To ensure that this product is correctly installed and does not compromise safety and health, refer to the material in the appropriate Application and Installation Guide and the material contained in this Operations and Maintenance Manual.
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
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Improper lift rigging can allow unit to tumble causing injury and damage. |
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Do not use the engine lifting eyes to remove the engine and generator together. |
Unpack the equipment with care in order to avoid scratching the painted surfaces. Move the unit to the mounting location. The unit can be moved by either of the following methods:
- Attach an overhead crane to the eyebolts that are installed on the generator frame.
- Use a lift truck in order to lift the generator.
The hoist and the hoist cables should have a rating that is greater than the weight of the generator. When the unit is moved, ensure that the generator is supported by the lift truck fork tines. Also ensure that the generator is balanced on the lift truck fork tines. Slide the fork tines beneath the attached skid in order to lift the generator.
If the generator is not installed immediately, store the generator in a clean area. This area should also have the following conditions: low humidity, stable humidity and stable temperature. Space heaters must be energized in order to keep condensation from the windings. All accessory equipment that is supplied with the unit should be stored with the generator. The combined unit should be covered with a durable cover in order to protect against the following contaminants:
- Dust
- Dirt
- Moisture
- Other airborne abrasive material
A storage period in excess of 6 months should be preceded by the following preparation:
- Install desiccant bags inside the exciter's cover and install desiccant bags inside the screen of the fan.
- Seal the unit in a covering of plastic or other material that has been designed for that purpose.
- Adequately tag the generator. Tagging will ensure that preservative greases and desiccant bags are removed before the unit is placed in operation.
Ball bearing generators use grease. This grease is subject to deterioration. If the generator is stored longer than 1 year, new ball bearings should be installed. These bearings should be greased to the proper level prior to being put into operation. If inspection indicates that bearings are free of rust or corrosion, and no noise or excessive vibration appear on start-up, replacement is not necessary.
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
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.
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS
This manual contains important instructions that shall be followed during installation and maintenance of the generator and batteries.
Factory UL Listed option requires generator set be installed to the minimum UL requirements contained in this section. Installation and sizing shall be performed by qualified personnel. Other installation site requirements may apply in addition to those contained in this section.
Load Connections – Generator Set Output
For units equipped with T– frame breaker: Installer shall connect conductors in accordance with separate T-frame breaker terminal instruction provided with unit. All conductors shall be sized based upon the
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| Illustration 1 | g03368914 |
Unit ground bar shall be connected in accordance with National Electrical Code, ANSI/NFPA 70, Article 250. Installer shall use UL Listed terminal connectors and install in accordance with terminal connector manufacturer instructions. Terminal connectors shall be used within UL rating limit and suitable for the application. A field wiring ground terminal shall be sized for the connection based on the minimum ground conductor size required by UL as shown in the corresponding column of Table 1.
Over-current protection devices
For units without installed circuit breaker over-current protection option, installer shall use off package mounted UL Listed circuit breaker within 7.6 m (25 feet) of generator set.
| Minimum Ground Conductor Size | ||||
| AWG or kcmil (mm2) | ||||
| (Amps) | Copper | Aluminum or copper-clad aluminum | ||
| 400 | 1/0 | (53.5) | 3/0 | (85.0) |
| 500 | 2/0 | (67.4) | 4/0 | (107.2) |
| 600 | 2/0 | (67.4) | 4/0 | (107.2) |
| 800 | 3/0 | (85.0) | 250 | (127) |
| 1000 | 3/0 | (85.0) | 250 | (127) |
| 1200 | 3/0 | (85.0) | 250 | (127) |
| 1600 | 3/0 | (85.0) | 250 | (127) |
| 2000 | 3/0 | (85.0) | 250 | (127) |
| 2500 | 3/0 | (85.0) | 250 | (127) |
Field Wiring – EMCP 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.
Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
When replacing batteries, use the same number and the following type batteries:
Cat Premium High Output (PHO) Batteries
Standard battery (wet) BCI Group 31, Calcium Lead Alloy Grid Design, 1000 CCA,
Oversize battery (wet) BCI Group 4D, Calcium Lead Alloy Grid Design, 1400 CCA,
Standard battery (dry) BCI Group 31, Calcium Lead Alloy Grid Design, 950 CCA,
Oversize battery (dry) BCI Group 4D, Low Maintenance, Hybrid Construction, 1300 CCA,
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Do not dispose of battery or batteries in a fire. The battery is capable of exploding. |
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Do not open or mutilate the battery or batteries. Released electrolyte has been know to be harmful to the skin and eyes and to be toxic. |
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A battery presents a risk of electrical shock and high short circuit current. |
- Remove watches, rings, or other metal objects, 2) Use tools with insulated handles
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The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. |
It 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 it off immediately with water,
- Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention, and
- Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.
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Lead-acid batteries present a risk of fire because they generate hydrogen gas. |
The following procedures are to be followed:
- DO NOT SMOKE when near batteries,
- DO NOT cause flame or spark in battery area, and
- Discharge static electricity from body before touching batteries by first touching a grounded metal surface.
Open generator sets shall be installed and located in a manner that contact with people is minimized.