Generator Installation

Generadores
FICHA TÉCNICA
Producto: Generador Diésel Súper Silencioso
DESCRIPCIÓN: Generador Diésel Súper Silencioso una

capacidad nominal de 15Kw /Máx 20Kw. Monofásico de una
velocidad total de 1500 RPM, su alternador es sin escobillas
con alambre de cobre. Motor de 4 tiempos de 4 cilindros
refrigerado por agua, eléctrico con una garantía de 3 meses
y un peso de 840 Kg.
Alternador
CÓDIGO: UTP2150K1
Alambre de cobre
Marca: Total Tools ATS: No integrado
Voltaje: 110 - 220V~50/60Hz Refrigeración: Enfriado por agua
Capacidad nominal: 15Kw /Máx 20Kw Encendido: Eléctrico
Fase: Monofásico Protección: contra falta de agua, aumento de
Velocidad: 1500 RPM temperatura y nivel de aceite
Alternador: sin escobillas Garantía: 3 meses
Motor: 4 tiempos / 4 cilindros Peso: 840 Kg.
Desplazamiento: 2.15 Procedencia: Importado
min-1 Motor
Potencia MAX de 4
15Kw 20Kw 1500 tiempos 840
1
One-Stop Tools Station
DIESEL GENERATOR
TP2100K1 TP2100K1-1 UTP2100K1 UTP2100K1-1 TP2100K1-5 TP2100K1-5-1
UTP2300K1 UTP2300K1-1 TP2300K3 TP2300K3-1 UTP2300K3 UTP2300K3-1
TP2300K3-5 TP2300K3-5-1 UTP2500K1 UTP2500K1-1 TP2500K3 TP2500K3-1
UTP2500K3 UTP2500K3-1 TP2500K3-5 TP2500K3-5-1
GENSET INSTALLATION MANUAL
FOREWORD
This installation manual will guide you to the factors to be

considered in the installation of your diesel generator
system. It discusses location and mounting of the
generating set; size of room; ventilation and air flow;
engine cooling water supply or radiator location; exhaust
outlet; fuel tank and fuel transfer system.
By following the suggestions in this installation manual,

you will be able to plan an economical, efficient
generating set installation with operating characteristics
suitable to each particular application.
You can make you work easier by enliting the aid of a

Distributor when planning your generating set installation.
Getting his advice early may save cost and avoid
problems. He knows engines, electrical equipment, local
laws and insurance regulations. With his help, you can be
sure your generating set installation will fulfill your needs
without unnecessary cost.
2
Item No. TP2100K1 TP2100K1-1 UTP2100K1 UTP2100K1-1 TP2100K1-5 TP2100K1-5-1
Rated AC voltage(V) 220,230,240 110-120/220-240 220,230,240
Rated frequency(Hz) 50 60 60
Rated AC output(kW) 10 10 10
Phase number 1 1 1
Power factor 1 1 1
Brushless, Brushless, Brushless,
Excitation mode Self-exciting Self-exciting Self-exciting
Diesel, Diesel, Diesel,
Type direct injection, direct injection, direct injection,
4-cycle,vertical 4-cycle,vertical 4-cycle,vertical
Cylinder number 4 4 4
Displacement(L) 1.809 1.809 1.809
Engine Max.
output(HP) 18.7 18.7 18.7
Starting system Electric Electric Electric

Cooling system Water Water Water
0#(summer)- 0#(summer)- 0#(summer)-
Fuel type 10#(winter)- 10#(winter)- 10#(winter)-
20#(chillness)disel 20#(chillness)disel 20#(chillness)disel
Fuel consumption
(g/kW·h) ≤255 ≤255 ≤255
CDgrade,SAE CDgrade,SAE CDgrade,SAE
Lube oil
W-30,15W-40 W-30,15W-40 W-30,15W-40
ATS or NOT No Yes No Yes No Yes

Rated AC voltage(V) 220/380,230/400,240/415 110-120/220-240 220/380,230/400,240/415
Phase number 3 3 3
Power factor 0.8 0.8 0.8
Displacement(L) 1.809 1.809 1.809
Engine Max.
output(HP) 18.7 18.7 18.7

Fuel consumption
(g/kW·h) ≤255 ≤255 ≤255
Lube oil
10W-30,15W-40 10W-30,15W-40 10W-30,15W-40
3
Rated AC voltage(V) 220,230,240 110-120/220-240 220,230,240
Phase number 1 1 1
Power factor 1 1 1
Displacement(L) 2.156 2.156 2.156
Engine Max.
output(HP) 28 28 28
Fuel consumption
(g/kW·h) ≤253 ≤253 ≤253
Lube oil
10W-30,15W-40 10W-30,15W-40 10W-30,15W-40

Rated AC voltage(V) 220/380,230/400,240/415 110-120/220-240 220/380,230/400,240/415
Phase number 3 3 3
Power factor 0.8 0.8 0.8
Displacement(L) 2.156 2.156 2.156
Engine Max.
output(HP) 28 28 28
Fuel consumption
(g/kW·h) ≤253 ≤253 ≤253
Lube oil
10W-30,15W-40 10W-30,15W-40 10W-30,15W-40
4
Item No. UTP2300K1 UTP2300K1-1 TP2300K3 TP2300K3-1 UTP2300K3 UTP2300K3-1 TP2300K3-5 TP2300K3-5-1
Rated AC voltage(V) 11-120/220-240 220/380,230/400,240/415 11-120/220-240 220/380,230/400,240/415
Rated frequency(Hz) 60 50 60 60
Rated AC output(kW) 30 30 30 30
Phase number 1 3 3 3
Power factor 0.8 0.8 0.8 0.8
Brushless, Brushless, Brushless, Brushless,
Excitation mode Self-exciting Self-exciting Self-exciting Self-exciting
Diesel, Diesel, Diesel, Diesel,
Type direct injection, direct injection, direct injection, direct injection,
4-cycle,vertical 4-cycle,vertical 4-cycle,vertical 4-cycle,vertical
Cylinder number 4 4 4 4
Displacement(L) 3.62 3.62 3.62 3.62
Engine Max.
output(HP) 59 59 59 59
Starting system Electric Electric Electric Electric

Cooling system Water Water Water Water
0#(summer)- 0#(summer)- 0#(summer)- 0#(summer)-
Fuel type 10#(winter)- 10#(winter)- 10#(winter)- 10#(winter)-
20#(chillness)disel 20#(chillness)disel 20#(chillness)disel 20#(chillness)disel
Fuel consumption
(g/kW·h) ≤251 ≤251 ≤251 ≤251
CDgrade,SAE CDgrade,SAE CDgrade,SAE CDgrade,SAE
Lube oil
10W-30,15W-40 10W-30,15W-40 10W-30,15W-40 10W-30,15W-40
ATS or NOT No Yes No Yes No Yes No Yes
Item No. UTP2500K1 UTP2500K1-1 TP2500K3 TP2500K3-1 UTP2500K3 UTP2500K3-1 TP2500K3-5 TP2500K3-5-1
Rated AC voltage(V) 11-120/220-240 220/380,230/400,240/415 11-120/220-240 220/380,230/400,240/415
Rated frequency(Hz) 60 50 60 60
Rated AC output(kW) 50 50 50 50
Phase number 1 3 3 3
Power factor 0.8 0.8 0.8 0.8
Brushless, Brushless, Brushless, Brushless,
Excitation mode Self-exciting Self-exciting Self-exciting Self-exciting
Diesel, Diesel, Diesel, Diesel,
Type direct injection, direct injection, direct injection, direct injection,
4-cycle,vertical 4-cycle,vertical 4-cycle,vertical 4-cycle,vertical
Cylinder number 4 4 4 4
Displacement(L) 4.33 4.33 4.33 4.33
Engine Max.
output(HP) 81.5 81.5 81.5 81.5
Starting system Electric Electric Electric Electric

Cooling system Water Water Water Water
0#(summer)- 0#(summer)- 0#(summer)- 0#(summer)-
Fuel type 10#(winter)- 10#(winter)- 10#(winter)- 10#(winter)-
20#(chillness)disel 20#(chillness)disel 20#(chillness)disel 20#(chillness)disel
Fuel consumption
(g/kW·h) ≤231 ≤231 ≤231 ≤231
CDgrade,SAE CDgrade,SAE CDgrade,SAE CDgrade,SAE
Lube oil
15W-30,15W-40 15W-30,15W-40 15W-30,15W-40 15W-30,15W-40
ATS or NOT No Yes No Yes No Yes No Yes
5
TABLE OF CONTENTS
1. INSTALLATION FACTORS
2. MOVING THE GENERATING SET
3. GENERATING SET LOCATION
4. GENERATING SET MOUNTING
5. VENTILATION
6. ENGINE EXHAUST
7. EXHAUST SILENCING
8. SOUND ATTENUATION
9. ENGINE COOLING
10. FUEL SUPPLY
11. SELECTING FUELS FOR STANDBY DEPENDABILITY
12. TABLES AND FORMULAS FOR ENGINEERING STANDBY GENERATING SETS:
Table 1 Length Equivalents
Table 2 Area Equivalents
Table 3 Mass Equivalents
Table 4 Volume and Capacity Equivalents
Table 5 Conversions for Units of Speed
Table 6 Conversions of Units of Power
Table 7 Conversions for Measurements of Water
Table 8 Barometric Pressures and Boiling Points of Water at Various Altitudes
Table 9 Conversions of Units of Flow
Table 10 Conversions of Units of Pressure and Head
Table 11 Approximate Weights of Various Liquids
Table 12 Electrical Formulae
Table 13 kVA/kW Amperage at Various Voltages
13. GLOSSARY OF TERMS
6
1. INSTALLATION FACTORS Never lift the generating set by attaching to
the engine or alternator lifting lugs!
Once the size of the generating set and the
required associated control panel and For lifting the generating set, lift points are
switchgear have been established, plans for provided on the base frame. Shackles and
installation can be prepared. Proper attention to chains of suitable length and lifting capacity
mechanical and electrical engineering details will must be used and a spreader bar is required to
assure a satisfactory power system installation. prevent damaging the set. See figure 2.1. An
optional "single point lifting bale" is available if
Factors to be considered in the installation of a the generating set will be regularly moved by
generator are: lifting.
 Access and maintenance location. 3. GENERATING SET LOCATION

