideal for applications
400--800 kW Waukesha 2--34 (4.6--80) 20--348 (8--137) with uninterrupted (onsite) fuel supply requirements.
Figure 6-5 Recommended Gas Fuel Supply
Fuel mixture. LP gas is propane, butane, or a mixture
Pressures
of the two gases. The ratio of butane to propane is
The typical gas system uses two gas regulators: especially important when the fuel flows from a large
outdoor tank. A fuel supplier may fill the tank in the warm
D Primary gas regulator. Provides initial control of gas summer months with a mixture composed mainly of
from the fuel supply. The primary gas regulator butane; however, this mixture may not provide sufficient
reduces the high pressure from a tank or transmission vaporized pressure at cold temperatures to start and
line to the low pressure required by the secondary gas operate the engine. A local fuel supplier is likely to be
regulator(s). Typically, the primary gas regulator is the best source of information on what size tank is
set at the higher pressure value when a range is necessary to provide adequate fuel vapor.
given. The gas supplier typically provides the primary
gas regulator, as conditions that dictate the type of The fuel mixture and vaporization pressure at the
gas regulator used vary depending on the method of anticipated temperatures influence the selection of gas
supplying fuel. The supplier is also responsible for regulator equipment. Pure butane gas has little or no
providing sufficient gas pressure to operate the vaporization pressure in temperatures below 4°C
primary gas regulator. Primary gas regulator must be (40°F). Even at 21°C (70°F), the pressure is
vented to the outside if installed within any building. approximately 124 kPa (18 psi). Some primary gas
regulators do not operate at tank pressures below
D Secondary gas regulator. This low-pressure gas 207 kPa (30 psi) while others operate at incoming
regulator is mounted on the engine and limits the pressures as low as 20.7--34.5 kPa (3--5 psi).
maximum inlet pressure to engine. The engine
operates satisfactorily at the lower pressure value when Fuel consumption and tank size. Since LP fuel is
a range is given, but these lower pressures may result supplied in pressurized tanks in liquid form, it must be
in poor response to load changes or a lack of power if converted to a vapor state before being introduced into
the primary gas regulator is not near the engine. the carburetor. The amount of vapor contained in 3.8 L
(1.0 gal.) of liquid (LP) fuel is:
Modification for fuel type. Many gas regulators are
compatible with both natural gas and LP gas. Typically, Butane Gas 0.88 m3 (31.26 cu. ft.)
the user installs the spring and retainer in the gas Propane Gas 1.03 m3 (36.39 cu. ft.)
regulator when connecting to natural gas and removes it
from the gas regulator when connecting to LP vapor

See the generator set specification sheets for fuel 6.4.2 LP Gas Liquid-Withdrawal
consumption at different loads, and contact your fuel Systems
supplier for information regarding tank sizes.
LP liquid-withdrawal fuel systems are available for
System types. Single-source gas fuel systems include generator sets but are not recommended for automatic
LP gas vapor-withdrawal and LP gas liquid-withdrawal. standby service. With liquid-withdrawal systems, liquid
LP at 1034--1379 kPa (150--200 psi) flows to the engine.
6.4.1 LP Gas Vapor-Withdrawal A combination of converters (vaporizers) and gas
regulators then reduces the pressure to a usable level.
Systems
In Figure 6-7, a converter (a combination of a vaporizer
A vapor-withdrawal system draws on the fuel vapor that
collects in the space above the liquid fuel. Consider the and primary and secondary gas regulators) changes the
following during installation: liquid to vapor using heat from the engine’s cooling
system. For a period following startup, a liquid-
D Generally, allow 10%--20% of tank capacity for fuel withdrawal system may be unable to vaporize enough
expansion from a liquid to a vapor state. The liquid fuel for an engine running under load until the engine
level in LP gas tanks must never exceed 90% of the reaches operating temperature. The engine needs time
tank capacity. to warm sufficiently to provide adequate heat to vaporize
the fuel.
D Maintain air temperature surrounding the tank high
enough to vaporize the liquid fuel.
1 2 3 4
Applications in colder climates may require an
independent heat source to increase natural
vaporization within the tank. Withdraw liquid fuel and
vaporize it in an electrically heated, engine water jacket-
heated, or LP gas-heated vaporizer. Figure 6-6 shows
the components of the vapor-withdrawal system used in
a typical stationary application. The LP gas regulator is
typically installed in the inverted position (pointing
downward).
1 2 3 4
TP-5700-6
1. Carburetor
Note: Install a gauge to test
2. Converter (vaporizer)
fuel pressure during setup
and replace with a pipe plug 3. Solenoid valve (quantity of two in series may be
when setup in complete, if required for UL applications)
required. 4. LP gas filter (supplied by gas supplier or installer)
5
1. Carburetor
Figure 6-7 LP Gas Liquid Withdrawal System
2. Secondary gas regulator
3. Solenoid valve (quantity of two in series may be required Some codes prohibit gas fuel pressurization greater
for UL applications) than 34.5 kPa (5 psi) inside buildings. This might
4. Pressure gauge preclude the use of a liquid-withdrawal system. To
5. Primary gas regulator (supplied by gas supplier or installer)
ensure code compliance, converters are sometimes
Figure 6-6 Typical LP Gas Vapor-Withdrawal located outside the building housing the generator set.
System However, the great length of pipe between the converter
and the carburetor does not allow sufficient heat buildup
and heat retention to maintain the fuel in its vapor state,
which can cause startup problems.

6.5 Natural Gas Systems 6.6 Combination Systems
The utility supplies natural gas in a vapor state. A Combination fuel source systems include:
natural gas fuel system consists of the same basic
D Natural gas and LP gas
components and operates with the same general
sequence as LP gas vapor-withdrawal systems. See D LP gas or natural gas and gasoline
Figure 6-8 and Figure 6-9. Note that when the heat
content of the fuel falls below 1000 Btu, as it does with 6.6.1 Combination Natural Gas and LP
sewage-derived and some other natural gas fuels, the Gas
generator set will not produce its rated power. The
natural gas regulator is typically installed in the upright Some applications use natural gas as the main fuel and
position (pointing upward). LP gas as the emergency fuel when natural gas is not
available.
1 2 3 4 5 The natural gas and LP gas, liquid withdrawal system

uses a converter (vaporizer) to change the LP liquid to
gas vapor. A pressure switch on the primary fuel source
closes when fuel pressure drops, which energizes a
relay that closes the primary fuel solenoid and opens the
secondary or emergency fuel solenoid.
Note: Install a gauge to test fuel
pressure during setup and replace A separate LP gas load adjustment valve ensures the
with a pipe plug when setup is
complete, if required. TP-5700-6
right fuel-to-air mixture in the carburetor. The load
adjustment valve is located inline between the converter
1. Primary gas regulator (supplied by gas
supplier or installer)
(vaporizer) and the carburetor. See Figure 6-10.
2. Pressure gauge
3. Solenoid valve (quantity of two in series may
be required for UL applications) 4
4. Secondary regulator 1 2 3
5. Carburetor
Figure 6-8 Natural Gas Fuel System with Pressure 5

Gauge
9 10
6
4
3 4 5
1
Note: Install a gauge to test fuel
pressure during setup and replace
with a pipe plug when setup is
complete, if required.
TP-5700-6
2 8 7
1. Carburetor
2. Load adjustment valve
050604 3. Converter (vaporizer)
4. Solenoid valve (quantity of two in series may be required for
1. Primary gas regulator (supplied by gas supplier or installer) UL applications)
2. Manual shutoff valve 5. LP gas filter (supplied by gas supplier or installer)
3. Solenoid valve (quantity of two in series may be required 6. LP gas supply
for UL applications) 7. Natural gas supply
4. Secondary gas regulator 8. Primary gas regulator (supplied by gas supplier or installer)
5. Carburetor 9. Secondary natural gas regulator
10. Pressure gauge
Figure 6-9 Natural Gas Fuel System without Figure 6-10 Natural Gas and LP Gas System, Liquid
Pressure Gauge and with Manual Withdrawal
Shutoff Valve

The natural gas and LP gas, vapor withdrawal system These systems use either a combination gas-gasoline
contains a separate secondary gas regulator and carburetor or a gasoline carburetor with a gas adapter.
solenoid valve for each fuel. The LP gas regulator With the exception of the carburetor, the combination
typically mounts in the inverted position. A pressure gas-gasoline systems use the same basic components
switch on the primary fuel source closes when fuel as those in the natural and LP gas systems. See
pressure drops, which energizes a relay that closes the Figure 6-12.
primary fuel solenoid and opens the secondary or
emergency fuel solenoid. A separate LP gas load 1 2 3 4
adjustment valve ensures the right fuel-to-air mixture in
the carburetor.
The load adjustment valve is located inline between the

secondary gas regulator and the carburetor. See
Figure 6-11.
8
1 2 3 4 5
7 6 5 TP-5700-6
1. Fuel pump
2. Gasoline shutoff
3. Gasoline carburetor
TP-5700-6
4. Fuel mixer
8 5. Secondary gas regulator
1. Carburetor 7 6. Solenoid valve (quantity of two in series
2. Load adjustment valve may be required for UL applications)
3. Secondary LP gas regulator 7. Gas fuel supply
4. Solenoid valve (quantity of two in series may be 8. Gasoline fuel supply
required for UL applications)
5. LP gas supply Figure 6-12 Combination Gas/Gasoline Fuel System
6. Natural gas supply
7. Low pressure switch Change fuel supplies manually at the generator set.
8. Secondary natural gas regulator Most engines, especially the smaller models, operate
Figure 6-11 Natural Gas and LP Gas System, Vapor successfully on gas or gasoline without extensive
Withdrawal modification or complicated mechanical changeover.
With a combination gas-gasoline fuel system,
changeover involves a few simple steps as outlined in
6.6.2 Combination LP Gas or Natural the generator set’s operation manual.
Gas and Gasoline
When installing this combination system, follow the
Combination LP gas or natural gas and gasoline installation considerations outlined for LP gas, natural
systems normally use a gas fuel as the primary fuel and gas, and gasoline systems.
use gasoline for emergency operation. Combination
natural gas and gasoline fuel systems are sometimes
used with gasoline as a standby fuel to meet code
requirements for an onsite fuel supply. Since gasoline
deteriorates after six months of storage, do not use a
combination system unless it is operated on gasoline
often enough to ensure that the fuel does not deteriorate
and that the carburetor is not subsequently clogged by
accumulated gum deposits.

6.7 Pipe Size Requirements for Figure 6-14 is based on gas pressures of 3.4 kPa
(0.5 psi, 13.8 in. water column) or less and a pressure
Gas Fuel Systems drop of 0.12 kPa (0.018 psi, 0.5 in. water column) with a
The type of fuel, the distance it must travel from gas 0.60 specific gravity and with a normal amount of
meter/tank to fuel shutoff solenoid, and the amount restriction from fittings. To calculate the correct pipe size
consumed by the engine must be considered when for a specific installation, refer to the chart and follow the
determining fuel line pipe size. procedure outlined below.
To find the correction necessary for the different specific

gravity of the particular fuel used, refer to Figure 6-13.
Fuel Specific Gravity Correction Factor

Sewage Gas 0.55 1.040
Natural Gas 0.65 0.962
Air 1.00 0.775
Propane (LP) 1.50 0.633
Butane 2.10 0.535
Figure 6-13 Fuel Correction Factors
Nominal Length of Pipe, m (ft.)

Iron Pipe Internal IPS 3.0 (10) 6.1 (20) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70)
Size Diameter
Diameter,
(IPS), In. mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
1/4 9.25 (0.364) 1.2 (43) 0.82 (29) 0.68 (24) 0.57 (20) 0.51 (18) 0.45 (16) 0.42 (15)
3/8 12.52 (0.493) 2.7 (95) 1.8 (65) 1.5 (52) 1.3 (45) 1.1 (40) 1.0 (36) 0.93 (33)
1/2 15.80 (0.622) 5.0 (175) 3.4 (120) 2.7 (97) 2.3 (82) 2.1 (73) 1.9 (66) 1.7 (61)
3/4 20.93 (0.824) 10.2 (360) 7.1 (250) 5.7 (200) 4.8 (170) 4.3 (151) 3.9 (138) 3.5 (125)
1 26.64 (1.049) 19.3 (680) 13.2 (465) 10.6 (375) 9.1 (320) 8.1 (285) 7.4 (260) 6.8 (240)
1 1/4 35.05 (1.380) 39.6 (1400) 26.9 (950) 21.8 (770) 18.7 (660) 16.4 (580) 13.9 (490) 13.0 (460)
1 1/2 40.89 (1.610) 59.5 (2100) 41.3 (1460) 33.4 (1180) 28.0 (990) 25.5 (900) 22.9 (810) 21.2 (750)
2 52.50 (2.067) 111.9 (3950) 77.9 (2750) 62.3 (2200) 53.8 (1900) 47.6 (1680) 43.0 (1520) 39.6 (1400)
2 1/2 62.71 (2.469) 178.4 (6300) 123.2 (4350) 99.7 (3520) 85.0 (3000) 75.0 (2650) 68.0 (2400) 63.7 (2250)
3 77.93 (3.068) 311.5 (11000) 218.0 (7700) 177.0 (6250) 150.0 (5300) 134.6 (4750) 121.8 (4300) 110.4 (3900)
4 102.26 (4.026) 651.2 (23000) 447.4 (15800) 362.5 (12800) 308.7 (10900) 274.7 (9700) 249.1 (8800) 229.4 (8100)
Nominal Length of Pipe, m (ft.)

