C7.1 Generator Sets Caterpillar

Receiving Inspection

If the generator is received during cold weather, allow the unit to reach room temperature before you remove the protective packing material. Warming the generator to room temperature will prevent the following problems:

• Water condensation on cold surfaces

• Early failures due to wet windings

• Early failures due to wet insulating materials

Unpacking

Moving the Generator

Show/hide table

Improper lift rigging can allow unit to tumble causing injury and damage.

Unpack the equipment with care in order to avoid scratching painted surfaces. Move the unit to the mounting location. Follow the instructions under the "Product Lifting" topic. The hoist and the hoist cables should have a rating that is greater than the weight of the generator.

Storage

If the generator is not installed immediately, refer to the "Product Storage" topic for the proper considerations for storing the unit.

Location

The location of the generator must comply with all local regulations. The location of the generator must also comply with all special industrial regulations. Locate the generator in an area that meets the following requirements:

• Clean

• Dry

• Well ventilated

• Easily accessible for inspection and maintenance

• Open generator sets shall be installed and located in a manner that contact with people is minimized.

Do not obstruct air inlet openings. Do not obstruct discharge openings. Air flow must reach these openings. If the generator is exposed to harsh environmental conditions, the generator can be modified in the field in order to add filters and space heaters. In addition, a more rigid periodic maintenance schedule should be established.

Note: For further information concerning the installation of this generator set, see the appropriate Application and Installation Guide.

Underwriters Laboratories (UL) 2200

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for all Cat UL Listed stationary engine generator assembly models, that should be followed during installation, and maintenance of the generator and batteries.

Load Connections – Generator Set Output

For units equipped with ABB Tmax^® circuit breaker: Installer shall connect and size conductors based upon ampacities found in the 75° C (167° F) column within Table 310.15(B) of the "National Electrical Code^®, ANSI/NFPA 70". An ampacity of no less than 115 percent (115%) of the maximum rated circuit current during normal operating conditions shall be used. All conductor insulation shall be rated 90° C (194° F) or greater.

For units equipped with power terminal strips: UL Listed field wiring terminals shall be sized for the connection of a conductor having an ampacity based upon ampacities found in the 75° C (167° F) column within Table 310.15(B) of the "National Electrical Code^®, ANSI/NFPA 70". An ampacity of no less than 115 percent (115%) of the maximum rated circuit current during normal operating conditions shall be used. All conductor insulation shall be rated 90° C (194° F) or greater. Field wiring terminals shall be installed in accordance with tooling and instructions recommended by their manufacturer.

A field wiring terminal shall be sized for the connection of a conductor having an ampacity based on the 75° C (167° F) column of Table 310.15(B) of the "National Electrical Code^®, ANSI/NFPA 70", of no less than 115 percent of the maximum current that the circuit carries during rated conditions. All conductors shall be rated 90° C (194° F) or greater.

Installation Access:

This stationary engine generator assembly shall be installed so that access is restricted to only qualified service personnel who have been instructed of the reasons for the restrictions applied to the location, and about any precautions that must be taken. Access shall be by using a special tool, or lock and key, or other means of security and shall be controlled by the authority responsible for the location.

Batteries and Servicing:

This stationary engine generator assembly utilizes one battery to produce a nominal 12V DC power supply.

Battery servicing is to be performed or supervised by qualified personnel knowledgeable of batteries and the required precautions. Keep unauthorized and unqualified personnel away from batteries.

When replacing batteries, use the same number and the following type batteries: lead-acid, vented type.

Show/hide table

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

Show/hide table

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

Show/hide table

A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries: Remove watches, rings, or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of batteries Disconnect charging source prior to connecting or disconnecting battery terminals Determine the battery is not inadvertently grounded. When inadvertently grounded, remove the source of ground. Contact with any part of a grounded battery is capable of resulting in electrical shock. The risk of such shock is reduced when such grounds are removed during installation and maintenance (applicable to a generator not having a grounded supply circuit)

Vented Batteries

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

Show/hide table

The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. The electrolyte is electrically conductive and corrosive. The following procedures are to be observed: Wear full eye protection and protective clothing Where electrolyte contacts the skin, wash electrolyte off immediately with water Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 500 gram (1 lb) bicarbonate of soda to 4 L (1 US gal) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

Show/hide table

Lead-acid batteries present a risk of fire because lead-acid batteries generate hydrogen gas. DO NOT SMOKE when near batteries DO NOT cause flame or spark in battery area Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Exhaust System (Shipped Loose or Not Complete)

Exhaust piping and chimneys shall be designed, constructed, and installed in accordance with the "Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines, NFPA 37".

Output Circuit Breaker Requirement

Installation of a UL 2200 Listed stationary engine generator assembly shipped without an installed output circuit breaker requires a UL Listed Circuit Breaker to be installed in the output circuit within 7.6 m (25 feet) of the stationary engine generator assembly.

Field Wiring – EMCP 4 Controller Interface

Installer shall use Class 1 wiring methods for all controller (customer) connections with following exception. Class 2 wiring methods shall be allowed for Class 2 controller interface wiring when Class 2 conductors are shielded with UL Listed/Recognized insulation sleeve or conduit rated to 600V for each individual circuit.