 Floor loading.
 Vibration transmitted to building and The set may be located in the basement or on
equipment. another floor of the building, on a balcony, in a
 Ventilation of room. penthouse on the roof or even in a separate
 Engine exhaust piping and insulation. building. Usually it is located in the basement for
 Noise reduction. economics and for convenience of operating
 Method of engine cooling. personnel. The generator room should be large
 Size and location of fuel tank. enough to provide adequate air circulation and
 Local, national or insurance regulations. plenty of working space around the engine and
 Smoke and emissions requirements. alternator.
2. MOVING THE GENERATING SET If it is necessary to locate the generating set

outside the building, it can be furnished
The generating set base frame is specifically enclosed in a housing and mounted on a skid or
designed for ease of moving the set. Improper trailer. This type of assembly is also useful,
handling can seriously damage the generator whether located inside or outside the building, if
and components. the installation is temporary. For outside
installation the housing is normally
Using a forklift, the generating set can be lifted "weatherproof". This is necessary to prevent
or pushed/pulled by the base frame. An optional water from entering the alternator compartment
"Oil Field Skid" provides forklift pockets if the set if the generating set is to be exposed to rain
will be regularly moved. accompanied by high winds.
4. GENERATING SET MOUNTING
The generating set will be shipped assembled on

a rigid base that precisely aligns the alternator
and engine and needs merely to be set in place
(on vibration isolation pads for larger sets) and
leveled. See figure 4.1
4.1 Vibration Isolation
It is recommended that the generating set be

mounted on vibration isolation pads to prevent
the set from receiving or transmitting injurious or
objectionable vibrations. Rubber isolation pads
are used when small amount of vibration
transmission is acceptable. Steel springs in
combination with rubber pads are used to
combat both light and heavy vibrations. On
smaller generating sets, these isolation pads
should be located between the coupled
engine/alternator feet and the base frame. The
base frame is then securely attached to the floor.
On larger sets the coupled engine/alternator
7
should be rigidly connected to the base frame the engine may not produce its rated power.
with vibration isolation between the base frame Operation of the engine and alternator radiates
and floor. Other effects of engine vibration can heat into the room and raises the temperature of
be minimized by providing flexible connections the room air. Therefore, ventilation of the
between the engine and fuel lines, exhaust generator room is necessary to limit room
system, radiator air discharge duct, conduit for temperature rise and to make clean, cool intake
control and power cables and other externally air available to the engine
connected support systems.
When the engine is cooled by a set mounted
4.2 Floor Loading radiator, the radiator fan must move large
quantities of air through the radiator core. There
Floor loading depends on the total generating must be enough temperature difference between
set weight (including fuel and water) and the the air and the water in the radiator to cool the
number and size of isolator pads. With the base water sufficiently before it re-circulates through
frame mounted directly on the floor, the floor the engine. The air temperature at the radiator
loading is: inlet depends on the temperature rise of air
flowing through the room from the room inlet
Floor Generating Set Weight ventilator. By drawing air into the room and
= expelling it outdoors through a discharge duct,
Loading Area of Skids
the radiator fan helps to maintain room
temperature in the desirable range.
With vibration isolation between the base frame
and the floor, if the load is equally distributed
In providing ventilation, the objective is to
over all isolators, the floor loading is:
maintain the room air at a comfortable
temperature that is cool enough for efficient
Total Generating Set
operation and full available power, but it should
Floor Weight
= not be so cold in winter that the room is
Loading Pad Area x Number of
uncomfortable or engine starting is difficult.
Pads
Though providing adequate ventilation seldom
poses serious problems, each installation should
Thus, floor loading can be reduced by increasing
be analyzed by both the distributor and the
the number of isolation pads.
customer to make sure the ventilation provisions
are satisfactory
If load is not equally distributed, the
maximum floor pressure occurs under the
pad supporting the greatest proportion of
5.1 Circulation
load (assuming all pads are the same size):
Good ventilation requires adequate flow into and

Max Floor Load on Heaviest Loaded
out of the room and free circulation within the
Pressure = Pad
room. Thus, the room should be of sufficient size
Pad Area
to allow free circulation of air, so that
temperatures are equalized and there are no
pockets of stagnant air. See figure 5.1. The
generating set should be located so that the
engine intake draws air from the cooler part of
the room. If there are two or more generating
sets, avoid locating them so that air heated by
the radiator of one set flows toward the engine
intake or radiator fan of an adjacent set. See
figure 5.2.
5. VENTILATION
Any internal combustion engine requires a liberal

supply of cool, clean air for combustion. If the air
entering the engine intake is too warm or too thin,
8
9
10
5.2 Ventilators engine intake.
To bring in fresh air, there should be an inlet 6. ENGINE EXHAUST

ventilator opening to the outside or at least an
opening to another part of the building through Engine exhaust must be directed to the outside
which the required amount of air can enter. In through a properly designed exhaust system that
smaller rooms, ducting may be used to bring air to does not create excessive back pressure on the
the room or directly to the engine's air intake. In engine. A suitable exhaust silencer should be
addition, an exit ventilator opening should be connected into the exhaust piping. Exhaust system
located on the opposite outside wall to exhaust components located within the engine room should
warm air. See Figure 5.3 be insulated to reduce heat radiation. The outer
end of the pipe should be equipped with a rain cap
Both the inlet and exit ventilators should have or cut at 60 o to the horizontal to prevent rain or
Louvers for weather protection. These may be snow from entering the exhaust system. If the
fixed but preferably should be movable in cold building is equipped with a smoke detection
climates. For automatic starting generating sets, system, the exhaust outlet should be positioned
if the louvers are movable, they should be so it cannot off the smoke detection alarm.
automatically operated and should be
programmed upon starting the engine. 6.1 Exhaust Piping
5.3 Inlet Ventilator Size For both installation economy and operating
Before calculating the inlet ventilator size, it is efficiency, engine location should make the
necessary to take into account the radiator cooling air exhaust piping as short as possible with minimum
flow requirements and the fan static pressure available bends and restrictions. Usually the exhaust pipe
when the generating set is operating at its rated load. extends through an outside wall of the building and
In standard room installations, the radiated heat is continues up the outside of the wall to the roof.
already taken into account in the radiator air flow. There should be a sleeve in the wall opening to
absorb vibration and an expansion joint in the pipe
For generator room installation with remote to compensate for length ways thermal expansion
radiators, the room cooling airflow is calculated or contraction. See figure 6.1.
using the total heat radiation to the ambient air of
the engine and alternator and any part of the It is not normally recommended that the engine
exhaust system. exhaust share a flue with a furnace or other
equipment since there is danger that back
Engine and alternator cooling air requirements for pressure caused by one will adversely affect
generating sets when operating at rated power are operation of the others. Such multiple use of a
shown on specification sheets. Exhaust system flue should be attempted only if it is not
radiation depends on the length of pipe within the detrimental to performance of the engine or any
room, the type of insulation used and whether the other equipment sharing the common flue.
silencer is located within the room or outside. It
usual to insulate the exhaust piping and silencer The exhaust can be directed into a special stack
so that heat radiation from this source may be that also serves as the outlet for radiator discharge
neglected in calculating air flow required for air and may be sound-insulated. The radiator
room cooling. discharge air enters below the exhaust gas inlet so
that the rising radiator air mixes with the exhaust
After determining the required air flow into the gas. See figures 6.2 and 6.3. The silencer may be
room, calculate the size of inlet ventilator opening located within the stack or in the room with its tail
to be installed in the outside wall. The inlet pipe extending through the stack and then outward.
ventilator must be large enough so that the Air guide vanes should be installed in the stack to
negative flow restriction will not exceed a turn radiator discharge air flow upward and to
maximum of 10 mm (0.4 in) H 2 0. Restriction values reduce radiator fan air flow restriction, or the
of air filters, screens and louvres should be sound insulation lining may have a curved contour
obtained from manufacturers of these items. to direct air flow upward.
5.4 Exit Ventilator Size