Iron Pipe Internal IPS 24.4 (80) 27.4 (90) 30.5 (100) 38.1 (125) 45.7 (150) 53.3 (175) 61.0 (200)
Size Diameter
Diameter,
(IPS), In. mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
1/4 9.25 (0.364) 0.39 (14) 0.37 (13) 0.34 (12) 0.31 (11) 0.28 (10) 0.25 (9) 0.23 (8)
3/8 12.52 (0.493) 0.88 (31) 0.82 (29) 0.76 (27) 0.68 (24) 0.62 (22) 0.57 (20) 0.54 (19)
1/2 15.80 (0.622) 1.6 (57) 1.5 (53) 1.4 (50) 1.2 (44) 1.1 (40) 1.0 (37) 0.99 (35)
3/4 20.93 (0.824) 3.3 (118) 3.1 (110) 2.9 (103) 2.6 (93) 2.4 (84) 2.2 (77) 2.0 (72)
1 26.64 (1.049) 6.2 (220) 5.8 (205) 5.5 (195) 5.0 (175) 4.5 (160) 4.1 (145) 3.8 (135)
1 1/4 35.05 (1.380) 13.0 (460) 12.2 (430) 11.3 (400) 10.2 (360) 9.2 (325) 8.5 (300) 7.9 (280)
1 1/2 40.89 (1.610) 19.5 (690) 18.4 (650) 17.6 (620) 15.6 (550) 14.2 (500) 13.0 (460) 12.2 (430)
2 52.50 (2.067) 36.8 (1300) 34.5 (1220) 32.6 (1150) 28.9 (1020) 26.9 (950) 24.1 (850) 22.7 (800)
2 1/2 62.71 (2.469) 58.1 (2050) 55.2 (1950) 52.4 (1850) 46.7 (1650) 42.5 (1500) 38.8 (1370) 36.2 (1280)
3 77.93 (3.068) 104.8 (3700) 97.7 (3450) 92.0 (3250) 83.5 (2950) 75.0 (2650) 69.4 (2450) 64.6 (2280)
4 102.26 (4.026) 212.4 (7500) 203.9 (7200) 189.7 (6700) 169.9 (6000) 155.7 (5500) 141.6 (5000) 130.3 (4600)
Note: When the fuel has a specific gravity of 0.7 or less no correction factor is necessary—use this table without a correction factor.
Figure 6-14 Maximum Flow Capacity of Pipe in Cubic Meters (Cubic Feet) of Gas per Hour

1. Refer to the fuel consumption on the generator set 5. Find the value closest to pipe length in the
specification sheet. Note type of fuel used, Length of Pipe column in Figure 6-14.
generator set application rating, and the m3/hr. Example:
(ft3/hr.) consumption at 100% load.
38.1 m (125 ft.).
Example:
Example:
80 kW, propane gas, 60 Hz standby rating = At 28.9 m 3/hr. (1020 ft 3/hr.) the pipe size = 2 in. IPS.
12.0 m 3/hr. (425 ft 3/hr.).
6. Move vertically down the table in Figure 6-14
2. Refer to the Fuel Correction Factors in Figure 6-13.
from the determined value in Length of Pipe
Locate the correction factor for specific gravity of column.
the selected fuel.
Example:
When the fuel has a specific gravity of 0.7 or less no 38.1 m (125 ft.)
correction factor is necessary—use Figure 6-14
without a correction factor. Stop at the value that is equal to or greater than
corrected consumption value from step 3.
Example:
propane gas specific gravity = 1.50 Example:
fuel correction factor = 0.633. 28.9m 3/hr. (1020 ft. 3/hr.).
3. Divide the consumption value from step 1 by the 7. Move to the left column from the value in step 6
correction factor from step 2. to determine the correct pipe size.
Example:
12.0 m 3/hr. (425 ft 3/hr.) divided by 0.633 =
19.0 m 3/hr. (671 ft 3/hr.).
4. Determine the length of pipe between the gas

meter/tank and the fuel shutoff solenoid at the
generator set.
Example:
34.7 m (114 ft.).

Notes

Section 7 Electrical System
Before installing the generator set, provide for electrical

WARNING
connections through conduit to the transfer switch and
other accessories for the generator set. Carefully install
the selected generator set accessories. Route wiring to
the generator set through flexible connections. Comply
with all applicable codes when installing a wiring
system. Hazardous voltage. Moving parts.
AC circuit protection. All AC circuits must include Operate the generator set only when
circuit breaker or fuse protection. Select a circuit all guards and electrical enclosures
breaker for up to 125% of the rated generator set output are in place.
current. The circuit breaker must open all ungrounded
conductors. The circuit breaker or fuse must be Short circuits. Hazardous voltage/current can cause
mounted within 7.6 m (25 ft.) of the alternator output severe injury or death. Short circuits can cause bodily injury
terminals. and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
WARNING
7.1 Generator Set Voltage

Reconnection
To change the voltage of 10- or 12-lead generator sets,
Accidental starting.
use the procedure shown in the operation manual
containing the respective controller setup. Adjust the
Disconnect the battery cables before governor and voltage regulator for frequency changes.
working on the generator set. Consult the generator set service manual for frequency
Remove the negative (--) lead first adjustment information.
when disconnecting the battery.
Reconnect the negative (--) lead last Voltage reconnection. Affix a notice to the generator set
when reconnecting the battery. after reconnecting the set to a voltage different from the
voltage on the nameplate. Order voltage reconnection
Disabling the generator set. Accidental starting can decal 246242 from an authorized service distributor/
cause severe injury or death. Before working on the dealer.
generator set or equipment connected to the set, disable the
generator set as follows: (1) Turn the generator set master Equipment damage. Verify that the voltage ratings of
switch and switchgear engine control switch to the OFF the transfer switch, line circuit breakers, and other
position. (2) Disconnect the power to the battery charger. accessories match the selected line voltage.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the Reconnect the generator set stator leads to change the
battery. Follow these precautions to prevent the starting of the output phase or voltage. Reference the connection
generator set by an automatic transfer switch or a remote schematics shown in Figure 7-1, Figure 7-2, Figure 7-3,
start/stop switch.
and Figure 7-4.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the Follow the safety precautions at the front of this manual
generator set or connected equipment, disable the generator and in the text and observe National Electrical Code
set as follows: (1) Move the generator set master switch to the (NEC) guidelines.
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
TP-5700 12/07 Section 7 Electrical System 59

Figure 7-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-H
60 Section 7 Electrical System TP-5700 12/07

Figure 7-2 20--300 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-H

Figure 7-3 60 (with Oversize Alternator)--300 kW Wound Field Alternators, ADV-5875C-H

Figure 7-4 350--2800 kW Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-H

7.2 Electrical Connections For customer-supplied wiring, select the wire
temperature rating in Figure 7-5 based upon the
Several electrical connections must be made between following criteria:
the generator set and other components of the system
for proper operation. Because of the large number of D Select row 1, 2, 3, or 4 if the circuit rating is
accessories and possible combinations, this manual 110 amperes or less or requires #1 AWG (42.4 mm2)
does not address specific applications. Refer to the or smaller conductors.
submittal catalog accessory drawings and wiring
diagrams for connection and location. Most field- D Select row 3 or 4 if the circuit rating is greater than
installed accessory kits include installation instructions. 110 amperes or requires #1 AWG (42.4 mm2) or
larger conductors.
Comply with applicable national and local codes when

installing a wiring system.
Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only
1 60_C (140_F) Use No. * AWG, 60_C wire or Use 60_C wire, either No. * AWG Cu, or No. * Use 60_C wire, No. * AWG or
or use No. * AWG, 75_C wire AWG Al or use 75_C wire, either No. * AWG use 75_C wire, No. * AWG
75_C (167_F) Cu or No. * AWG Al
2 60_C (140_F) Use No. * AWG, 60_C wire Use 60_C wire, either No. * AWG Cu or No. * Use 60_C wire, No. * AWG
AWG Al
3 75_C (167_F) Use No. *[ AWG, 75_C wire Use 75_C wire, either No. *[ AWG Cu or No. *[ Use 75_C wire, No.*[ AWG
AWG Al
4 90_C (194_F) Use No. *[ AWG, 90_C wire Use 90_C wire, either No. *[ AWG Cu or No. *[ Use 90_C wire, No.*[ AWG
AWG Al
* The wire size for 60_C (140_F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for the
wire given in Table 310-16 of the National Electrical Coder, in ANSI/NFPA 70, and on 115% of the maximum current that the circuit carries
under rated conditions. The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
[ Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the
guidelines in the preceding footnote.
Figure 7-5 Terminal Markings for Various Temperature Ratings and Conductors
7.3 Load Lead Connections

1
Feed load leads to the generator junction box from one
of several different areas. Generator sets rated 300 kW
and below commonly use the bottom entry where
conduit is stubbed up into the junction box from the
concrete slab. Other methods include flexible conduit
roughed into the sides or top of the junction box. When
using flexible conduit, do not block the front or rear of the
2
controller. See Figure 7-6. TP-5700-7
Use a minimum of 13 mm (0.5 in.) spacing between the 1. Conduit from ceiling
conduit bushing and any uninsulated live parts in the 2. Conduit stubbed up from below
junction box. All conduit openings in the junction box
must be made such that no metal particles including drill Figure 7-6 Typical Load Lead Connection
chips contaminate the components in the junction box.
The four bus bars contained in the optional bus bar kits
Generator sets larger than 300 kW have the junction box simplify the connection process by offering a neutral bus
mounted on the rear of the generator set. Larger sets bar in addition to the three load bars. Optional bus lugs
may have oversized junction boxes supplied as an offer an array of terminal and wire connections.
option or to accommodate bus bar connections. Refer
to the generator set dimension drawing and/or the
electrical contractor prints for detailed information
including stub-up area recommendations.

7.4 Grounding and Grounded Generator sets are typically shipped from the factory
with the neutral attached to the alternator in the junction
Conductor (Neutral) box for safety reasons per NFPA 70. At installation, the
Connections neutral can remain grounded at the alternator or be lifted
from the grounding stud and isolated if the installation
Connect the electrical system grounding conductor to requires an ungrounded neutral connection at the
the equipment grounding connector on the alternator. generator set. The generator set will operate properly in
See Figure 7-7. Depending upon code requirements, either configuration.
the grounded conductor (neutral) connection is typically
grounded. Various regulations and site configurations including the
National Electrical Coder (NEC), local codes, and the
type of transfer switch used in the application determine
the grounding of the neutral at the generator set.
Min. Size of Recommended

Allowable Equipment Copper Compression Lug,
Ampacity, Grounding Conductor, ILISCO Part No. or
Amps AWG or kcmil Equivalent (UL Listed)
20 12 SLUH-90
EQUIPMENT
GROUND 60 10 SLUH-90
90 8 SLUH-90/125
100 8 SLUH-90/125
150 6 SLUH-90/125/225
200 6 SLUH-90/125/225
VIEWED FROM 300 4 SLUH-90/125/225
ENGINE END TP-5700-7
400 3 SLUH-90/125/225
Figure 7-7 Generator Set Equipment Grounding 500 1 SLUH-125/225
Connection 600 1 SLUH-125/225
800 1/0 SLUH-225/300/400
Ungrounded neutral connections use an insulated 1000 2/0 SLUH-225/300/400
standoff (not supplied) to isolate the neutral connection 1200 3/0 SLUH-225/300/400
from the grounding connection. For grounding lug 1600 4/0 SLUH-225/300/400/650
selection, see Figure 7-8. 2000 250 SLUH-225/300/400/650
2500 350 SLUH-300/400/650
The four bus bars contained in the optional bus bar kits
3000 400 SLUH-400/650
simplify the connection process by offering a neutral bus
4000 500 SLUH-400/650
bar in addition to the three load bars. Optional bus lugs
offer an array of terminal and wire connections. 5000 700 SLUH-650
6000 800 SLUH-650
Figure 7-8 Grounding Lug Selection
The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.