Where the engine and room are cooled by a set
mounted radiator, the exit ventilator must be large
enough to exhaust all of the air flowing through
electric motor to discharge air vertically.the room,
except the relatively small amount that enters the
11
12
For a generating set enclosed in a penthouse on waves may cause high back pressure
the roof or in a separate outdoor enclosure or
trailer, the exhaust and radiator discharges can Excessive restriction in the exhaust system can be
flow together above the enclosure without a stack. avoided by proper design and construction. To
Sometimes for this purpose the radiator is make sure you will avoid problems related to
mounted horizontally and the fan is driven by an excessive restriction, ask the distributor to
electric motor to discharge air vertically. review your design.
6.2 Exhaust Pipe Flexible Section The effect of pipe diameter, length and the
restriction of any bends in the system can be
A flexible connection between the manifold and the calculated to make sure your exhaust system is
exhaust piping system should be used to prevent adequate without excessive back pressure. The
transmitting engine vibration to the piping and the longer the pipe, and the more bends it contains,
building, and to isolate the engine and piping from the larger the diameter required avoiding
forces due to thermal expansion, motion or weight excessive flow restriction and back pressure. The
of piping. A well designed flex section will permit backpressure should be calculated during the
operation with ± 13 mm (0.5 in) permanent installation stage to make certain it will be within
displacement in any direction of either end of the the recommended limits for the engine.
section without damage. Not only must the section
have the flexibility to compensate for a nominal Measure the exhaust pipe length from your
amount of permanent mismatch between piping installation layout. See figure 6.4. Take exhaust
and manifold, but it must also yield readily to flow data and backpressure limits from the
intermittent motion of the Generating Set on its generating set engine specification sheet. Allowing
vibration isolators in response to load changes. for restrictions of the exhaust silencer and any
The flexible connector should be specified with elbows in the pipe, calculate the minimum pipe
the Generating Set. diameter so that the total system restriction will not
exceed the recommended exhaust backpressure
6.3 Exhaust Pipe Insulation limit. Allowance should be made for deterioration
and scale accumulation that may increase
No exposed parts of the exhaust system should be restriction over a period of time.
near wood or other inflammable material. Exhaust
piping inside the building (and the silencer if
mounted inside) should be covered with suitable
insulation materials to protect personnel and to
reduce room temperature. A sufficient layer of
suitable insulating material surrounding the piping
and silencer and retained by a stainless steel or
aluminum sheath may substantially reduce heat
radiation to the room from the exhaust system.
An additional benefit of the insulation is that it

provides sound attenuation to reduce noise in the
room.
6.4 Minimizing Exhaust Flow Restriction
Free flow of exhaust gases through the pipe is

essential to minimize exhaust backpressure.
Excessive exhaust backpressure seriously affects Elbow restriction is most conveniently handled by
engine horsepower output, durability and fuel calculating an equivalent length of straight pipe for
consumption. Restricting the discharge of gases each elbow and adding it to the total length of
from the cylinder causes poor combustion and pipe. For elbows and flexible sections, the
higher operating temperatures. The major design equivalent length of straight pipe is calculated as
factors that may cause high backpressure are: follows:
45 o Elbow:
 Exhaust pipe diameter too small Length(ft) = 0.75 × Diameter (inches)
o
 Exhaust pipe too long 90 Elbow:
 Too many sharp bends in exhaust system Length(ft) = 1.33 × Diameter (inches)
 Exhaust silencer restriction too high
 At certain critical lengths, standing pressure
13
Flexible Sections: backpressure within limits recommended by the
Length(ft): 0.167 × Diameter (inches) engine manufacturer.
Silencers are rated according to their degree of

The following formula is used to calculate the silencing by such terms as "low degree" or
backpressure of an exhaust system: "industrial", "moderate" or "residential" and
degree" or "critical".
CLRQ 2
P =  Low-Degree or Industrial Silencing Suitable for
D5
industrial areas where 'high background noise
Where:
level is relatively high or for remote areas where
P = back pressure in inches of mercury partly muffled noise is permissible.
C = .00059 for engine combustion airflow of 100 to
400 cam  Moderate-Degree or Residential Silencing -
= .00056 for engine combustion airflow of 400 to Reduces exhaust noise to an acceptable level in
700 cam localities where moderately effective silencing is
required - such as semi-residential areas where
= .00049 for engine combustion airflow of 700 to
a moderate background noise is always present.
2000 cam  High-Degree or Critical Silencing – Provides
= .00044 for engine combustion airflow of 2000 to maximum silencing for residential, hospital,
5400 cam school, hotel, store, apartment building and
L = length of exhaust pipe in feet other areas where background noise level is low
R = exhaust density in pounds per cubic foot and generating set noise must be kept to a
minimum.
41.1 Silencers normally are available in two
R =
Exhaust temperature o F* + 460 o F configurations - (a) end inlet, end outlet, or (b) side
inlet, end outlet. Having the choice of these two
configurations provides flexibility of installation,
Q = exhaust gas flow in cubic feet per minute*
such as horizontal or vertical, above engine, on
D = inside diameter of exhaust pipe in inches* outside wall, etc. The side-inlet type permits 90o
Available from engine specification sheet change of direction without using an elbow. Both
silencer configurations should contain drain fittings
These formulae assume that the exhaust pipe is in locations that assure draining the silencer in
clean commercial steel or wrought iron. The whatever attitude it is installed.
backpressure is dependent on the surface finish of
The silencer may be located close to the engine,
the piping and an increase in the pipe roughness with exhaust piping leading from the silencer to the
will increase the backpressure. The constant 41.1 outside; or it may be located outdoors on the wall
is based on the weight of combustion air and fuel or roof. Locating the silencer close to the engine
burned at rated load and SAE conditions. See affords best overall noise attenuation because of
engine specification sheet for exhaust gas minimum piping to the silencer. Servicing and
temperature and airflow. Conversion tables to other draining of the silencer is likely to be more
convenient with the silencer indoors.
units are provided in Section 12.
However, mounting the silencer outside has the
7. EXHAUST SILENCING advantage that the silencer need not be insulated
(though it should be surrounded by a protective
Excessive noise is objectionable in most locations screen). The job of insulating piping within the
Since a large part of the generating set noise is room is simpler when the silencer is outside, and
produced in the engine's pulsating exhaust, this the insulation then can aid noise attenuation.
noise can be reduced to an acceptable level by
Since silencers are large and heavy, consider their
using an exhaust silencer. The required degree of
dimensions and weight when you are planning the
silencing depends on the location and may be exhaust system. The silencer must be adequately
regulated by law. For example, the noise of an supported so its weight is not applied to the
engine is objectionable in a hospital area but engine's exhaust manifold or turbocharger. The
generally is not as objectionable in an isolated silencer must fit into the space available without
pumping station. requiring extra bends in the exhaust piping, which
would cause high exhaust back pressure, A
side-inlet silencer may be installed horizontally
above the engine without requiring a great amount
7.1 Exhaust Silencer Selection of headroom.
The silencer reduces noise in the exhaust system
by dissipating energy in chambers and baffle tubes
and by eliminating wave reflection that causes Silencer or exhaust piping within reach of personnel
resonance. The silencer is selected according to should be protected by guards or insulation. Indoor,
the degree of attenuation required by the site it is preferable to insulate the silencer and piping
conditions and regulations. The size of silencer because the insulation not only protects personnel,
and exhaust piping should hold exhaust but it reduces heat radiation to the room and further
14
reduces exhaust system noise. Silencers mounted coolant-to-raw water (heat exchanger) types.
horizontally should be set at a slight angle away
from the engine outlet with a drain fitting at the
In the most common generating set installation,
lowest point to allow the disposal of any
accumulated moisture. the engine coolant is cooled in a set-mounted
radiator with air blown through the radiator core by
8. SOUND ATTENUATION an engine driven fan. Some installations use a
remotely mounted radiator, cooled by an electric
If noise level must be limited, it should be specified motor-driven fan. Where there is a continuously
in terms of a sound pressure level at a given available supply of clean, cool raw water, a heat
distance from the generator enclosure. Then the exchanger may be used instead of a radiator; the
enclosure must be designed to attenuate the noise engine coolant circulates through the heat
generated inside the enclosure to produce the exchanger and is cooled by the raw water supply.
required level outside. Don't attempt to make this
noise level unnecessarily low, because the means An important advantage of a radiator cooling
of achieving it may be costly. system is that it is self-contained. If a storm or
accident disrupted the utility power source, it might
Use of resilient mounts for the generating set plus also disrupt the water supply and disable any
normal techniques for controlling exhaust, intake generating set whose supply of raw water
and radiator fan noise should reduce generating depended upon a utility.
set noise to an acceptable level for many
installations. If the remaining noise level is still too Whether the radiator is mounted on the generating
high, acoustic treatment of either the room or the set or mounted remotely, accessibility for servicing
generating set is necessary. Sound barriers can be the cooling system is important. For proper
erected around the generating set, or the walls of maintenance, the radiator fill cap, the cooling
the generator room can be sound insulated, or the system drain cocks, and the fan belt tension
generating set can be enclosed in a specially adjustment must all be accessible to the operator.
developed sound insulated enclosure. See figure
8.1. 9.1 Set Mounted Radiator
A set-mounted radiator is mounted on the

generating set base in front of the engine. See
figure 9.1. An engine-driven fan blows air through
the radiator core, cooling the liquid engine coolant
flowing through the radiator.
In most cases it is necessary that the air intake

and air discharge openings will have to be fitted
with sound attenuators. If it is desired to protect
operating personnel from direct exposure to
generating set noise, the instruments and control
station may be located in a separate
sound-insulated control room.
9. ENGINE COOLING
Some diesel engines are air-cooled but the

majority is cooled by circulating a liquid coolant
through the oil cooler if one is fitted and through
passages in the engine block and head. Hot
coolant emerging from the engine is cooled and
reticulated through the engine. Cooling devices
are commonly coolant-to-air (radiator) or
15
Set mounted radiators are of two types. One type is

used with the cooling fan mounted on the engine. The
It is recommended that a set-mounted radiator's

Discharge air should flow directly outdoors through
a duct that connects the radiator to an opening in
an outside wall. The engine should be located as
close to the outside wall as possible to keep the
Set mounted radiators are of two types. One type is avoid clogging the radiator core. Adequate
used with the cooling fan mounted on the engine. The filtration of air flowing into the room should assure
fan is belt-driven by the crankshaft pulley in a relatively clean air. However if the air at the site
two-point drive. The fan support bracket, fan normally contains a high concentration of dirt, lint,
spindle and drive pulley are adjustable with sawdust, or other matter, the use of a remote
respect to the crankshaft pulley in order to radiator, located in a cleaner environment, may
maintain proper belt tension. The fan blades alleviate a core-clogging problem.
project into the radiator shroud, which has
sufficient tip clearance for belt tension adjustment. It is recommended that a set-mounted radiator's
Discharge air should flow directly outdoors through
The other type of set mounted radiator consists of an a duct that connects the radiator to an opening in
assembly of radiator, fan, drive pulley' and an outside wall. The engine should be located as
adjustable idler pulley to maintain belt tension. close to the outside wall as possible to keep the
Fan is mounted with its center fixed in a venture ducting short. If the ducting is too long, it may be
shroud with very close tip clearance for high- more economical to use a remote radiator. The
efficiency performance. The fan drive pulley, idler airflow restriction of the discharge and the inlets
pulley and engine crankshaft pulley are precisely duct should not exceed the allowable fan static
aligned and connected in a three-point drive by the pressure.
belts. This second type of set-mounted radiator When the set-mounted radiator is to be connected
usually uses an airfoil-bladed fan with the to a discharge duct, a duct adapter should be
close-fitting shroud. specified for the radiator. A length of flexible duct
material (rubber or suitable fabric) between the
The proper radiator and fan combinations will be radiator and the fixed discharge duct is required to
provided by and furnished with the generating isolate vibration and provide freedom of motion
set. Air requirements for cooling a particular between the generating set and the fixed duct.
generator are given in the specification sheet. The
radiator cooling air must be relatively clean to
avoid clogging the radiator core. Ad
9.2 Remote Radiator
16
A remote radiator with electric motor-driven can be Ethylene glycol permanent antifreeze is
installed in any convenient location away from the recommended for diesel engines. It includes its
generating set. See figure 9.2.
own corrosion inhibitor, which eventually may have
A well-designed remote radiator has many useful to be replenished. Only a non-chromate inhibitor
features and advantages that provide greater should be used with ethylene glycol.
flexibility of generating set installations in
buildings. The proportion of ethylene glycol required is
dictated primarily by the need for protection
More efficient venture shroud and fan provide a
against freezing in the lowest ambient air
substantial reduction in horsepower required for
engine cooling. The fan may be driven by a temperature that will be encountered. The
thermostatically controlled motor, which will only concentration of ethylene glycol must be at least
draw power from the generating set when required 30% to afford adequate corrosion protection. The
to cool the engine. A remote radiator can be concentration must not exceed 67% to maintain
located outdoors where there is less air flow adequate heat transfer capability.
restriction and air is usually cooler than engine
room air, resulting in higher efficiency and smaller
For heat exchanger cooling, antifreeze does only
size radiator; and fan noise is removed from the
building. half the job since it can only be used in the engine
waterside of the heat exchanger. There must be
Remote radiators must be connected to the assurance that the raw water source will not
engine cooling system by coolant piping, freeze.
including flexible sections between engines and
piping.
9.6 Water Conditioning
9.3 Remote Radiator/Heat
Exchanger System Soft water should always be used in the engine
whether cooling is by radiator or by heat
Another type of remote radiator system employs a exchanger. Adding a commercial softener is the
heat exchanger at the engine. See figure 9.3 and easiest and most economical method of water
9.4. In this application, the heat exchanger
softening. Your Distributor can recommend
functions as an intermediate heat exchanger to
isolate the engine coolant system from the high suitable softeners. Manufacturers instructions
static head of the remote radiator coolant. The should be carefully followed.
engine pump circulates engine coolant through the
engine and the element of the heat exchanger. 10. FUEL SUPPLY
A separate pump circulates radiator coolant A dependable fuel supply system must assure
between the remote radiator and the heat
exchanger tank. instant availability of fuel to facilitate starting and to
keep the engine operating. This requires, at a
Heat exchangers also are used for cooling the minimum, a small day tank (usually incorporated
engine without a radiator, as described in the into the generating set base frame - called a base
Following section. tank) located close to the set. With generally only a
capacity of 8 hours operation, this day tank is often
backed up by an auxiliary remote fuel system
9.4 Heat Exchanger Cooling
including a bulk storage tank and the associated
A heat exchanger may be used where there is a pumps and plumbing. Extended capacity base
continuously available supply of clean, cool raw tanks are also generally available for longer
water. Areas where excessive foreign material in operation prior to refueling. Especially for standby
the air might cause constant radiator clogging - generating sets it not advisable to depend on
such as in sawmill installations - may be logical
regular delivery of fuel. The emergency that
sites for heat exchanger cooling. A heat exchanger
cools the engine by transferring engine coolant requires use of the standby set may also interrupt
heat through passages in the elements to cool raw the delivery of fuel.
water. Engine coolant and raw cooling water flows
are separated completely in clos ed systems, each 10.1 Fuel Tank Location
with its own pumps, and never intermix. The day tank should be located as close to the
generating set as possible. Normally it is safe to
store diesel fuel in the same room with the
9.5 Antifreeze Protection generating set because there is less danger of fire
or fumes with diesel than with petrol (gasoline).
If the engine is to be exposed to low temperatures, the Thus if building codes and fire regulations permit,
cooling water in the engine must be protected from the day tank should be located in the base of the
freezing. In radiator-cooled installations, antifreeze generating set, along side the set, or in an
may be added to the water to prevent freezing. adjacent room.
17
the engine, fuel from the bulk tank is strained just
Where a remote fuel system is to be installed with prior to the electric fuel pump. When the base tank
a bulk storage tank, the bulk tank may be located is full, as sensed by the fuel level sensor, the pump
outside the building where it will be convenient for stops. If there should be any overflow of fuel in the
refilling, cleaning and inspection. It should not, base tank, the excess will drain back into the bulk
however, be exposed to freezing weather because tank via tile return line.
fuel flow will be restricted as viscosity increases
with cold temperature. The tank may be located With this system, the base tank must include the
either above or below ground level. overflow (via the return line), a 1.4 metro extended
vent to prevent overflow through the vent, sealed
10.2 Remote Fuel Systems fuel level gauges on the base tank and no manual
fill facility All other connections on top of the tank
Which is higher than the base tank, remote fuel systems are must be sealed to prevent leakage. Fuel System 1
recommended by the manufacturer: is not compatible with the polyethylene fuel tanks
standard on smaller generating sets. The
Fuel System1: Installations where the bulk fuel tank is optional metal tank is required. A 2001 Series
lower than the day tank. control system (or above) is required.
Fuel System 2: Installations where the fuel tank is
higher than the day tank. The position of the bulk fuel tank should take into
Fuel System 3: Installations where the generating account that the maximum suction lift of the fuel
set is fed directly from a high-level bulk tank. transfer pump is approximately 3 meters and that
Fuel System 4: Installations where fuel must be the maximum restriction caused by the friction
pumped from a freestanding bulk fuel tank to the losses in the return fuel line should not exceed
day tank. 2psi.
Fuel System 5: Installation where a separate day tank
is fed via a pumped system from a bulk fuel Fuel System 2: The bulk tank is located higher
tank. Than the base tank. With this system the fuel is
Gravity fed from the bulk tank to the base tank.
Fuel System 1: The bulk fuel tank is lower than Figure 10.2.
the day tank. The fuel must be pumped up from the
bulk tank to the day tank, which is integrated into
the base frame. See figure 10.1.
The key components are the bulk fuel tank (item 1), system
controls (item 2) located in the generating set
The key components are the bulk fuel tank (item control panel, a DC motorized fuel valve (item3),
1) which is lower than the base tank, remote fuel fuel level switches in the base tank (item 4), an
system controls (item 2) located in the generating extended vent/return line (continuous rise) on the
set control panel, an AC powered electric fuel base tank (item 5), the fuel supply line (item 6), a
pump (item 3), fuel level switches in the base tank fuel strainer (item 7) and an isolating valve at the
(item 4), an extended vent on the base tank bulk tank (item 8).
(item5), the fuel supply line (item 6), the fuel return When set to automatic, the system operates as
line (item 7), and a fuel strainer (item 8) on the follows: the fuel level sensor senses low fuel level in
inlet side of the pump. the base tank. The DC motorized valve is opened
and fuel is allowed to flow from the high
When set to automatic, the system operates as Level bulk tank to the base tank by the force of
follows: the fuel level sensor senses Low fuel level Gravity. To help ensure that clean fuel reaches the
in the base tank. The pump begins to pump fuel Engine, fuel from the bulk tank is strained just prior
from the bulk tank to the base tank through the fuel to the motorized valve. When the base tank is full,
supply line. To help ensure that clean fuel reaches as sensed by the fuel level sensor, the motorized
18
valve is closed. Any overflow into the base tank or Fuel System 4: Some installations may require a
overpressure in the base tank will flow back to the system where fuel is pumped from a freestanding
bulk tank via the extended vent. bulk tank (see Figure 10.4). This pumped system
would only be used if gravity feed were not
With this system, the base tank must include an possible from the bulk tank to the base tank.
overflow via the return line, sealed fuel level
gauges and no manual fill facility. All other The key components are the above ground bulk
connections on top of the tank must be sealed to fuel tank (item 1), remote fuel system controls
prevent leakage. Fuel System 2 is not compatible (item 2) located in the generating set control panel,
with the polyethylene fuel tanks standard on an AC Fuel Pump (item 3), a DC motorized fuel