7.5 Terminal Connector Torque Socket Size Across Flats, Tightening Torque,
mm (in.) Nm (in. lb.)
Use torque values shown in Figure 7-9 or Figure 7-10 3.2 (1/8) 5.1 (45)
for terminal connectors. Refer to UL 486A--486B and
4.0 (5/32) 11.4 (100)
UL 486E for information on terminal connectors for
aluminum and/or copper conductors. See Section 7.2, 4.8 (3/16) 13.8 (120)
Electrical Connections, for information on temperature 5.6 (7/32) 17.0 (150)
rating of the customer-supplied wire. Comply with 6.4 (1/4) 22.6 (200)
applicable national and local codes when installing a 7.9 (5/16) 31.1 (275)
wiring system.
9.5 (3/8) 42.4 (375)
If a connector has a clamp screw such as a slotted, 12.7 (1/2) 56.5 (500)
hexagonal head screw with more than one means of 14.3 (9/16) 67.8 (600)
tightening, test the connector using both applicable Note: For values of slot width or length not corresponding to
torque values provided in Figure 7-10. those specified, select the largest torque value
associated with the conductor size. Slot width is the
nominal design value. Slot length is to be measured at
the bottom of the slot.
Figure 7-9 Tightening Torque for Pressure Wire

Connectors with Internal-Drive
Socket-Head Screws
Tightening Torque, Nm (in. lb.)

Wire Size for Unit Hexagonal Head—External
Connection Slot Head 4.7 mm (No. 10) or Larger* Drive Socket Wrench
Slot Width <1.2 mm (0.047 in.) Slot Width >1.2 mm (0.047 in.) Split-Bolt Other
AWG, kcmil (mm2) Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections
18--10 (0.82--5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75)
8 (8.4) 2.8 (25) 4.5 (40) 9.0 (80) 8.5 (75)
6--4 (13.3--21.2) 4.0 (35) 5.1 (45) 18.6 (165) 12.4 (110)
3 (26.7) 4.0 (35) 5.6 (50) 31.1 (275) 16.9 (150)
2 (33.6) 4.5 (40) 5.6 (50) 31.1 (275) 16.9 (150)
1 (42.4) — 5.6 (50) 31.1 (275) 16.9 (150)
1/0--2/0 (53.5--67.4) — 5.6 (50) 43.5 (385) 20.3 (180)
3/0--4/0 (85.0--107.2) — 5.6 (50) 56.5 (500) 28.2 (250)
250--350 (127--177) — 5.6 (50) 73.4 (650) 36.7 (325)
400 (203) — 5.6 (50) 93.2 (825) 36.7 (325)
500 (253) — 5.6 (50) 93.2 (825) 42.4 (375)
600--750 (304--380) — 5.6 (50) 113.0 (1000) 42.4 (375)
800--1000 (406--508) — 5.6 (50) 124.3 (1100) 56.5 (500)
1250--2000 (635--1016) — — 124.3 (1100) 67.8 (600)
* For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size.
Slot width is the nominal design value. Slot length is to be measured at the bottom of the slot.
Note: If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the
connector using both applicable torque values.
Figure 7-10 Tightening Torque for Screw-Type Pressure Wire Connectors

7.6 Batteries Note: Some units are equipped with a reflective heat
shield insulative sleeve on the battery cables and
Battery location. When determining the battery other wires that are fastened to the starter
placement, ensure that the location: solenoid. This sleeve is a conductive material
and must be secured approximately 25 mm
D Is clean, dry, and not exposed to extreme (1 in.) away from the exposed cable terminal.
temperatures
D Provides easy access to battery caps for checking the 7.7 Battery Chargers
electrolyte level (when using maintenance type
batteries) Engine-driven, battery-charging alternators charge the
batteries whenever the generator set operates.
D Is close to the generator set to keep cables short, Engine-driven systems are normally capable of charge
ensuring maximum output rates of 30 amps or more and can quickly restore the
charge used in a normal cranking cycle.
Refer to the submittal drawings for the generator set
when choosing a battery rack. Figure 7-11 shows a When the engine is not operating, a very low charge rate
typical battery system. from an AC-powered battery charger is usually sufficient
to maintain a full charge on the batteries. Some small
industrial generator sets have no battery-charging
1 alternators and, therefore, require a separate AC-
powered battery charger.
2 Select an automatic or manual battery charger with a
high charge rate of 2 amps and a trickle charge rate up
to 300 milliamps. The low maximum charge rate makes
the charger ill-suited to restore fully discharged batteries.
3 For full recovery capability independent of the engine-
1. Battery cables 4 TP-5700-7
driven charging system, use an automatic float battery
2. Battery secured in mounting rack charger with a high charge rate of at least 10 amps.
3. End view
4. Generator set skid Use separate, self-contained battery chargers or units
built into the automatic transfer switch. Run leads from a
Figure 7-11 Typical Battery System, Side View
transfer switch-mounted battery charger in conduit
Battery type. Starting batteries are usually the lead- separate from the conduit that holds the generator load
acid type and are sized according to the engine cables or remote engine-start circuits.
manufacturer’s recommendation for a particular
Note: Digital controllers with microprocessor circuitry
ambient temperature and required cranking time.
and vacuum fluorescent displays typically draw
NFPA 110 recommends cranking periods, including a
more than 300 milliamps, making trickle charge
single 45-second cycle for generator sets below 15 kW
battery chargers inappropriate for systems with
and three 15-second crank cycles separated by 15-
these controllers. Select only automatic float/
second rests for larger models. Refer to the respective
equalize battery chargers with a 3 amp or greater
generator set specification sheet for the required battery
rating for units with digital controllers.
cold-cranking ampere (CCA) rating.
Battery failure is the most common reason for
Nickel-cadmium batteries are sometimes used for
emergency generator set start failure. Two common
standby generator sets because of their long life
battery failure causes are a manual charge rate set too
(20 years). However, initial high cost, larger space
low to maintain the battery and a manual charge rate set
requirements, and special charging requirements can
too high, resulting in loss of battery electrolyte. To avoid
offset this benefit. Therefore, conventional lead-acid
battery failure, use an automatic float charger, which
batteries have proven satisfactory for the majority of
varies the charge rate in response to battery condition.
generator set applications.
For large engines with two starters, use either one bank
Battery cables. A UL 2200 listed generator set
of batteries and chargers for both starters or use
requires battery cables with positive (+) lead boots.
separate battery systems. The latter system is
Factory-supplied and optional battery cables include
preferable because it reduces the chance of a single
positive (+) lead boots. When battery cables are not
component failure rendering the entire system
factory-supplied, source battery cables with positive (+)
inoperative.
lead boots for UL 2200 compliance.

7.8 Optional Accessories Terminal strips and available connections vary by
controller. Refer to the respective controller operation
The generator set manufacturer offers optional manual and the accessory wiring diagrams in the wiring
accessories that require connection to other diagram manual for connection of kits. Field-installed
components in the system. These accessories enable accessories include installation instructions and/or
the generator set to meet standards for local and wiring diagrams.
national codes, make operation and service more
convenient, or satisfy specific customer installation
requirements.
7.8.1 Audiovisual Alarm
An audiovisual alarm warns the operator at a remote
Accessories vary with each generator set model and
location of fault shutdowns and prealarm conditions
controller. Accessories are available factory-installed
(except battery charger fault and low battery voltage) at
and/or shipped loose. Some accessories are available
the generator set. Audiovisual alarms include an alarm
only with the microprocessor and digital controllers.
horn, an alarm silence switch, and a common fault lamp.
Obtain the most current list of accessories from the
See Figure 7-13.
respective generator set specification sheet or by
contacting your local authorized service distributor/
dealer. The following sections detail a few common
accessories and their functions.
Front View Side View
Accessory kits generally include installation
instructions. See the wiring diagrams manual for
electrical connections not shown in this section. See
the installation instructions and drawings supplied with
the kit for information on the kit mounting location.
The instructions provided with the accessory kit

supersede these instructions, if different. In general,
run AC and DC wiring in separate conduit. Use
shielded cable for all analog inputs. Observe all
applicable national and local electrical codes during
A-292887
accessory installation.
Figure 7-13 Audiovisual Alarm
Accessory wiring. To determine the appropriate size
for the customer-supplied wiring of the engine battery-
powered accessories, use the guidelines in Figure 7-12. 7.8.2 Bus Bar Kits/Bus Lugs
Use 18--20 gauge wire for signal wires up to 305 m
(1000 ft.). The four bus bars contained in the optional bus bar kits
simplify the connection process by offering a neutral bus
Length, m (ft.) Wire Gauge bar in addition to the three load bars. Optional bus lugs
30.5 (100) 18--20
offer an array of terminal and wire connections. See
Figure 7-14.
152.4 (500) 14
304.8 (1000) 10
Figure 7-12 Wire Length and Size, Lead N and 42B L1
Match the wire terminals to the terminal strip conductor L2

screw size. Use a maximum of two wire terminals per L3
terminal strip screw unless otherwise noted on the
L0
respective accessory drawing or installation instruction.
Accessory connections. Do not direct-connect

accessories to the controller terminal strip. Connect
accessories to either a single-relay dry contact kit or
ten-relay dry contact kit. Connect the dry contact kit(s)
to the controller (customer) connection kit. Connect all
accessories except the emergency stop kit to the
connection kit terminal strip(s). TP-5700-7
Figure 7-14 Bus Bar Kits/Bus Lugs

7.8.3 Common Failure Relay Kit
CHARGER
The common failure relay kit provides one set of MALFUNCTION
contacts to trigger customer-provided warning devices if
a fault occurs. The user defines common failure relay
faults. Connect up to three defined common fault relay
kits to the controller output. See Figure 7-15.
LV HV CM
BATTERY CHARGER
ALARM TERMINAL
STRIP
TT-680
Figure 7-16 Float/Equalize Battery Charger

Connections
C-294301
Figure 7-15 Common Failure Relay Kit

TP-5352-1
Figure 7-17 Line Circuit Breaker

7.8.4 Controller (Customer) Connection
Kit
7.8.7 Low Fuel (Level or Pressure)
The controller connection kit allows easy connection of Switch
controller accessories without accessing the controller
terminal strip. The kit uses a wiring harness to link the Some gaseous-fueled models offer a low fuel pressure
controller terminal strip(s) with a remote terminal strip. switch. The low fuel pressure switch connects to the
With the exception of a few terminals, the remote same terminal as the low fuel level switch on diesel- or
terminal strip has connections similar to the controller. gasoline-fueled models. See Figure 7-18.
Connect all accessories except the emergency stop kit
to the connection kit terminal strip(s). Note: The main tank or the transfer/day tank includes
the low fuel level switch. The fuel tank supplier
typically provides the low fuel level switch.
7.8.5 Float/Equalize Battery Charger Kit
with Alarm Option
The float/equalize battery charger with alarm option
charges the engine start battery(ies) and connects to
the controller for fault detection. Your distributor/dealer
offers battery chargers for 12- or 24-volt models. See
Figure 7-16.
7.8.6 Line Circuit Breaker

TP-5700-7
The line circuit breaker interrupts generator output if an
overload or short circuit occurs. Use the line circuit Figure 7-18 Low Fuel Switch (Level or Pressure)
breaker to manually disconnect the generator set from
the load during generator set service. See Figure 7-17.
The circuit breaker must open all ungrounded

connectors. Refer to Service Bulletin 611 for circuit
breaker instantaneous overcurrent trip adjustment
information.
7.8.8 Remote Annunciator Kit 7.8.9 Remote Serial Annunciator (RSA)
A remote annunciator allows convenient monitoring of The remote serial annunciator (RSA 1000) (Figure 7-20)
the generator set’s condition from a remote location. monitors the condition of the generator set from a
See Figure 7-19. location remote from the generator set using RS 485
connection. If a generator alarm condition occurs, the
remote annunciator alerts the operator through visual
Remote Annunciator
and audible signals.
A-258782
14-Relay Dry Contact Box
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14

INPUT CONTACT RATINGS: PCB LOAD
10A @120VAC RES. ASSY A--320639
.01A @28VDC MIN. LOT NO.
10A @28VDC MAX.
NOK1C NOK2 C NOK3C NOK4 C NOK5 C NOK6 C NOK7C NOK8C NOK9C NO

K10C NOK11C NOK12C NOK13C NOK14C
42B P
P
FBA--1 10 AMP
A-293983
Figure 7-20 Remote Serial Annunciator (RSA 1000)
Figure 7-19 Remote Annunciator with 14-Relay Dry
Contact Kit The remote serial annunciator kit includes components
for flush and surface mounting. One RSA (master) can
The remote annunciator includes an alarm horn, an support up to a maximum of three additional RSAs
alarm silence switch, a lamp test, and the same lamp (slaves). The RSA will function as master or slave by
indicators (except air damper and auxiliary prealarm/ changing the DIP switch position on the RSA board. If a
high battery voltage) as the microprocessor controller, generator set fault occurs, the RSA 1000 horn activates
plus the following: and the corresponding LED illuminates.
D Line power. Lamp illuminates to indicate that the
power source is a commercial utility.
D Generator set power. Lamp illuminates to indicate

that the power source is the generator set.