smaller generating sets. The optional metal tank valve (item 4), fuel level switches in the base tank
is required. A 2001 Series control system (or above) (item 5), the fuel supply line (item 6), an extended
is required. vent/return line (continuous rise) on the base tank
(item 7), a fuel strainer (item 8) and an isolating
Distance 'A' in Figure 10.2 is limited to 1400mm valve at the bulk tank, (item 9).
for all generating sets with metal base tanks.
When set to automatic, the system operates as
Fuel System 3: It is possible to have the engine follows: the fuel level sensor senses low fuel level
base frame (see Figure 10.3). in the base tank. The DC motorized valve is
opened and the pump begins to pump fuel from the
bulk tank to the base tank through the supply line.
To help ensure that clean fuel reaches the engine,
fuel from the bulk tank is strained just prior to the
motorized valve. When the base tank is full, as
sensed by the fuel level sensor, the pump stops
and the motorized valve is closed. Any overflow
into the base tank or overpressure in the base tank
will flow back to the bulk tank via the extended
vent.
The key components are the high-level bulk fuel With this system, the base tank must include an
tank (item 1), the fuel supply line (item 2), a fuel overflow via the return line, sealed fuel level
return line (item 3) and an isolating valve at the gauges and no manual fill facility. All other
bulk tank (item 4). connections on top of the tank must be sealed to
prevent leakage. Fuel System 4 is not compatible
The system operates as follows: With the isolating with the polyethylene fuel tanks standard on smaller
valve open, fuel is gravity fed to the engine. Any generating sets. The optional metal tank is
overflow is passed back to the bulk tank via the required.
return line.
Distance 'A’ in Figure 10.3 is limited to: Distance 'A' on Figure 10.4 is limited to 1400mm
For all generating sets with metal base tanks. Note
Output range Height that the maximum restriction caused by friction
losses and height of the return line should not
30KVA-250KVA 3300mm exceed 2 psi.
275KVA-750KVA 6000mm
1550KVA-2200 KVA 2500mm Fuel System 5: In some installations it is
necessary to use a separate day tank supplied
Note: These are maximum heights. These heights via a pumped system from a bulk tank (see
may need to be reduced depending on further Figure 10.5).
restriction caused by pipeline sizes, length and
obstruction in the return line.
19
The key components are the bulk fuel tank (item should extend below the minimum fuel level in the
1), the day tank (item 2), remote fuel system tank. Where practical, a low point in the tank
controls (item 3) located in a separate custom built should be equipped with a drain valve or plug, in
panel, an AC Fuel Pump (item 4), a DC motorized an accessible location, to allow periodic removal of
fuel valve (item 5), fuel level switches in the day water condensation and sediment. Or a hose may
tank (item 6), the fuel supply line to the day tank be inserted through the tank's filter neck when
(item 7), the fuel supply line to the engine (item 8), necessary to suck out water and sediment,
a fuel return line to the day tank (item 9) an The filler neck of the bulk fuel tank should be located in
extended vent/return line (continuous rise) on the a clean accessible location. A removable wire screen of
day tank (item 10), an isolation valve on the day approximately 1.6 mm (1/16 inch) mesh should be
tank (item 11) a fuel strainer (item 12) and an placed in the filler neck to prevent foreign material from
isolating valve at the bulk tank (item 13). entering the tank. The filler neck cap or the highest
When set to automatic, the system operates as point in the tank should be vented to maintain
Follows: the fuel level sensor senses low fuel level atmospheric pressure on the fuel and to provide
in the day tank. The DC motorized valve is opened pressure relief in case a temperature rise causes the
and the pump begins to pump fuel from the bulk fuel to expand. It will also prevent a vacuum as
tank to the day tank through the supply line. To fuel is consumed. The tank may be equipped with
help ensure that clean fuel reaches the engine, a fuel level gauge - either a sight gauge or a
fuel from the bulk tank is strained just prior to the remote electrical gauge.
motorized valve. When the day tank is full, as
sensed by the fuel level sensor, the pump stops 10.4 Fuel Lines
and the motorized valve is closed. Any overflow
into the day tank or overpressure in the day tank The fuel lines can be of any fuel compatible
will flow back to the bulk tank via the extended material such as steel pipe or flexible hoses that
vent. With the day tank isolating valve open, while will tolerate environmental conditions.
the engine is operating fuel flows from the day
tank to the engine and any overflow is returned to Fuel delivery and return lines should be at least as
the day tank. large as the fitting sizes on the engine, and
The day tank should be designed to take into overflow piping should be one size larger. For
account the head 'A' of the bulk tank and the longer runs of piping or low ambient temperatures
friction losses in the overflow line. Normally the the size of these lines should be increased to
tank design head is approximately 3 meters ensure adequate flow. Flexible piping should be
although this will vary with each layout. The day used to connect to the engine to avoid damage or
tank should be designed generally in accordance leaks caused by engine vibration.
with BS799 Part 5 to take account of the design
head. Distance 'A' in Figure 10.5 is limited to: The fuel delivery line should pick up fuel from a
Output range Height point no lower than 50 mm (2'’) from the bottom of
tank at the high end, away from the drain plug.
30KVA-250KVA 3300mm
275KVA-750KVA 6000mm 10.5 Day Tank Capacity
1550KVA-2200 KVA 2500mm
The capacity of the day tank is based on the fuel
In the event that the bulk tank overfills the day consumption and the expected number of hours of
tank, engines with unit injector systems may operation that is requested between refills.
experience leakage into the cylinders. It is Particularly with standby generators, the
essential that before restarting the engine this fuel availability of fuel delivery service will determine
be removed from the cylinders. the number of operating hours that must be
provided for. Don't depend on quick service the
10.3 Tank Construction very day your set starts to operate. A power
outage may hamper your supplier's operation also.
Fuel tanks are usually made of welded sheet steel
reinforced plastic. If an old fuel tank is used, be In addition, the size of the day tank should be
sure it is made of a proper material. It should be large enough to keep fuel temperatures down,
cleaned thoroughly to remove all rust, scale and since some engines return hot fuel used to cool
foreign deposits. the injectors. This is especially critical on larger
generating sets, models KM825E - KM2250E
Connections for fuel suction and return lines must where the returning hot fuel can raise the
be separated as much as possible to prevent temperature sufficiently to detrimentally impact the
re-circulation of hot fuel and to allow separation of operation of the engine if the fuel capacity is not
any gases entrained in the fuel. Fuel suction lines large enough to absorb the heat. For these
20
generating sets, the day tank should have the fuels. As a result, some diesel fuel systems must
following capacity to absorb excess heat in undergo major modifications to accommodate this
addition to the fuel required for operation: type of fuel. For use of jet fuel please consult
Reliable operation of diesel engines may vary
Output range Extra Capacity from one fuel to another, depending on many
factors, including fuel characteristics and engine
With Fuel Without Fuel
operating conditions.
Coolers Coolers
The fuels commonly known as high-grade fuels
750KVA-1055 KVA 1500 Liters 3000Litres seldom contribute to the formation of harmful
1160KVA-1500 KVA 2250 Liters 4500Litres Engine deposits and corrosion. On the other hand,
1550KVA-2200 KVA 3000 Liters 6000Litres while refining improves the fuel, it also lowers the
B.T.U. or heat value of the fuel. As a result, the
higher-grade fuels develop slightly less power than
the same quantity of low-grade fuel. This is usually
11. SELECTING FUEL FOR
more than offset by the advantages of high-grade
STANDBY DEPENDABILITY
fuels such as quicker starts and less frequent
overhauls. Before using low-grade fuels, therefore,
The types of fuels available for diesel engines vary
some understanding of the problems and extra
from highly volatile jet fuels and kerosene to the
costs that may be encountered is necessary.
heavier fuel oils. Most diesel engines are capable of
burning a wide range of fuels within these extremes.
Fuels with high sculpture content cause corrosion
The following information will assist you in selecting the
wear and deposits in the engine. Fuels that are not
type of fuel that will afford the best overall performance
volatile enough or don't ignite rapidly may leave
and reliability of your Generating Set.
harmful deposits in the engine and may cause poor
starting or running under adverse operating
11.1 Types Of Fuel Oil
conditions. The use of low-grade fuels may require
the use of high priced, higher detergent lubricating
The quality of fuel oil can be a dominant factor in
oils and more frequent oil changes.
satisfactory engine life and performance. A large
variety of fuel oils are marketed for diesel engine use.
Their properties depend upon the refining practices 11.2 Fuel Selection Guide
employed and the nature of the crude oils from which
they are produced. For example, fuel oils may be
Specify fuel properties according to the
produced within the boiling range of 148 to 371oC (300
following chart.
to 700oF), having many possible combinations of other
properties.
Final Cetane Sculpture
The additional contaminants present in low-grade Boiling Number Number
fuels may result in darker exhaust and more Point (Min) (Max)
pronounced odor. This may be objectionable in o o
Winter 290 C (550 F) 45 0.5 %
hospitals, offices commercial and urban locations
o o
Thus, location, application and environmental Summer 315 C (600 F) 40 0.5 %
conditions should be considered when selecting
fuel. Selecting a fuel that keeps within these
specifications will tend to reduce the possibility of
The Generating Set owner may elect to use a harmful deposits and corrosion in the engine, both
low-grade fuel because high-grade fuels are not of which could result in more frequent overhauls
readily available in his area or because he can and greater maintenance expense. Specify exact
realize a net saving with low-grade fuels despite fuel properties to your local fuel supplier.
higher engine maintenance costs. In that case,
frequent examination of lubrication oil should be
made to determine sludge formation and the extent 11.3 Maintaining Fresh Fuel
of lube oil contamination. Most fuels deteriorate if they stand unused for a
period of many months. With standby generators it
Aside from the various grades of fuel oil commonly is preferable to store only enough fuel to support a
used in diesel engines, aircraft jet fuels also are few days or even only eight hours of continuous
sometimes used, especially in circumstances running of the Generating Set so that normal engine
where the jet fuels are more readily available than testing will mm over a tank full within a year and a
conventional fuels. Jet fuels are lower in B.T.U. half.
content and lubrication quality than conventional
21
Other solutions are to add inhibitors to the fuel or to
obtain greater turnover by using the fuel for other
purposes. A gum inhibitor added to diesel fuel will
keep it in good condition up to two years.
If the building furnace has an oil burner, it

possible to bum diesel fuel in the furnace,
connecting both the engine and the furnace to the
same tank. In this way, a large supply of diesel
fuel is available for emergency use by the
Generating Set, and the fuel supply is
continuously turned over since it is being burned
in the furnace. Thus, there is no long-term storage
problem.
11.4 Self Contained Dependability
In some areas, where natural gas is cheap,

natural gas spark ignition engines are used in
Generating Sets that are intended for continuous
service. For standby service, however, this is not
recommended. The natural gas supply and
regulation system adds substantially to the
complexity of the installation, and there is little to be
gained in terms of fuel cost over a period of time.
More important, it makes the emergency power less
dependable. Not only is such an engine less
dependable than a diesel, but often the same storm
or accident that disrupts the normal electric power
also cuts off gas service. Thus, a natural gas engine
would be disabled at the very time it is needed. By
contrast, a diesel engine, with its fuel in a nearby
tank, is a self-contained system that does not
depend on outside services. It is more dependable
and affords greater standby protection than systems,
which depend on a public utility for fuel.
22
12. TABLES AND FORMULAS FOR ENGINEERING STANDBY GENERATING SETS
Table 1. Length Equivalents
Unit Microns Meters Kilometers Inches Feet Yards Miles
1 Micron 1 0.000001 --- 0.00003937 --- --- ---

1 Meter 1,000,000 1 --- 39.37 3.281 1.0936 ---
1Kilometre --- 1000 1 39,370 3281 1093.6 0.621
1 Inch 25,400 0.0254 --- 1 0.0833 0.0278 ---
1 Foot --- 0.3048 --- 12 1 0.3333 ---
1 Yard --- 0.9144 --- 36 3 1 ---
1 Mile --- 1609 1.609 63,360 5280 1760 k 1
One unit in the left-hand column equals the value of units under the top heading
Table 2. Area Equivalents
Unit In2 Ft: Acre Mile: M2 Hectare Km2:
1 In2 1 0.006944 --- --- 0.00064516 --- ---

2
1 Ft 144 1 U --- 0.0929 --- ---
1 Acre2 --- 43,560 1 0.0015625 4,047 0.4047 0.004047
2
1 Mile --- 27,878,400 640 1 2,589,998 258.99 2.5899
2
1M 1550 10.764 --- --- 1 --- ---
1 Hectare --- 107,639 2.471 0.003861 10,000 1 0.01
2
1 Km --- 10,763,867 247.1 0.3861 1,000,000 100 1
Table 3. Mass Equivalents
Tons
Unit Ounces Pounds Kilograms
Short Long Metric
1 Ounce 1 0.0625 0.02835 --- --- ---
1 Pound 16 1 0.4536 --- --- ---
1 Kilogram 35.27 2.205 1 --- --- ---
1 Short Ton 32000 2000 907.2 1 0.8929 0.9072
1 Long Ton 35840 2240 1016 1.12 1 1.016
1 Metric Ton 35274 2205 1000 1.102 0.9842 1
One unit in the left-hand column equals the value of units under the top heading.
23
Table 4. Volume and Capacity Equivalents
3
US Liquid Imperial
Unit Inches Feet3 Yards3 Meters3 Liters
Gallons Gallons
1 Inch3 1 0.000579 0.0000214 0.0000164 0.004329 0.00359 0.0164
3
1 Ft. 1728 1 0.03704 0.0283 7.481 6.23 28.32
3
1 Yd. 46656 27 1 0.765 202 168.35 764.6
3
1M 61023 35.31 1.308 1 264.2 220.2 1000
1U.S.Liq.Gal 231 0.1337 0.00495 0.003785 1 0.833 3.785
1 Imp. Gal. 277.42 0.16 0.00594 0.004546 1.2 1 4.546
1Litre 61.02 0.03531 0.001308 0.001 0.2642 0.22 1
Table 5. Conversion for Units of Speed
Unit Feet/Second Feet/Min Miles/Hr Meters/Sec Meters/Min Km/Hr
1 Foot/Sec 1 60.0 0.6818 0.3048 18.288 ---

1 Foot/Min 0.0167 1 0.1136 0.00508 --- ---
1 Mile/Hr 1.467 88 1 --- 26.822 1.6093
1 Meter/Sec 3.281 196.848 --- 1 --- ---
1 Meter/Min 0.05468 --- 0.03728 --- 1 ---
1 Km/Hr --- --- 0.6214 0.2778 --- 1
Table 6. Conversions For Units Of Power
Metric
Unit Horsepower Foot-lb/Minute Kilowatts Btu/Minute
Horsepower
1 Horsepower 1 33,000 0.746 1.014 42.4
1 Foot-lb/Minute --- 1 --- --- 0.001285
1 Kilowatt 1.341 44,260 1 1.360 56.88
1 Metric Horse0ower 0.986 32,544 0.736 1 41.8
1 Btu. /Minute 0.0236 777.6 0.0176 0.0239 1
Mechanical power and ratings of motors and engines are expressed in horsepower
Electrical power is expressed in watts or kilowatts.
24
Table 7. Conversions for Measurements of Water
Gay.
3
Gal Gal Head 2 2
Head 3
Unit Feet Pounds Liters Lb/in Ton/Ft Ft /Min (U.S)/
(U.S) (IMP) (Ft) (m)
Hr
Feet3 1 62.42 --- --- --- --- --- --- --- --- ---
Pounds 0.016 1 0.12 0.10 0.4536 --- --- --- --- --- ---
Gal (U.S) --- 8.34 1 --- --- --- --- --- ---
Gal (IMP) --- 10.0 --- 1 --- --- --- --- ---
Liters --- 2.2046 --- --- 1 --- --- ---
Head (Ft) --- --- --- --- --- 1 4.335 ---
0.703
Lb/in2 --- --- --- --- --- 2.3070 1 0.02784
9
Ton/Ft2 --- --- --- --- --- 35.92 --- 1 ---
Head
--- --- --- --- --- --- 1.4221 --- 1
(Meters)
Ft3/Min --- --- --- --- --- --- --- --- --- 1 448.92
Gal.
--- --- --- --- --- --- --- --- --- 0.00223 1
(U.S)/Hr
Table 8. Barometric Pressures and Boiling Points of Water as Various altitudes
Barometric Pressure Water Boiling Point
Lb/in2 o o
(Ft) Inches of Mercury Feet Water F C
Sea Level 29.92 14.69 33.95 212.0 100
1000 28.86 14.16 32.60 210.1 99
2000 27.82 13.66 31.42 208.3 98
3000 26.81 13.16 30.28 206.5 97
4000 25.84 12.68 29.20 204.6 95.9
5000 24.89 12.22 28.10 202.8 94.9
6000 23.98 11.77 27.08 201.0 94.1
7000 23.09 11.33 26.08 199.3 93
8000 22.22 10.91 25.10 197.4 91.9
9000 21.38 10.50 24.15 195.7 91
10,000 20.58 10.10 23.25 194.0 90
11,000 19.75 9.71 22.30 192.0 88.9
12,000 19.03 9.34 21.48 190.5 88
13,000 18.29 8.97 20.65 188.8 87.1
14,000 17.57 8.62 19.84 187.1 86.2
15,000 16.88 8.28 18.07 185.4 85.2
25
Table 9. Conversions of Units of Flow
U.S Million U.S