Figure 7-21 shows the status of the system ready LED, The RSA requires connection to the controller Modbusr
generator running LED, communication status LED, RS-485 port. If the RS-485 port is needed for switchgear
common fault LED, common fault output, and horn for monitoring or a wireless monitor, the RSA cannot be
each fault or status condition. See Figure 7-22, connected to the controller. If the RS-485 port is
Figure 7-23, and Figure 7-24 for RSA wiring unavailable, please select an alternate annunciator kit.
connections.
Modbusr is a registered trademark of Schneider Electric.
System Monitoring LEDs and Functions

Fault System Generator Comm. Common Common
Fault and Status Condition LEDs Ready LED Running LED Status LED Fault LED Fault Output Horn
Overcrank Shutdown Red Red SF Off Green Off On On
High Engine Temperature Warning Yellow Red SF Green Green Off On On
High Engine Temperature Shutdown Red Red SF Off Green Off On On
Low Oil Pressure Warning Yellow Red SF Green Green Off On On
Low Oil Pressure Shutdown Red Red SF Off Green Off On On
Overspeed Shutdown Red Red SF Off Green Off On On
Emergency Stop Red Red SF Off Green Off On On
Low Coolant Level Red Red SF Off Green Off On On
Low Coolant Temperature Yellow Red SF Off Green Off On On
Low Fuel—Level or Pressure * Yellow Red SF Green Green Off On On
EPS Supplying Load (550 Controller) Yellow Green Green Green Off Off Off
EPS Supplying Load (RSA) Yellow Green Green or Off Green Off Off Off
System Ready Green Green Green or Off Green Off Off Off
System Not Ready Red Red SF Green or Off Green Off On On
No Device at Powerup Red Off Off Red SF Off On On
Loss of Controller Comm. (Master RSA) Red Off Off Red FF Off On On
Loss of Controller Comm. (Slave RSA) Red Off Off Red SF Off On On
Not-In-Auto Red Red SF Green or Off Green Off On On
Battery Charger Fault * Yellow Red SF Green or Off Green Off On On
High Battery Voltage Yellow Green Green or Off Green Off Off Off
Low Battery Voltage Yellow Green Green or Off Green Off Off Off
User Input #1 (RSA) Red Green Green or Off Green Off On On
User Input #2 (RSA) Red Green Green or Off Green Off On On
User Input #1 (550 Controller) Red Red SF Green or Off Green Off On On
Common Fault Red Green Green or Off Green Red SF On On
SF = Slow Flash, FF = Fast Flash
* May require optional kit or user-provided device to enable function and LED indication.
Figure 7-21 System Monitoring LEDs and Functions

550 CONTROLLER
550 CONTROLLER
16--LIGHT CONTROLLER
Figure 7-22 RSA Wiring Connections

Figure 7-23 RSA Interconnection Diagram ADV-6990A-C
Figure 7-24 RSA Interconnection Diagram ADV-6990B-C
7.8.10 Remote Emergency Stop Kit 7.8.12 Safeguard Breaker
Figure 7-25 shows the remote emergency stop switch. The safeguard breaker senses output current on each
Activating the emergency stop switch in the remote generator phase and shuts off the AC voltage regulator if
emergency stop kit lights the controller lamp and shuts a sustained overload or short circuit occurs. It is not a
down the unit. Before restarting the generator set, reset line circuit breaker and does not disconnect the
the emergency stop switch by replacing the glass piece generator from the load. See Figure 7-27.
and reset the generator set by placing the master switch
in the OFF/RESET position. The switch holds a single
replacement glass piece. Order additional replacement
glass as a service part.
X-796
Figure 7-27 Safeguard Breaker
7.8.13 Single-Relay Dry Contact Kit

A-222654
Figure 7-25 Emergency Stop Kit The single-relay dry contact kit has a common fault relay
that uses one set of contacts to trigger customer-
provided warning devices if a fault condition occurs. Any
7.8.11 Run Relay Kit controller fault output can connect to the single-relay kit.
The kit typically signals the following common fault
The run relay kit energizes only during generator set
conditions:
operation. The three sets of contacts typically control air
intake and/or radiator louvers. However, alarms and D Emergency stop
other signaling devices can also connect to the
D High coolant temperature
contacts. See Figure 7-26.
D Low oil pressure
D Overcrank
D Overspeed
D Low oil pressure
D High engine temperature
A total of three dry contact kits may connect to a single

controller output. Figure 7-28 shows the single-relay
dry contact kit.
273705
Figure 7-26 Run Relay Kit
A-273945
Figure 7-28 Single-Relay Dry Contact Kit

7.8.14 Ten-Relay Dry Contact Kit Warning devices (lamp and/or audible alarms) and other
accessories typically connect to the following controller
The ten-relay dry contact kit allows monitoring of the outputs:
generator set and/or activating accessories. The kit
includes ten sets of relay contacts for connecting D Overspeed
customer-provided devices to desired generator set D Overcrank
functions. A total of three dry contact kits may connect to
D High engine temperature
a single output on the controller. Refer to Figure 7-29 for
D Low oil pressure
an internal view of the contact kit.
D Low water temperature
D Auxiliary fault
D Air damper, if equipped
D Anticipatory high engine temperature
D Anticipatory low oil pressure
D Emergency stop
7.9 Wiring Connections

A-273936 Although equipment and connections vary, Figure 7-30
Figure 7-29 Ten-Relay Dry Contact Kit shows examples of the options and wire connections
necessary to make an industrial system operational.
Always refer to the wiring diagram for details of wire size,
location, and number.
NEGATIVE CONNECTION
Based on ADV-5795-S-E
Figure 7-30 Generator Set Connections, Typical

Section 8 Paralleling and Remote Start/Control Systems
This section provides information about changes and

WARNING
adjustments when the system involves paralleling
generator sets and/or remote start applications. Use the
respective switchgear literature as supplied with the
unit. Some of the items mentioned are available
generator set accessories.
Hazardous voltage. Moving parts.
Before installing the generator set, provide for electrical Can cause severe injury or death.
connections through conduit to the transfer switch and Operate the generator set only when
other accessories for the generator set. Carefully install all guards and electrical enclosures
the selected generator set accessories. Route wiring to are in place.
the generator set through flexible connections. Comply
with all applicable codes when installing a wiring Short circuits. Hazardous voltage/current can cause
system. severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
See Section 7, Electrical System for additional wiring connections with tools or jewelry while making adjustments or
information. repairs. Remove all jewelry before servicing the equipment.
WARNING 8.1 Automatic Transfer Switches

A typical standby system has at least one automatic
transfer switch connected to the generator set output to
automatically transfer the electrical load to the
generator set if the normal source fails. When normal
power returns, the switch transfers the load back to the
Accidental starting.
Can cause severe injury or death. normal power source and then signals the generator set
to stop.
Disconnect the battery cables before
working on the generator set. The transfer switch uses a set of contacts to signal the
Remove the negative (--) lead first engine/generator to start. When the normal source fails
when disconnecting the battery.
and the generator set master switch is in the AUTO
Reconnect the negative (--) lead last
when reconnecting the battery.
position, the transfer switch contacts close to start the
generator set.
Disabling the generator set. Accidental starting can The engine start terminals are usually located near the
cause severe injury or death. Before working on the transfer switch contactor with an engine start decal
generator set or equipment connected to the set, disable the identifying the terminals. Refer to the transfer switch
generator set as follows: (1) Turn the generator set master
decal, operation/installation manual, or wiring diagram
switch and switchgear engine control switch to the OFF
position. (2) Disconnect the power to the battery charger. manual to identify the engine start terminals prior to
(3) Remove the battery cables, negative (--) lead first. making connections.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent the starting of the Make connections to the transfer switch engine-start
generator set by an automatic transfer switch or a remote terminals and remote manual engine-start switch using
start/stop switch. wire run through conduit. Use separate conduits for
Disabling the generator set. Accidental starting can engine-start leads, generator set load cables, battery
cause severe injury or death. Before working on the charger leads, and remote annunciator wiring.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the Use a minimum of 13 mm (0.5 in.) spacing between the
OFF position. (2) Disconnect the power to the battery charger. conduit bushing and any uninsulated live parts in the
(3) Remove the battery cables, negative (--) lead first. ATS enclosure. All conduit openings in the ATS
Reconnect the negative (--) lead last when reconnecting the enclosure must be made such that no metal particles
battery. Follow these precautions to prevent starting of the including drill chips contaminate the components in the
generator set by an automatic transfer switch, remote
ATS enclosure.
start/stop switch, or engine start command from a remote
computer.
TP-5700 12/07 Section 8 Paralleling and Remote Start/Control Systems 77

8.2 550 Controller, Menu 15 Paralleling Applications Only. Analog input A07 is the
voltage adjustment for paralleling applications only.
Paralleling Relays This input adjusts input up or down from value entered in
Menu 15 provides the necessary paralleling relays for Menu 11, Voltage Regulator. If keypad entry does not
units with the optional paralleling protection feature. If match the displayed value for voltage adjust, the analog
the generator set personality profile did not include the input is not at zero (2.5 VDC). Analog input A07 can be
paralleling option, this menu will not appear on the monitored or checked in Menu 3, Analog Monitoring.
display.
Note: Paralleling applications require enabling VAR/PF
The following list shows the paralleling relays. See the controls. Utility Gain Adjust is used for VAR or PF
550 controller operation manual for further details stability adjustment while paralleling to a utility.
regarding Menu 15, Paralleling Relays.
See the 550 controller operation manual for further
D PR Overvoltage VAC details regarding Menu 11, Voltage Regulator, and
d Time Delay Seconds changing the voltage configuration.
D PR Undervoltage VAC
d Time Delay Seconds
D PR Overfrequency Hz 8.4 Reactive Droop Compensator
The reactive droop compensator is used to distribute the
D PR Underfrequency Hz
load evenly when two generator sets are used in
parallel. A qualified electrician or technician should
D PR Reverse Power kW
install these kits. See Figure 8-1 and Figure 8-2.
Additional generator set connections are shown in
D SD Reverse Power kW
Figure 7-1 through Figure 7-4.
D PR Over Power kW
D SD Over Power kW
D PR Loss of Field kVAR
D SD Loss of Field kVAR
D PR Overcurrent Amps
D SD Overcurrent Amps
D Synchronization
d Synch Voltage Match VAC
d Synch Freq. Match Hz
d Synch Phase Match Degrees
8.3 550 Controller, Menu 11

Voltage Regulator
Menu 11 provides the setup of the voltage regulator
functions including the line-to-line voltages,
underfrequency unloading (volts per Hz), reactive
droop, power factor, and kVAR adjustments. See Notes: Current transformer dot or “HI”
toward generator except as noted for
Appendix G, Voltage Regulator Definitions and optional droop C.T. 1 phase connections.
The 380 volt, 480 volt, and 600 volt
Adjustments, for additional information. generator sets require two turns of output
leads through current transformer. All
others require one turn of output leads
The user must enable the programming mode to edit the through current transformer.
Phase Rotation:
display.
A B C
L1 L2 L3
Note: Press the Menu Right → key prior to entering the DC-273000-S
decimal values where necessary.
Figure 8-1 Generator Set Connections
78 Section 8 Paralleling and Remote Start/Control Systems TP-5700 12/07
X-467-4 (Rheostat)
283869 (Nameplate)
Note: Position locating ring
or rheostat so terminals are
in the 6 o’clock position as
Wiring Instructions: shown. Nameplate is located
1. Remove lead connecting TB4-V8 & (black) on front of rheostat.
stator or PT2 lead “V8”
2. Reroute this lead and connect it to QCON2
3. Reroute (black) stator or PT2 lead “V8” and
connect it to QCON1
GM39328-A
Figure 8-2 Wiring Diagram
Test Procedure b. Observe the voltmeter on unit #1 with the

reactive droop rheostat set at minimum. As the
To test and adjust the reactive droop compensator, rheostat is turned clockwise, the voltmeter
proceed as follows. Read the entire procedure before should show a decrease in voltage. If a larger
beginning. voltage is obtained when the reactive droop
rheostat is turned clockwise, shut down the
1. With the reactive droop rheostat set at minimum
system and reverse the direction of the
(full counterclockwise position), record the rpm or
generator load line through the current
frequency and voltage at 1/4 load steps to full load
transformer, or reverse the transformer leads.
on unit #1. Repeat Step 1 for unit #2.
Recheck the droop.
2. Compare the readings and make final adjustments
c. Adjust the reactive droop rheostat to a value at
so that the voltage is within 1 volt at each load step
approximately 4% below rated voltage at full
and the speed is within 3 rpm or the frequency is
load. As an example, the voltage will droop
within 0.1 Hz for each unit. Adjust the voltage using
(decrease) 19.2 volts on a 480-volt system at
the local or remote voltage adjusting potentiometer.
full load or 9.6 volts at 1/2 load. To determine
Adjust the speed at the governor or at the remote
voltage droop at other than full load, use the
speed adjusting potentiometer.
following formula:
3. Check the droop compensation on each unit as
Rated Voltage x 0.04 x Actual Load
follows:
(expressed as a percent of full load)
a. With unit #1 operating at the correct speed and = Voltage Droop
voltage, apply a lagging power factor load. This
Note: With full load 0.8 power factor, a droop
load should preferably be 1/2 to full load and
of 3%-5% should be adequate for
must be inductive, as resistance loads cannot
paralleling.
be used.