Unit Feet3 /Second Meters3/Hour Liters/Second
Gallons/Minute Gallons/Day
1 U.S
1 0.001440 0.00223 0.2271 0.0630
Gallon/Minute
1 Million U.S
694.4 1 1.547 157.73 43.8
Gallons/Day
1 Foot3/Second 448.86 0.646 1 101.9 28.32
3
1 Meter /Hour 4.403 0.00634 0.00981 1 0.2778
1 Liter/Second 15.85 0.0228 0.0353 3.60 1
Table 10. Conversions of Units of Pressure and Head
Unit Mm Hg In. Hg In H2O Ft H20 Lb/in2 Kg/cm2 Atoms KPa
1 mmHg 1 0.0394 0.5352 0.0447 0.01934 0.00136 0.0013

1 inch 25.4 L 13.5951 1.1330 0.49115 0.03453 0.0334 3.386
I in H2O 1.86827 0.0736 1 0.0833 0.03613 0.00254 0.0025 0.249
1 ft H2O 22.4192 0 .8827 12 1 0.43352 0.030479 0.0295 2.989
1 lb/in2 51.7149 2.0360 27.6807 2.3067 1 0.0703 0.0681 6.895
2
1 kg/cm 735.559 28.959 393.7117 32.8093 14.2233 1 0.9678 98.07
Atoms. 760.456 29.92 406.5 33.898 14.70 1.033 1 101.3
KPa 7.50064 0.2953 4.0146 0.3346 0.14504 0.0102 0.0099 1
One unit in the left hand column equals the value of units under the top heading
Table 11. Approximate weights of Liquids
Pounds per U.S Gallon Specific Gravity

Diesel Fuel 6.88 - 7.46 0.825- 0.895
Ethylene Glycol 9.3 - 9.6 1.12- 1.15
Furnace Oil 6.7-7.9 0.80 - 0.95
Gasoline 5.6 - 6.3 0.67 - 0.75
Kerosene 6.25 - 7.1 0.75 - 85
Lube. Oil (Medium) 7.5 - 7.7 0.90 - 0.92
Water 8.34 1.00
26
Table 12. Electrical formulae
Desired Data Single Phase Three-Phase Direct Current
Kilowatts (kW) I x V x PF 3 x lx V x PF IxV

1000 1000 1000
Kilovolt- IxV 3 xVxE

Amperes kVA 1000
1000
Electric Motor I x V x Eff, x PF 3 x lx V x Eff.x PF I x V x Eff.

Horsepower 746 746 746
Output (HP)
Amperes (I)
HP x 746 HP x 746 HP x 746
When
Horsepower is
V x Eff. X PF Vx Eff
known 3 x V x Eff.x PF
Amperes (I) KW x 1000 kW x 1000 kW x 1000
When Kilowatts
are known V x PF V
3 x V x PF
Amperes (I)
kVA x 1000 kVA x 1000
When kVA is
known V 3 xV
Where:
V = Volts
I = Amperes
Eff = Percentage Efficiency
Watts
PF = Power Factor =
IxV
27
TABLE 13. kVA/kW AMPERAGE AT VARIOUS VOLTAGES
(0.8 Power Factor)
kVA kW 208V 220V 240V 380V 400V 440V 460V 480V 600V 2400V 3300V 4160V
6.3 5 17.5 16.5 15.2 9.6 9.1 8.3 8.1 7.6 6.1
9.4 7.5 26.1 24.7 22.6 14.3 13.6 12.3 12 11.3 9.1
12.5 10 34.7 33 30.1 19.2 18.2 16.6 16.2 15.1 12
18.7 15 52 49.5 45 28.8 27.3 24.9 24.4 22.5 18
25 20 69.5 66 60.2 38.4 36.4 33.2 32.4 30.1 24 6 4.4 3.5
31.3 25 87 82.5 75.5 48 45.5 41.5 40.5 37.8 30 7.5 5.5 4.4
37.5 30 104 99 90.3 57.6 54.6 49.8 48.7 45.2 36 9.1 6.6 5.2
50 40 139 132 120 77 73 66.5 65 60 48 12.1 8.8 7
62.5 50 173 165 152 96 91 83 81 76 61 15.1 10.9 8.7
75 60 208 198 181 115 109 99.6 97.5 91 72 18.1 13.1 10.5
93.8 75 261 247 226 143 136 123 120 113 90 22.6 16.4 13
100 80 278 264 240 154 146 133 130 120 96 24.1 17.6 13.9
125 100 347 330 301 192 182 166 162 150 120 30 21.8 17.5
156 125 433 413 375 240 228 208 204 188 150 38 27.3 22
187 150 520 495 450 288 273 249 244 225 180 45 33 26
219 175 608 577 527 335 318 289 283 264 211 53 38 31
250 200 694 660 601 384 364 332 324 301 241 60 44 35
312 250 866 825 751 480 455 415 405 376 300 75 55 43
375 300 1040 990 903 576 546 498 487 451 361 90 66 52
438 350 1220 1155 1053 672 637 581 568 527 422 105 77 61
500 400 1390 1320 1203 770 730 665 650 602 481 120 88 69
625 500 1735 1650 1504 960 910 830 810 752 602 150 109 87
750 600 2080 1980 1803 !150 1090 996 975 902 721 180 131 104
875 700 2430 2310 2104 1344 1274 1162 1136 1052 842 210 153 121
1000 800 2780 2640 2405 1540 1460 1330 1300 1203 962 241 176 139
1125 900 3120 2970 2709 1730 1640 1495 1460 1354 1082 271 197 156
1250 1000 3470 3300 3009 ! 920 1820 1660 1620 1504 1202 301 218 174
1563 1250 4350 4130 3765 2400 2280 2080 2040 1885 1503 376 273 218
1875 1500 5205 4950 4520 2880 2730 2490 2440 2260 1805 452 327 261
2188 1750 5280 3350 3180 2890 2830 2640 2106 528 380 304
2500 2000 6020 3840 3640 3320 3240 3015 2405 602 436 348
2812 2250 6780 4320 4095 3735 3645 3400 2710 678 491 392
3125 2500 7520 4800 4560 4160 4080 3765 3005 752 546 435
3750 3000 9040 5760 5460 4980 4880 4525 3610 904 654 522
4375 3500 10550 6700 6360 5780 5660 5285 4220 1055 760 610
5000 4000 12040 7680 7280 6640 6480 6035 4810 1204 872 695
28
13. GLOSSARY OF TERMS
ALTERNATING CURRENT (AC) - A current which periodically reverses in direction and changes its
magnitude as it flows through a conductor or electrical circuit. The magnitude of an alternating
current rise from zero to maximum value in one direction, returns to zero, and then follows the same
variation in the opposite direction. One complete alternation is one cycle or 360 electrical degrees. In
the case of 50 cyc alternating current the cycle is completed 50 times per second.
AMBIENT TEMPERATURE - The air temperature of the surroundings in which the operates. This may be
expressed in degrees Celsius or Fahrenheit.
AMPERE(A) – The unit of measurement of electric flow. One ampere of current will flow when one volt
is applied across a resistance of one ohm.
APPARENT POWER (kVA~ VA) - A term used when the current and voltage are not in phase i.e. voltage
and current do not reach corresponding values at the same instant. The resultant product of current
and voltage is the apparent power and is expressed in kVA.
AUTOMATIC SYNCHRONIZER - This device in its simplest form is a magnetic type control relay
which will automatically close the generator switch when the conditions for paralleling are satisfied.
BREAK MEAN EFFECTIVE PRESSURE(BMEP) – This is the theoretical average pressure on the
piston of an engine during the power stroke when the engine is producing a given number of
horsepower. It is usually expressed in pounds/inch2. The value is strictly a calculation as it cannot be
measured, since the actual cylinder pressure is constantly changing. The mean or average pressure
is used to compare engines on assumption that the lower the BMEP, the greater the expected engine
life and reliability. In practice, it is not a reliable indicator of engine performance for the following
reasons. :
The formula favors older design engines with relatively low power output per cubic inch of
displacement in comparison with more modem designs. Modem engines do operate with higher
average cylinder pressures, but bearings and other engine parts are designed to withstand these
higher pressures and to still provide equal or greater life and reliability than the older designs. The
formula also implies greater reliability when the same engine produces the same power at a higher
speed. Other things being equal, it is unlikely that a 60 Hz generating set operating at 1800 RPM is
more reliable than a comparable 50 Hz generating set operating at 1500 RPM. Also it is doubtful that
a generator operating at 3000 RPM will be more reliable than one operating at 1500 RPM even if the
latter engine has a significantly higher BMEP. The BMEP for any given generating set will vary with the
rating which changes depending on fuel, altitude and temperature. The BMEP is also affected by
generator efficiency which varies with voltage and load.
CAPACITANCE(C) – If a voltage is applied to two conductors separated by an insulator, the insulator