d. Repeat Steps 3 a., b., and c. for unit #2 and be reduce the current of the unit(s) that has the
certain the amount of voltage droop is equal at highest reading. Adjust the rheostat to
the same load point as on unit #1. increase current on the unit(s) with the lower
reading. Continue making minor adjustments
e. With this procedure, the two units will share until each unit supplies current proportional to
reactive currents proportionately. its capacity as a proportion of the total system
capacity.
4. In addition to Steps 1-3, it is desirable to use the
following procedure to check that the units are c. As a result of performing Steps 4 a. and b., the
sharing the reactive load correctly. governors have been adjusted to balance the
load and the reactive droop rheostat has been
a. Parallel the units at 1/2 to full load. Check the adjusted to balance the current. These settings
wattmeters to determine that each unit is would be optimum for parallel operation.
carrying equal kW load or a load proportional to
its capacity. If the loads are incorrect, adjust Note: The voltage must droop on lagging
and recheck the governor throttle control to power factor loads (inductive loads). A
correctly balance loading. Engine speed will little change in voltage is acceptable on
determine load sharing ability. unity power factor loads (resistive
loads).
Note: Use wattmeters, not ammeters, to verify
load balance.
8.5 Remote Speed Adjustment
b. With the load balanced, check the ammeters to
see that equal current is being produced or the This kit provides remote engine speed adjustments with
current is proportional according to capacity of an approximate range of ±5% at 1800 rpm. This kit
each generator set. If the currents are requires a generator set with an electronic governor.
incorrect, adjust the reactive droop rheostat to See Figure 8-3 and Figure 8-4.
USE GM30860 BRACKET USE GM30860 BRACKET EXISTING

USE GM30860 BRACKET
Note: Dimensions shown in mm AS TEMPLATE FOR DRILLING AS TEMPLATE FOR AS TEMPLATE FOR TERMINAL BLOCK
2X 6.40 HOLES DRILLING DRILLING
2X 6.40 HOLES
2X 6.40 HOLES
C.T. TERMINAL
254.0 REF. BLOCK
(INSIDE OF J--BOX) VOLTAGE
SEE DETAIL D
102.0 REF.
REGULATOR
SEE DETAIL D
305.0 REF.
76.2 REF.
EXISTING TERMINAL 123456

BLOCK
(INSIDE OF J--BOX)
GM30862 DECAL,
SPEED ADJUST
76.2 REF. EXISTING TERMINAL
SEE DETAIL D BLOCK 76.2 REF.
GM30860
VIEW A--A VIEW B--B VIEW C--C
38.0 REF.
GM31213
JUNCTION A
BOX B
RELAY PANEL
C C
A LO
M933--06014--60 (2) EXP

M6923--06--80 (2) EXP
B
DETAIL D
(INSIDE OF BOX)
230--300 KW 350--400 KW 450--2000 KW

GM30859-A
Figure 8-3 Remote Speed Potentiometer Installation

8.6 Remote Voltage Adjustment
This kit provides the ability to fine adjust the generator
2 1
output voltage from a remote location. Use this kit on
1
20--300 kW 16-light controller models. The maximum
WHT
3
RED
BLK
recommended wire length from the potentiometer to the
generator set is 15 ft. (4.6 m); 18-gauge twisted pair
wire is recommended. Use a remote voltage regulator
kit if further distance is required. See Figure 8-5 and
WHT
WHT
RED
RED
BLK
BLK
Figure 8-6.
1 2 3 4 5 6 1 2 3 4 5 6 1
2
953
916
510
952
510
952
7
*
2 2
See Notes
3
3 3 4
4
DDEC MDEC
CONNECTIONS CONNECTIONS
7
Notes: GM30859-A
• Wire number is 542 on 2000/4000 series engine or

545 on 60 series engine (for DDEC connections only).
•. Remove and tape wire 542 (545) when installing 6
manual speed adjust kits.
5
1. GM31213 potentiometer assembly ref. TT-919
2. Existing terminal block
3. Existing engine wiring harness
3.51 mm (1.38 in.)
1.27 mm (0.50 in.)

Figure 8-4 Remote Speed Adjusting Control Wiring
Diagram
To program the 550 controller, MDEC-equipped DDC/ ∅1.03 mm (0.046 in.)
MTU engines only, use the following instructions. See ∅0.48 mm (0.188 in.)
the 550 controller operation manual for further
information, if necessary.
∅0.40 mm (0.156 in.)
1. Go to Menu 14—PROGRAMMING MODE to
enable LOCAL programming.
2. Go to Menu 7—GENERATOR SYSTEM.

3.35 mm (1.32 in.)
3. Press MENU Down # Key to access ENABLE VSG 6.67 mm (2.625 in.)
(variable governor speed) data. TT-941
1. Potentiometer 5. Knob
4. Press the YES Key.
2. Panel 6. Screw
3. Nameplate 7. Washer
5. Press the ENTER z Key to confirm entry. 4. Nut
6. Verify ENABLE VSG code YES appears on the Figure 8-5 Potentiometer Installation
display.
7. Go to Menu 14—PROGRAMMING MODE to

change to programming mode OFF.

327097-A
Figure 8-6 Disconnection of Controller Voltage Adjusting Potentiometer

8.7 Remote Wiring
Figure 8-7 is the assembly drawing for the 16-light
controller and Figure 8-8 is the accessory
interconnection diagram showing the remote wiring for
the 550 controller.
GM28631C-B
Figure 8-7 16-Light Controller Remote Wiring
GM16088A-F
Figure 8-8 550 Controller Remote Wiring

8.8 Remote Voltage Regulator Kit, recommended distance between the voltage
adjustment potentiometer and the voltage regulator is
20--300 kW 4.3 m (15 ft.). See Figure 8-9, Figure 8-10, and
The remote mount voltage regulator kit is recommended Figure 8-11 for 20--300 kW models. See Figure 8-12 for
whenever the voltage adjustment potentiometer is 350--2000 kW models.
located beyond 4.3 m (15 ft.) from the generator set.
Maximum distance between the generator set and Note: A remote voltage adjustment potentiometer kit is
required when relocating the voltage regulator.
voltage regulator is 287.4 m (1000 ft.). Maximum
1
141312 1110 9 8 7 6 5 4 3 2 1
7N 3
14 13 1211 10 9 8 7 6 5 4 3 2
V8
NO. 2 ON MARKER
3B
STRIP MUST BE IN LINE
WITH 7N LEAD ON
5B TERMINAL BLOCK.
V7
1B
68
67
1. Remote Regulator Mounting Plate Assembly (A-263266)

2. Regulator Assembly
3. Wiring Harness (273941) BS-272000-D
Figure 8-9 Remote Voltage Regulator Kit Installation, 20--300 kW

CONNECTIONS BETWEEN TERMINAL BLOCKS AND TO REMOTE
VOLTAGE ADJUST POTENTIOMETER ARE CUSTOMER SUPPLIED
REMOTE VOLTAGE
SWITCHGEAR ADJUST POTENTIOMETER GENERATOR SET
(BACK VIEW) JUNCTION BOX
1 1
7N 2 2 7N
3 3
3 2 1 V8 4
4 V8
6 5 4
5 5
9 8 7 3 2 1
3B 6 6 3B
12 11 10 6 5 4
7 7
9 8 7 CONNECT TO
8 8 AC HARNESS
12 11 10
5B 9 9 5B
V7 10 10 V7
1B 11 11 1B
12 12
68 13 13
VOLTAGE 67 14 14
REGULATOR
TG2
REMOTE REGULATOR KIT

LEGEND
3B PHOTO--COUPLING
5B PHOTO--COUPLING
67 VOLTAGE ADJUST
68 VOLTAGE ADJUST
V7 AC VOLTAGE SENSING
V8 AC VOLTAGE SENSING
7N BATTERY GROUND
1B BATTERY VOLTAGE PLUS
BS-272000-D
Figure 8-10 Wiring Diagram, 20--300 kW
BS-272000-D
Figure 8-11 Schematic Diagram, 20--300 kW

View C
Connect Between Terminal Block and Voltage Regulator
See View C
See View C
View A View B
GM129340-B
Figure 8-12 Remote Voltage Regulator Kit Installation, 350--2000 kW
8.9 Voltage Regulator Use Figure 8-14 for installation and troubleshooting of
the electrical wiring system.
DVR 2000EC/Remote Voltage
Regulator Kit, 350 kW and
Above BA F
CDE
The DVR 2000E is used with nonparalleling

applications and the DVR 2000EC is used when GND
paralleling is required.
If the voltage configuration is changed, make 1

adjustments to the DVR 2000 voltage regulator at the
voltage regulator. Remove the junction box cover to
adjust the DVR 2000 voltage regulator. See
Figure 8-13, Figure 8-14, and TP-5579, Operation
Manual, DVR 2000 Voltage Regulator, for more
information.
GM16780-A
DVR 2000t is a trademark of Marathon Electric Mfg. Corp.

1. DVR 2000 voltage regulator
Figure 8-13 DVR 2000 Voltage Regulator Mounting

Location

Junction Box Legend
PMG -- Permanent Magnet Generator
STAT -- Stator
TB5 -- Controller AC Fuse Block
QCON(#) -- Quick Connect
Generator
GM20500-
Figure 8-14 DVR 2000 Voltage Regulator/Alternator Interconnection Wiring Diagram

8.10 Voltage Regulator, PMG Volt/Hz Potentiometer Adjustment Procedure
If the voltage configuration is changed, use the following This adjustment determines engine speed (Hz) at which
procedure to make adjustments to the voltage regulator alternator output voltage will begin to drop.
used on PMG alternators.
1. Turn generator set master switch to OFF/RESET.
The AVR monitors output voltage magnitude and
2. Turn stability potentiometer fully counterclockwise.
frequency to supply current to the stationary LED board.
The AVR circuit board includes volts/Hz and stability 3. Connect a 100-watt light bulb across terminals V0
adjustment potentiometers. The volts/Hz adjustment is and V7 on controller terminal strip or across
factory-set and normally requires no further adjustment. terminals on controller frequency meter.
If operating the generator set under extreme loads
results in voltage instability, adjust the potentiometers 4. Start generator set. With generator running at no
according to the following procedure. See Figure 8-15. load, observe light bulb flicker. Excessive light bulb
flicker indicates poor stability.
5. Adjust stability potentiometer until minimum flicker

is obtained.
1 6. Use controller voltage adjustment potentiometer
(or remote voltage adjustment potentiometer) to
2
make adjustments to the generator set while
running under normal load (if required).
3
7. Adjust the engine speed to the desired cut-in
frequency (factory setting is 57.5--58.0 Hz for 60 Hz
models or 47.5--48.0 Hz for 50 Hz models) as
measured on frequency meter. See the governor
manual for information on engine adjustment.
8. Rotate the volts/Hz adjustment potentiometer

clockwise until voltage level begins to drop (as
C-255670-B
measured on voltmeter). When set to these
1. 60 Hz voltage adjustment 3. Stability adjustment specifications, the generator set will attempt to
2. 50 Hz voltage adjustment
maintain normal output until engine speed drops
Figure 8-15 AVR Adjustment below the frequency set in the previous step (as
load is applied).
Stability Potentiometer. Fine tunes voltage regulator
to reduce light flicker. 9. Adjust the engine speed to obtain a full load engine
speed of 1800 rpm (60 Hz) or 1500 rpm (50 Hz).
Volt/Hz Potentiometer. This adjustment determines Confirm and adjust the output voltage as needed.
engine speed (Hz) at which generator output voltage will
begin to drop. 10. Use controller voltage adjustment potentiometer
(or remote voltage adjustment potentiometer) to
make final adjustments to the generator set while
running under normal load.
11. Readjust stability potentiometer (if necessary).

8.11 Voltage Regulator, Wound Stability Potentiometer. Potentiometer fine tunes the
regulator circuitry to reduce light flicker.
Field
Volts/Hz Potentiometer. Potentiometer adjustment
The voltage regulator is factory-set and, under normal
determines the engine speed (Hz) at which the
circumstances, requires no further adjustment.
alternator output begins to drop.
However, for wound field alternators, if the voltage/
frequency reconnection has been done, readjust the Voltage Adjustment (remote only). Use the generator
voltage regulator according to the following procedure. set controller voltage adjustment control to adjust the
The voltage regulator components are identified and alternator output. See the respective generator set
described in the following paragraphs. Figure 8-16 operation manual for further information.
illustrates the voltage regulator features. Figure 8-17
identifies the voltage regulator connections to the P40
Voltage Regulator Adjustment Procedure
socket.
Figure 8-18 illustrates the wiring connections necessary
Note: Frequency reconnection. Refer to the respective for the voltage regulator adjustment procedure.
generator set spec sheet to determine if engine
frequency (speed) is fixed or field-convertible.
9 10 11 12
5 6 7 8
1 2 1
1 2 3 4
+ C4 R28 R32 LED1 LED2 D6 C32 R56 R60 D8

C
C14 SHTDWN
OUT R50 R57 U7
R9 R21 R33
D3 U2 C18 C27 U6 C33
R10
C6 R34
R11
D2 C35 C46
R22 C15 R35 Q1 C34 R58
R23 D7 R61 R71 V1
C16 Z1
R12
C7 U3
C5 C19
Q2 C36
C45 R72
9
L8
P40
12 8
D1 R5 R13 C8 R36 R45 R51 R62 L3
R6 R14 C9 C20
C24 C28 C29 C37 L4
R1 C2 R37
VR1 R59 R63
C1 U1 R24
C10
R29 + C21
R53 C39
C38 R64
R65 L5
1 4
2 V7 V8
R2 R73
R3 C3 R15R25 R38 R42 C25 VADJ R75
C17 U5 C30 L1 C40 R66
R4 R7 R16 C11 U4 R39 R43 C26 R74 R76
R17 C12 R40 D4 R46
C31
L2 C41 R67
R77
F1 (F+) F2 (F--) 1 2 3 4
R18 C13 R47
C22 R54 C42 R68
R19R26 C23 D5 R48
R20 R27
R30
R31 R41 R44 R49
R55 C43 R69 L6
C44 R70 L7
T1 T2 7 3
R8 V/HZ R52 STAB VAR/PF--VAR/PF+
GM31850A-E
5 4 3 AC F+
AC
AC F --
1. LED1 (red shutdown) 4. Stability potentiometer

2. LED2 (green output) 5. Volts/Hz potentiometer
3. 12-pin socket P40 66 55
6
Figure 8-16 Voltage Regulator Features 5 4
TP-6349-4
1. Sensing leads
2. Stator main windings
Socket 3. Rotor main field
P40- Lead Description/Function
4. Voltage regulator power supply leads
1 68 Remote voltage adjustment 5. Rotating rectifier assembly (RRA)
2 V7 TB4-V7 sensing input 6. Exciter armature
7. Exciter field winding
3 V8 TB4-V8 sensing input 8. Voltage regulator (P40 socket)
4 FP Exciter field output
Figure 8-18 Voltage Regulator Connection
5 67 Remote voltage adjustment
6 EOV Overvoltage controller output signal 1. Verify that the generator set master switch is in the
7 — Not used OFF/RESET position.
8 FN Exciter field output
9 7N TB11-7N (battery negative) 2. Turn the Volts/Hz and the stability potentiometers
fully counterclockwise. Connect the voltmeter to
10 1B Safeguard circuit breaker (battery positive)
the AC circuit or an electrical outlet.
11 55 Voltage regulator power supply
12 66 Voltage regulator power supply 3. Move the generator set master switch to the RUN
Figure 8-17 Voltage Regulator P40 Connections position.

4. Change the voltage adjustment control (located at 8. Rotate the volts/Hz potentiometer clockwise until
the generator set controller) until the desired output the voltage level as measured on the voltmeter
voltage is achieved. begins to drop. When the regulator is set to these
specifications, the alternator will attempt to
5. Rotate the stability potentiometer clockwise until maintain normal output until the engine speed
light flicker minimizes. drops below the frequency set in step 7 as load is
applied.
6. Readjust the voltage adjustment control (located at
the generator set controller) until the desired output 9. Readjust the engine speed to 1800 rpm for 60 Hz
voltage is achieved. models or 1500 rpm for 50 Hz models.
7. If the engine has a speed adjustment governor, 10. Readjust the voltage adjustment control (located at
adjust the engine speed to the specified cut-in the generator set controller) until the desired output
frequency as measured on the frequency meter. is achieved.
The factory setting is 57.5--58 Hz for 60 Hz models
and 47.5--48 Hz for 50 Hz models. 11. Readjust the stability potentiometer until light
flicker minimizes.
Note: Some engines do not permit engine speed
adjustment. 12. Move the generator set master switch to the OFF/
RESET position to stop the generator set.

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge
TP-5700 12/07 Appendix 91

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram μF microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph., ∅ phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mΩmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay
92 Appendix TP-5700 12/07

Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.
Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.
See Appendix C, General Torque Specifications, and 3. Follow these SAE washer rules after determining
other torque specifications in the service literature. exit hole type:
a. Always use a washer between hardware and a

Preferred Nut/Bolt Clearance slot.
1 2 b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female

thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3 2
1
3
G-585
1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
5
4
6
G-585
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque
Torq e Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) —
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) —
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288)
3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39)
3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44)
7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63)
7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) See Note 3
1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96)
1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108)
9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138)
9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154)
5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191)
5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216)
3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338)
3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378)
1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818)
1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)
M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)
M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48)
M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50)
M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85)
M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) See Note 3
M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133)
M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140)
M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205)
M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212)
M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288)
M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305)
Notes:
1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings
when they differ from the above torque values.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.

Appendix D Fuel Physical Properties
Physical Property Manufactured or

@ 15°C (60°F) Butane Propane Natural Gas Sewage Gas Gasoline Diesel Fuel
Normal
atmospheric state Gas Gas Gas Gas Liquid Liquid
Boiling point,
Initial, °C (°F) — — — — 36 (97) 177 (350)
End, °C (°F) 0 (32) 42 (--44 ) --162 (--259) — 216 (420) 357 (675)
Heating value, Btu
/gal. (net, LHV*) 94670 83340 63310 — 116400 130300
/gal. (gross) 102032 91500 — — 124600 139000
/ft3 (gas) 3264 2516 1000 600--700 6390 —
Density,
Ft3 of gas/gal. 31.26 36.39 57.75 — 19.5 —
Wt./gal. liquid, lb. 4.81 4.24 2.65 — 6.16 7.08
Octane Number
Research 94 110+ 110+ — 80--100 —
Motor 90 97 — — 75--90 —
* Lower Heating Value
Figure 3 Engine Fuels, Physical Properties
Characteristic, LP Gas* Butane Propane

Formula C4H10 C3H8
Boiling point, °C (°F) 0 (32) --42 (--44)
Specific gravity of gas (air = 1.00) 2.00 1.53
Specific gravity of liquid (water = 1.00) 0.58 0.51
Btu/lb. of gas 21221 21591
Ft3 of vapor at 16°C (60°F)/lb. of liquid at 16°C (60°F) 6.506 8.547
Latent heat of vaporization at boiling point, Btu/gal. 808.0 785.0
Combustion Data:
Ft3 air required to burn 1 ft3 of gas 31.02 23.86
Flash point, °C (°F) N/A --104 (--156)
Ignition temperature in air, °C (°F) 482--538 (900--1000) 493--549 (920--1020)
Max. flame temperature in air, °C (°F) 1991 (3615) 1979 (3595)
Limits of inflammability, percentage of gas in air
mixture:
At lower limit, % 1.9 2.4
At upper limit, % 8.6 9.6
Octane Number (ISO-Octane = 100) 92 Over 100
* Commercial quality. Figures shown in this chart represent average values.
Figure 4 Additional LP Gas Characteristics

Appendix E Gas Fuel Vapor Pressures
14.06 kg/cm2 (200 psi)
12.65 kg/cm2 (180 psi)
11.25 kg/cm2 (160 psi)
9.84 kg/cm2 (140 psi)
8.44 kg/cm2 (120 psi)

Pressure
7.03 kg/cm2 (100 psi)
5.62 kg/cm2 (80 psi)
4.22 kg/cm2 (60 psi)
2.81 kg/cm2 (40 psi)
1.41 kg/cm2 (20 psi)
0 kg/cm2 (0 psi)
--40°C --28°C --18°C --7°C 4°C 15°C 27°C 38°C
(--40°F) (--20°F) (0°F) (20°F) (40°F) (60°F) (80°F) (100°F)
Temperature
Figure 1 Vapor Pressures of LP Gases Graph
Approximate Pressure, kg/cm2 (PSIG)

Temperature,
Temperature
°C (°F) Propane 50/50 Mixture Butane
--40 (--40) 0.1 (1) — —
--36 (--33) 0.4 (5) — —
--28 (--20) 0.7 (10) — —
--23 (--10) 1.2 (17) 0.2 (3) —
--18 (0) 1.7 (24) 0.4 (5) —
--12 (10) 2.2 (32) 0.6 (8) —
--7 (20) 3.0 (42) 0.9 (13) —
--1 (30) 3.7 (52) 1.3 (19) —
4 (40) 4.6 (65) 1.8 (26) 0.1 (2)
10 (50) 5.5 (78) 2.4 (34) 0.5 (7)
15 (60) 6.5 (93) 3.0 (42) 0.8 (12)
21 (70) 7.7 (109) 3.5 (50) 1.2 (17)
27 (80) 9.6 (136) 4.2 (60) 1.7 (24)
32 (90) 10.3 (147) 5.1 (72) 2.2 (32)
38 (100) 11.9 (169) 6.0 (85) 2.8 (40)
43 (110) 14.1 (200) 7.0 (100) 3.5 (50)
Figure 2 Vapor Pressures of LP Gases Table

Appendix F Gas Fuel System Installation Planning
Determining Propane Cylinder Determining Propane Vaporization

Quantity Capacity
Guide for Installing 100 lb. Cylinders Guide for ASME LP Gas Storage
Containers
For continuous draws where temperatures may reach
--18°C (--0°F). Assume the vaporization rate of 100 lb.
cylinder as approximately 50000 Btu/hr. % of Container K Propane* Vaporization Capacity
Filled Equals at --18°C (0°F) in Btu/Hr.[
Number of cylinders/side = Total load in Btu 60 100 D x L x 100
50000 50 90 D x L x 90
40 80 D x L x 80
Example:
30 70 D x L x 70
Assume total load = 20000 Btu/hour. 20 60 D x L x 60
10 45 D x L x 45
Cylinders/side = 20000 = 4 cylinders/side * These formulae allow for the temperature of the liquid to
50000 refrigerate to --29°C (--20°F), producing a temperature
differential of --7°C (20°F) for the transfer of heat from the air to
The chart in Figure 1 shows the vaporization rate of the container’s wetted surface and then into the liquid. The
vapor space area of the vessel is not considered since its
containers in terms of the temperature of the liquid and effect is negligible.
the wet surface area of the container. When the [ D=outside diameter in inches
temperature is lower or if the container contains less L=overall length in inches
liquid, the vaporization rate of the container is a lower K=constant for percent volume of liquid in container.
value. Figure 2 Propane Vaporization Capacity
Maximum Continuous Draw In Btu/Hour At Vaporizing Capacities for Other Air

Various Temperatures In °C (°F)
Lb. of
Lb
--7°C 4°C 16°C
Temperatures
Propane --18°C 21°C
in Cyl. (0°F) (20°F) (40°F) (60°F) (70°F)
Multiply the results obtained with the formulae in
100 113000 167000 214000 277000 300000 Figure 2 by one of the factors in the following table for
90 104000 152000 200000 247000 277000 the prevailing air temperature.
80 94000 137000 180000 214000 236000
70 83000 122000 160000 199000 214000
Prevailing Air
60 75000 109000 140000 176000 192000 Temperature Multiplier
50 64000 94000 125000 154000 167000 --26°C (--15°F) 0.25
40 55000 79000 105000 131000 141000 --23°C (--10°F) 0.50
30 45000 66000 85000 107000 118000 --21°C (--5°F) 0.75
20 36000 51000 68000 83000 92000 --18°C (0°F) 1.00
10 28000 38000 49000 60000 66000 --15°C (5°F) 1.25
Figure 1 Vaporization Rate, 100 lb. Propane --12°C (10°F) 1.50