will take an electrical charge. Expressed in micro-farads(μ f).
CIRCUIT BREAKER – A protective switching device capable of interrupting current flow at a

pre-determined value.
CONTINUOUS LOAD - Any load up to and including full rated load that the generating set is capable
of delivering for an indefinitely long period, except for shut down for normal preventive maintenance.
CONTINUOUS RATING - The load rating of an electric generating system which is capable of supplying
without exceeding its specified maximum temperature rise limits.
CURRENT (I) - The rate of flow of electricity. DC flows from negative to positive. AC alternates in
direction. The current flow theory is used conventionally in power and the current direction is
positive to negative.
CYCLE - One complete reversal of an alternating current or voltage from zero to a positive maximum
to zero to a negative maximum back to zero. The number of cycles per second is the frequency,
expressed in Hertz(Hz).
DECIBL(dB) - Unit used to define noise level.
29
DELTA CONNECTION – A three phase connection in which the start of each phase is connected to
the end of the next phase, forming the Greek letter Delta (D). The load lines are connected to the
corners of the delta. In some cases a center tap is provided on each phase, but more often only on
one leg, thus supplying a output.
DIRECT CURRENT - An electric current which flows in one direction only for a given voltage and
electrical resistance. A direct current is usually constant in magnitude for a given load.
EFFIIENCY - The efficiency of a generating set shall be defined as the ratio of its useful power
output to its total power rapt expressed as a percentage.
FREQUENCY - The number of complete cycles of an alternating voltage or current per unit of time,
usual second. The unit for measurement is the Hertz (Hz) equivalent to 1 cycle per second (CPS).
FREQUENCY BAND - The permissible variation from a mean value under steady state conditions.
FREQUENCY DROOP – The change in frequency between steady state no load and steady state
full load which is a function of the engine and governing systems.
FULL LOAD CURRENT - The full load current of a machine or apparatus is the value of current in
RMS or DC amperes which it carries when delivering its rate output under its rated conditions.
Normally, the full load current is the "rated" current.
GENERATOR – A general name for a device for converting mechanical energy into electrical energy.
The electrical energy may be direct current (DC) or alternating current (AC). An AC generator may be
called an alternator.
HERTZ (Hz) – SEE FREQUENCY.
INDUCTANCE (L) - Any device with iron in the magnetic structure has what amounts to magnetic
inertia. This inertia opposes any change in current. The characteristic of a circuit which causes this magnetic
inertia is know as self inductance; it is measured in Henries and the symbol is "L".
INTERRUPTABLE SERVICE – A plan where by an electric utility, elects to interrupt service to a

specific customer at any time. Special rates are often available to customers under such
agreements.
kVA – 1,000 Volt amperes (Apparent power). Equal to kW divided by the power factor.
KW - 1,000 Watts (Real power). Equal to KVA multiplied by the power factor
POWER - Rate of performing work, or energy per unit of time. Mechanical power is often measured in
horsepower, electrical power in kilowatts.
POWER FACTOR – In AC circuits, the inductances and capacitances may cause the point at which the voltage
wave passes through zero to differ from the point at which the current wave passes through zero. When the
voltage wave precedes the current wave, a lagging power factor expressed as an angle q. Power factor is
calculated as the cosine of the q between zero points and is expressed as a decimal fraction (0.8) or other words,
kW= kVA x percentage (80%). It can also be shown to be the ratio of kW, divided by kVA. In other words,
kW=kVA x P.F.
PRIME POWER – That source of supply of electrical energy utilized by the user which is normally available
continuously day and night, usually supplied by an electric utility company but sometimes by owner generation.
RATED CURRENT – The rated continuous current of a machine or apparatus is the value of current in RMS or
DC amperes which it can carry continuously in normal service without exceeding the allowable
30
temperature rises.
RATED POWER – The stated or guaranteed net electric output which is obtainable continuously from a
generating set when it is functioning at rated conditions, lf the set is equipped with additional power
product devices, then the stated or guaranteed net electric power must take into consideration that the
auxiliaries are delivering their respective stated or guaranteed net output simultaneously, unless
otherwise agreed to.
RATED SPEED - Revolutions per minute at which the set is designed to operate.
RATED VOLTAGE - The rated voltage of an engine generating set is the voltage at which it is
designed to operate.
RATED SPEED – Revolutions per minute at which the set is designed to operate.
REAL POWER - A term used to describe the product of current, voltage and power factor, expressed in
kW.
RECTIFIER - that converts AC to DC.
ROOT MEAN SQUARE (RMS) - The conventional measurement of alternating current and voltage
and represents a proportional value of the true sine wave.
SINGLE PHASE - An AC load or source of power normally having only output terminals if a source.
STANDBY POWER - An independent reserve source of electrical energy which upon failure or outage
of the normal source, provides electric power of acceptable quality, and quantity so that the user's
facilities may continue in satisfactory operation.
STAR CONNECTION – A method of interconnecting the phases of a three phase system to form a
configuration resembling a star (or the letter Y). A fourth or neutral wire can be connected to the
center point.
TELEPHONE INFLUENCE FACTOR (TIF) - The telephone influence factor of a synchronous generator measure of the
possible effect of harmonics in the generator voltage wave on telephone circuits at the generator terminals on
open circuit at rated voltage and frequency.
THREE PHASE - Three complete voltage/current sine waves, each of 360 electrical degrees in
length, occurring 120 degrees apart. A three phase system may be either 3 wire or 4 wire (3 wires
and a neutral).
UNINTERRUPTABLE POWER SUPPLY (UPS) - system designed to provide power without delay or
transients, during any period when the normal power supply is incapable of performing acceptably
UNITY POWER FACTOR – A load whose power factor 1.0 has no reactance causing the voltage
wave lag or lead the current wave.
WATT- Unit of electrical power. In DC, equals the volts multiply amperes. In AC, it equals the
effective volts times the effective amps times power factor times a constant dependent on the
number of phases.
31
One-Stop Tools Station
DIESEL
GENERATOR
DIESEL GENERATOR
www.totaltools.cn
TOTAL TOOLS CO.,LIMITED
MADE IN CHINA
T0815.V03

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Generadores

DESCRIPCIÓN: Generador Diésel Súper Silencioso una

Marca: Total Tools ATS: No integrado

Voltaje: 110 - 220V~50/60Hz Refrigeración: Enfriado por agua

Capacidad nominal: 15Kw /Máx 20Kw Encendido: Eléctrico

Fase: Monofásico Protección: contra falta de agua, aumento de

Velocidad: 1500 RPM temperatura y nivel de aceite

Alternador: sin escobillas Garantía: 3 meses

Motor: 4 tiempos / 4 cilindros Peso: 840 Kg.

Desplazamiento: 2.15 Procedencia: Importado

This installation manual will guide you to the factors to be

By following the suggestions in this installation manual,

You can make you work easier by enliting the aid of a

Starting system Electric Electric Electric

Item No. TP2100K3 TP2100K3-1 UTP2100K3 UTP2100K3-1 TP2100K3-5 TP2100K3-5-1

Starting system Electric Electric Electric

ATS or NOT No Yes No Yes No Yes

Item No. TP2150K3 TP2150K3-1 UTP2150K3 UTP2150K3-1 TP2150K3-5 TP2150K3-5-1

Starting system Electric Electric Electric Electric

Starting system Electric Electric Electric Electric

3. GENERATING SET LOCATION

4. GENERATING SET MOUNTING

10. FUEL SUPPLY

11. SELECTING FUELS FOR STANDBY DEPENDABILITY

12. TABLES AND FORMULAS FOR ENGINEERING STANDBY GENERATING SETS:

Table 1 Length Equivalents

Table 2 Area Equivalents

Table 3 Mass Equivalents

Table 4 Volume and Capacity Equivalents

Table 5 Conversions for Units of Speed

Table 6 Conversions of Units of Power

Table 7 Conversions for Measurements of Water

Table 8 Barometric Pressures and Boiling Points of Water at Various Altitudes

Table 9 Conversions of Units of Flow

Table 10 Conversions of Units of Pressure and Head

Table 11 Approximate Weights of Various Liquids

Table 12 Electrical Formulae

Table 13 kVA/kW Amperage at Various Voltages

13. GLOSSARY OF TERMS

 Access and maintenance location. 3. GENERATING SET LOCATION

2. MOVING THE GENERATING SET If it is necessary to locate the generating set

4. GENERATING SET MOUNTING

The generating set will be shipped assembled on

4.1 Vibration Isolation

It is recommended that the generating set be

Good ventilation requires adequate flow into and

Any internal combustion engine requires a liberal

To bring in fresh air, there should be an inlet 6. ENGINE EXHAUST

5.4 Exit Ventilator Size

An additional benefit of the insulation is that it

6.4 Minimizing Exhaust Flow Restriction

Free flow of exhaust gases through the pipe is

Silencers are rated according to their degree of

A set-mounted radiator is mounted on the

In most cases it is necessary that the air intake

Some diesel engines are air-cooled but the

Set mounted radiators are of two types. One type is

It is recommended that a set-mounted radiator's

If the building furnace has an oil burner, it