Cylinders, Approximate --26°C (15°F) 1.75
--7°C (20°F) 2.00
Figure 3 Propane Vaporization Temperature

Appendix G Voltage Regulator Definitions and Adjustments
The following definitions and adjustment/setting mathematically by Ohm’s law, which states that power is
specifications are intended for users planning to adjust equal to the voltage squared divided by the impedance.
the voltage regulator beyond the default settings in As the voltage is reduced, the power delivered by the
order to customize the alternator for a specific alternator decreases by a squared relationship. Since it
application. is the power in the alternator that translates into engine
torque, the engine load is also reduced.
This information is not intended to be a comprehensive
explanation of all the terms mentioned. There are By changing various parameters of this compensation
numerous documents available that define these terms technique, the controlling system can be tailored to
more completely than described herein. Any user match the performance capabilities of most engine and
planning to change the generator set controller alternator combinations. The point at which the
adjustment settings or to apply the generator set to unloading begins to act or how much unloading occurs
these types of applications should understand these can be adjusted to impact maximum voltage droop,
terms. maximum speed droop, or time to recover. Some
applications may not need unloading and, in these
This appendix contains references to other sections of cases, set the unloading parameter to disable the
this manual. Please refer to these sections for further function. These parameters are further described
information and explanation. below. An example is provided to help clarify the
relationship between these parameters.
Paralleling generator sets can be a complicated and
dangerous exercise. Application programming must be
performed by appropriately skilled and suitably-trained Underfrequency Unload Slope
personnel.
Underfrequency unload slope is the term used to
describe the amount that the voltage is reduced,
Definitions per-cycle-per-second or per-hertz (Hz), when in an
underfrequency condition. The slope or schedule is
sometimes called the volts-per-hertz slope. When the
Underfrequency Unloading electrical frequency drops below the cut-in point (see
below), the excitation control system temporarily
Underfrequency unloading is a function used in the
alternator excitation control system to improve the reduces the regulated voltage to reduce the subsequent
torque on the engine. The amount that the control
overall generator set system (engine and alternator)
system reduces voltage is defined as the product or
response. In particular, underfrequency unloading
relates to large-block load applications. When applied multiplication of the slope and the amount of frequency
or speed below the cut-in point. For every Hz below the
to engine-driven alternators, large-block loads cause a
subsequent transient torque load on the engine. This cut-in point, the control system reduces the line-to-line
torque load can reduce the engine’s speed below the voltage by an amount equal to the slope.
normal operating point. Typically, the engine speed Because each engine responds differently to the
controller or governor will compensate for this by
various loads encountered, the slope may be adjusted
commanding an increase in fuel. If, however, the fuel to improve the system response. If, when large loads
system is inadequate to recover from a relatively large are applied to the generator set, the engine speed drops
load, the speed may never recover. In these instances,
below the acceptable limit (as determined by the
other measures must be taken. This is where the particular loads applied), the slope may need to be
underfrequency unloading occurs.
increased. Increasing the slope will cause the voltage to
When the excitation control system detects a drop in the droop more during load applications, consequently
reducing the load torque on the engine and allowing the
speed or electrical frequency below some
predetermined point, the control system enters an speed to increase. If, however, the voltage drops below
an acceptable lower limit (as determined by the
unloading condition. This can be described as moving
particular loads connected to the generator set), a lower
to a lower voltage regulation point. By reducing the
output voltage of the alternator, the load on the slope may work better. The underfrequency unloading
function may be disabled by setting the slope to zero.
generator set is reduced. This can be shown

Frequency Setpoint or Cut-In Point alternators are designed to produce balanced, equal
voltage on all three phases. If the loads applied to the
The point at which the underfrequency unloading begins generator set including no load are equal and balanced,
to take effect is adjustable, allowing the system to be the output voltage on each phase will be nearly equal.
tailored for each application. Because the
characteristics of the engine have the largest effect on However, in some applications, individual phases may
the system’s performance, the engine’s response have unequal or unbalanced loads. In these cases, the
should determine the unloading point. The unloading output voltages will not be equal on each phase. In
setpoint is the frequency below which the excitation general, the phase with the greatest load will have the
control will reduce the voltage so that the engine may lowest voltage while the phase with the least load will
begin to recover. have the highest voltage. This is true regardless of the
type of sensing used in the regulator system. A
The cut-in point, or frequency setpoint, should be set single-phase sensing excitation controller will keep the
0.5--3.0 Hz lower than the normal steady-state band of voltage of the sensed phase at the voltage adjustment
operation. If the engine normally operates within a very value. A three-phase sensing system will average the
narrow range of speeds close to the nominal, a setpoint three phases and hold the average to the adjustment
of 0.5 to 1.0 Hz below nominal should be suitable. If the setting. The average is the sum of the voltages of three
engine normally operates over a wide range of speeds, phases divided by 3.
the setpoint may need to be 2.0--3.0 Hz from the
nominal. The underfrequency unloading function can As stated above, three-phase sensing does not
be eliminated by setting the cut-in point below the eliminate the unequal voltage phenomenon.
minimum expected operating frequency. Three-phase sensing balances the inequality of voltage
between the phases to the desired value. In other
Example words, if a system with unbalanced loads uses a
single-phase control feedback, the voltage on the
A 90 kW load is applied to a 100 kW, 60 Hz generator set sensed phase would be at the setpoint while the other
driven by a turbocharged diesel engine with an two phases would vary by their proportional loads. For
electronical control module (ECM). The speed drops example, if the sensed phase had rated load while the
10% and takes 20 seconds to recover to at least 59.5 Hz. two other phases were only loaded at half the rated
The voltage, meanwhile, drops from 480 to 460 and value, those two phases would have higher-than-rated
recovers to 480 within 15 seconds. Therefore, some voltage which may be undesirable. If a three-phase
underfrequency unloading should be provided. A good sensing feedback were utilized, the phase with rated
starting point would be a frequency setpoint or cut-in of load would be regulated to a voltage slightly below the
59 Hz. A slope of 15 volts per-cycle-per-second is rated voltage while the other two phases would be
appropriate as well. If after these adjustments the slightly above the rated voltage (but lower than in the
speed recovers very quickly, in about 5 seconds, but the previous case). The sum of the three, divided by 3,
voltage drops below 440 volts, the slope should be would be equal to the regulation setpoint.
reduced to 12 volts per cycle. More adjusting may be
required to get the most desirable compromise between In a single-phase system, line-to-line voltage is held
speed and voltage. equal to the line-to-line voltage adjust setting. In a
three-phase system, the average of the three line-to-line
voltage is regulated to the voltage adjust setting. In
Three-Phase Sensing some cases, it may be desirable to keep one phase at a
Three-phase sensing describes how the excitation particular value. Modify the voltage adjust setting higher
control or voltage regulator determines the condition of or lower accordingly for any unique requirements for the
the alternator output voltage. Early types of regulators particular application. Each of the individual phase
sensed the voltage on just one phase of the alternator. voltages is available in Menu 11, Voltage Regulator.
Single-phase sensing is not uncommon today as most

Reactive Droop If the reactive current is not stable in the system, adjust
the droop lower in all generator sets.
Reactive droop refers to another compensation
technique used in excitation control systems. Reactive As implied above, the reactive droop is not usually
droop means that the generator set voltage droops with necessary in stand-alone applications. Therefore,
increasing reactive current. Although this sounds like some means of disabling the feature is provided. If the
an undesirable effect, it is quite beneficial in paralleling generator set will not be paralleled with other generator
applications with multiple generator sets. Because the sets, the reactive droop feature should be disabled. A
terminals of the generator set are connected to another reactive droop setting of 0 will also effectively disable the
generator set(s), the voltage at the terminals is not reactive droop feature. It should be noted that reactive
solely determined by either generator set’s excitation. droop applies strictly to the reactive current or
Rather, it is determined by the combination of the volt-ampere-reactive (VAR) loading. Primarily, the
excitation level, the generated voltage, and the voltage fueling or speed governing system controls the real
drop across the armature impedance or armature current which contributes to watts loading.
reactance for each generator set.
The gain of the reactive droop function is determined by
Normally the generated voltage is higher than the the voltage droop setting. For most applications, a
voltage at the terminals because the generator set droop of 3%--5% of rated voltage at rated load at 0.8 PF
current causes a drop across the armature impedance. is adequate. Prior to actually connecting the generator
In a parallel application, the generated voltage of one sets in parallel, test the droop by applying full rated load
generator set may be slightly higher than the generated at 0.8 PF. The system is operating correctly if this test
voltage of another generator set. Differences in shows a reduction in voltage equal to the voltage droop
potential between the generator sets will cause current setting. If the available load is less than full load, the
to flow into the lower voltage generator set and will also correct voltage droop should be proportional to the
cause the generator sets to share the load current applied VAR load as a fraction of the rated VAR output
disproportionately. Both results are undesirable. for the generator set. For instance, a 480-volt generator
set with a voltage droop setting of 4% should drop 19.2
By introducing reactive droop, the reactive current can volts with full rated (0.8 PF) load applied (480 x 0.04) or
be better predicted and controlled. If the current is 9.6 volts with half the rated load applied (480 x 0.04 / 2).
measured, the regulator/controller can adjust the
excitation up or down accordingly, reducing excitation When a generator set will be connected in parallel with
as more current is supplied or increasing excitation as the utility, VAR or PF control should be ENABLED. If
the reactive current decreases. If all the parallel there are multiple generator sets in parallel as well, then
generator sets incorporate this type of compensation, reactive droop should be ENABLED also.
the reactive current can be shared equally based on the
proportional size of the generator sets. For an example, Example
see below.
Two 100 kilowatt (kW) generator sets are paralleled to
The stability and accuracy of this technique depends on provide 150 kW of power at 0.8 PF and wired for a
several factors. Most important, the regulation point for 277/480-volt wye system.
each generator set must be equal. That is, each voltage
adjust setting must be the equal to the other(s). This is a Total kVA load:
basic requirement prior to the actual paralleling
connection. Also, the effects of the reactive current in kVA = kW / PF
each generator set must be compensated for
187.5 = 150 / 0.8
individually, which requires an adjustable droop for each
generator set. This adjustment happens to be the KVAR load:
reactive droop adjust. The reactive droop adjust is
quantified as the droop in operating voltage from the kVAR = kVA * sin (acos [ PF ] )
adjusted setting when full rated load with 0.8 power
factor (PF) is applied. A droop setting of 4% voltage at 112.5 = 187.5 * 0.6
full rated load is a recommended starting point. If the
reactive current is not shared proportionately in each Line current:
generator set, the respective droops may need
adjustment. Adjust those generator sets that have I = ( VA / 3 ) / VL-N
proportionately higher current for more droop and those
226 amps = (187500 / 3) / 277
generator sets with lower reactive current for less droop.
100 Appendix TP-5700 12/07

Reactive current: The term rated VARs is a bit obscure. In essence, it is a
value derived from the rated kW of the generator set.
I = (VAR / 3) / VL-N For a typical standby rating, the full load of the generator
set is defined to have 0.8 PF. This means that the kW
135 amps = ( 112500 / 3) / 277 load is eight-tenths of the VA load. As described earlier,
the PF for a linear load may be calculated as the cosine
Where: acos is arccosine or inverse cosine
of the angle between voltage and current. This
W is Watt relationship is based on the power triangle. Using this
L-N is line-to-neutral power triangle concept, it can be shown that the reactive
PF is power factor power for a linear load is equal to the sine of the power
angle. Then, using these trigonomic functions, it can be
VA is volt-ampere
shown that for a PF of 0.8, the VARs are related similarly
k is kilo ( = 1000 ) to the VA by a factor of 0.6. More explicitly, the power
Therefore, each generator set in this case should carry angle is equal to the inverse cosine (arccosine) of the
113 amps per phase or half the 226 calculated line PF. For a PF of 0.8, the power angle is 36.9 degrees
amps. The 113 amps includes 67.5 amps of reactive (0.2 radians). The sine of this angle, sine (36.9 degrees)
current, half of the calculated reactive current of is 0.6. This is the factor for calculating rated VARs from
135 amps. The reactive droop should be adjusted until the rated VA. The ratio of these two factors is 0.75 (0.6 /
each generator set carries equal reactive current. The 0.8), which can be used to calculate rated VARs directly
load sharing control should be adjusted so that real from the rated kW; rated VARs equals rated watts * 0.75.
current and/or watts are shared equally as well.
When a generator set will be connected in parallel with
If one generator set is larger than the other, it should be the utility, VAR or PF control should be ENABLED. If
adjusted to carry proportionate current. For this multiple generator sets are in parallel as well, then
example, if a 150 kW generator set is paralleled to a reactive droop should be ENABLED also. Additionally,
75 kW generator set, the larger generator set would note that VAR control should be used only when the
carry 90 amps reactive (135 * 2 / 3) and the other would generator set is connected in parallel with the utility.
carry 45 amps reactive (135 * 1 / 3). Adjust the reactive Parallel connection with the utility requires the logical
droop based on the ratio of the actual measured indication that the circuit breakers tying the generator
currents, not the calculated values. set bus to the utility bus are closed. This indication is
made by use of the programmable digital input for
VAR/PF mode. If this input function is activated, the
VAR Control excitation control changes to the selected VAR or PF
control. If the logical indicator is not present and the
VAR control is analogous to the reactive droop function VAR or PF control is not enabled, the control will not
described above. It differs in that it applies to utility switch to VAR or PF control. Because the active state for
paralleling applications. Because the utility represents the digital input is a HI or open connection, the default for
a nearly infinite bus, the voltage at the load terminals is the digital input (VAR/PF Mode) is DISABLED (displays
not controlled at all by the generator set, and it is ENABLED NO). If the input is ENABLED by the user, it
impossible to compare the ratio of the generator set should be held low by a contact or jumper until the actual
current to the utility based on its rated output. In this closing of the connecting circuit breaker(s). The proper
situation, the excitation control changes from voltage control method, VAR or PF, must be ENABLED within
feedback to VAR feedback. More specifically, the the regulator’s configuration menu.
excitation is controlled to maintain a certain VAR output
rather than a voltage output. This is called VAR control
and again is used only in utility paralleling applications. Power Factor Control
The VAR adjust can be set to any value within the PF control is much like the VAR control above. PF
generator set’s rated capability. Because the VARs control is used only when the generator set is paralleled
cause heating in the armature, any value beyond the to the utility grid. The difference is that the PF of the
generator set’s rating could damage the alternator. In generator set current is held constant. The setting for
most cases, the generator set will be adjusted to the PF adjust determines the relationship of the current
generate VAR (lagging PF) but could absorb VARs and voltage from the generator set. The PF is a term that
(leading PF) as well. However, the VAR setting is defines the ratio of real watts to the volt-ampere (VA)
maintained regardless of the relative PF. If the particular product. For linear loads, a trigonomic relationship can
load requires more VARs than the generator set setting, describe the PF. The PF equals the cosine of the angle
the excess is derived from the utility bus. between the current and voltage. PF is further defined
TP-5700 12/07 Appendix 101

as leading or lagging. That is to say, if the current lags The voltage adjust setting may be changed by means
the voltage (i.e., is later in time), the PF is lagging; if the other than the menu including user-defined digital input
current leads the voltage (i.e., is earlier in time), the PF is or remote communications. If voltage adjustment
leading. Inductive loads have lagging PF while occurs, the new value will be displayed accordingly in
capacitive loads have leading PF. The current in a the voltage adjust menu.
purely resistive load is in phase with the voltage (not
leading or lagging) and the PF is 1.0 (cos. [0] ).
Underfrequency Unload Enable
Set the PF adjust according to the requirements of the
The underfrequency unload enable menu is used to turn
application. When a generator set will be connected in
the underfrequency unload on or off. A YES entry will
parallel with the utility, VAR or PF control should be
turn the feature on and the display will show ENABLED
ENABLED. If there are multiple generator sets in
YES. A NO entry will turn the feature off and the display
parallel as well, then reactive droop should be
will show ENABLED NO. The underfrequency unload
ENABLED also. Additionally, note that PF control
defaults to an enabled (ON) condition.
should be used only while the generator set is
connected in parallel with the utility. Parallel connection
with the utility requires the logical indication that the Frequency Setpoint
circuit breakers tying the generator set bus to the utility
bus are closed. This indication is made by use of the The frequency setpoint is the cut-in point for
programmable digital input for VAR/PF mode. If this underfrequency unloading. At any operating frequency
input function is activated, the excitation control below the frequency setpoint, the output voltage will be
changes to the selected VAR or PF control. If the logical reduced. The frequency may be entered with resolution
indicator is not present and the VAR or PF control is not to tenths of a Hz. The range of acceptable entries is 30
enabled, the control will not switch to VAR or PF control. to 70 Hz. Any entry beyond these limits causes a
Because the active state for the digital input is a HI or RANGE ERROR display and the setting will not change.
open connection, the default for the digital input The default value is one cycle-per-second (or two for
(VAR/PF mode) is DISABLED (displays ENABLED NO). non-ECM engines) below the normal system frequency.
If the input is ENABLED by the user, it should be held low The frequency setpoint changes to the default value if
by a contact or jumper until the actual closing of the the system frequency changes. A setting of 30 Hz
connecting circuit breaker(s). The proper control essentially disables the underfrequency unload feature
method, VAR or PF must be ENABLED within the because most engines do not normally drop to speeds
regulator’s configuration menu. this low, even during load applications.
Underfrequency Unload Slope

Adjustment and Setting
Specifications The slope determines how much voltage is reduced
during an unloading condition. The line-to-line voltage
is regulated to a value less than the voltage adjust
Voltage Adjust setting by this amount for every cycle below the
The voltage adjust is entered as the rated or otherwise frequency setpoint. The voltage may be entered with
desired line-to-line voltage. The average of the resolution as fine as one-tenth of one volt. The default
line-to-line voltages is then regulated to the value is 2.0 volts per-cycle-per-second. A zero entry for
corresponding value as previously described. The the slope in effect turns the underfrequency unload
setting may be as fine as tenths of volts. The voltage feature off.
adjust defaults to the rated system voltage whenever
the system voltage is changed. The voltage adjust may Reactive Droop Enable
be set to any value within ±10% of the system voltage.
The upper limit is ±10% above the system voltage and This menu allows the user to enable the reactive droop
the lower limit is ±10% below the system voltage. If a feature. A YES entry turns the feature on and the display
value beyond these limits is entered, a RANGE ERROR shows ENABLED YES. A NO entry turns the feature off
message will be displayed. and the display shows ENABLED NO. Reactive droop is
intended to be used in a generator set-to-generator set
As a reference, the present voltage adjust setting is paralleling application.
displayed as well as the average value of the line-to-line
voltages. The individual line-to-line voltages are also
displayed on the subsequent menu screens. This
allows the user to monitor any individual phase, if
desired.
102 Appendix TP-5700 12/07

Voltage Droop Generating/Absorbing
The amount of reactive droop is entered here. The While operating in the VAR control mode, the reactive
droop is entered as a percentage of system voltage load on the generator set may be specified to be out of
when a fully rated load at 0.8 PF is applied. The entry GENERATING or into ABSORBING the generator set.
may be made with resolution as fine as one-tenth of one Specifying the VAR type or direction is done through the
volt. This entry determines how much the voltage will GENERATING/ABSORBING menu. Because the
droop when the alternator provides reactive current. normal flow of reactive current is out of the generator
The actual amount the voltage changes is equal to the set, the default value is GENERATING. If ABSORBING
voltage droop setting times the VAR load as a fraction of is desired, a NO entry at this menu will change the
the rated VARs (at 0.8 PF). If the generator set were control mode to ABSORBING. When ABSORBING is
providing full rated load (at 0.8 PF), the expected selected, another NO entry will revert the control mode
voltage change would equal the voltage droop setting as back to GENERATING. It is assumed that this mode will
a percentage of system voltage. A voltage droop setting not be changed when the generator set is running. An
of zero in effect disables the reactive droop feature. The attempt to change the mode while running will return a
default value is 4% droop at full rated load at 0.8 PF. RANGE ERROR message. The generator set will need
to be shut down in order to change this setting.
The present voltage droop setting is displayed for
reference. The display may change if this value is
changed via remote communication. PF Adjust
Use the PF adjust to set the desired operating
VAR Control Enable relationship for the generator set’s output voltage and
current when the generator set is connected in parallel
In order for the VAR control function to operate, it must with the utility. The excitation is regulated to maintain a
be enabled. Entering YES at this menu will turn the PF equal to the entered value. The value entered may
feature on. Because the function is designed to operate be as low as 0.7 for leading PFs or as low as 0.6 for
while the generator set is in parallel with the utility, VAR lagging PFs. Any entries below these limits will cause a
control also requires the proper indication that all tying RANGE ERROR message to display.
circuit breakers are closed. This is done through the
user-programmable digital inputs. The upper limit for PF adjust is 1.0 and the default value
is 0.8 lagging. Each time the system’s rated kW is
Because VAR control cannot be enabled at the same changed, the PF adjust will revert to this default value.
time that PF control is enabled, turning VAR control on The PF adjust display setting may change if the PF
(ENABLED) when PF control is enabled turns the PF adjust is changed via other inputs.
control off (DISABLED).
Lagging/Leading
KVAR Adjust
It is possible to select either a leading or lagging PF for
Using the kVAR adjust sets the desired operating value utility parallel applications. The selected mode is
for the generator set’s reactive load when the generator displayed. A NO entry switches the controller to use the
set operates in a utility paralleling application. The other reference. Because the most common mode of
desired generator set load is entered directly as kVARs. operation will be with a lagging PF, LAGGING is the
The value entered may be as low as zero or as high as default value. Because this mode should not be
the rated value (rated kW x 0.75). Any entry beyond the changed while the generator set is running, attempting
rated value will not be accepted, and a RANGE ERROR to change this mode during operation will return a
message will be displayed. RANGE ERROR message. Always shut down the
generator set to change the lagging/leading mode
The default value for kVAR adjust is zero. Each time the setting.
system’s rated kW is changed, the kVAR adjust will
revert to zero. The displayed kVAR setting may change
if the kVAR setting is changed via other inputs.
TP-5700 12/07 Appendix 103

Notes
104 Appendix TP-5700 12/07

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-5700 12/07h 7 Jurong Pier Road
Singapore 619159
E 1993, 2001, 2006, 2007 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

Kohler Generator Mounting Instructions

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Installation

Industrial Generator Sets

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Model Designation Manufacturer

Accessory Number Accessory Description

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

TP-5700 12/07 Table of Contents 3

Section 5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 Table of Contents TP-5700 12/07

Section 8 Paralleling and Remote Start/Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

TP-5700 12/07 Table of Contents 5

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-5700 12/07 Safety Precautions and Instructions 7

Do not use copper tubing in diesel

Fire. The exhaust system must be WARNING

Do not smoke or permit flames or

Explosive fuel vapors.

8 Safety Precautions and Instructions TP-5700 12/07

TP-5700 12/07 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-5700 12/07

Hot engine and exhaust system. NOTICE

TP-5700 12/07 Safety Precautions and Instructions 11

12 Safety Precautions and Instructions TP-5700 12/07

Information in this publication represents data available

For professional advice on generator set power China

TP-5700 12/07 Introduction 13

14 Service Assistance TP-5700 12/07

Figure 1-1 Typical Stationary-Duty Generator Set Installation

TP-5700 12/07 Section 1 General 15

D UL 2200 Stationary Engine Generator Assemblies

16 Section 1 General TP-5700 12/07

Figure 2-1 Lifting Hook Placement (above 1000 kW)

TP-5700 12/07 Section 2 Loading and Transporting 17

1. Spreader bars may be necessary to protect generator set

Figure 2-3 Generator Set with Lifting Bars in Skid

Figure 2-2 Generator Set with Lifting Hooks in Skid

D Lift the generator set by inserting bars that extend

Lifting Fixture Method

Figure 2-4 Generator Set with Lifting Fixture

18 Section 2 Loading and Transporting TP-5700 12/07

1. Remove the sound shield‘s attaching bolts. These

2. Lift the sound shield by the eyebolts to remove it

3. Reinstall the sound shield after installing the

TP-5700 12/07 Section 2 Loading and Transporting 19

20 Section 2 Loading and Transporting TP-5700 12/07

3.1 Location Factors D Provide adequate protection to prevent injury in the

D Provide easy access for service and repair. 3 6

TP-5700 12/07 Section 3 Location 21

Use an oil drain pump if clearance below the oil drain or

Figure 3-4 Four-Pad Mounting

3.2.4 Mounting Pad Specifications

Mounting pad weight. The weight of the single

Mounting pad specifications. Mounting pad

The recommended concrete mixture by volume is

Note: Refer to the generator set and accessory

22 Section 3 Location TP-5700 12/07

Isolator types. The two primary types of isolators are

TP-5700-3 Figure 3-6 Vibration Spring Isolators

1. To engine-generator Generator sets with integral vibration isolation.