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Generator Installation
05/20/12
A detailed installation guide will usually be provided with your generator.
Here are some important points to consider when you install your generator.
We strongly recommend that the installation be performed by a licensed electrical
or mechanical contractor. They have the tools, the know-how and an understanding
of regulations and local codes. Their expertise will save you money in the long
run. Should you chose to perform the installation yourself, PLEASE do your homework
before tackling the job and obtain the proper permits required by your local
jurisdiction. While all GenSets have some basic requirements, each brand and
model has unique installation requirements. Also, it is extremely important
to have all relative codebooks for reference and to adhere to strictly adhere
to the laws which were designed for your safety. Most important of all, your
system must be inspected before starting to prevent fires and explosions from
improper installation.
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LOCATION
Ensure the following items are considered, read the manual for the generator.
* Air inlet for combustion and engine cooling.
* Outlets for exhaust and hot cooling air.
* Fuel, battery and AC electrical connections.
* Remember to monitor for carbon monoxide!
* Rigid, level mounting platforms (many sets are already mounted on a steel
skid base).
* Open accessibility for easy service.
* Isolation from living space. Keep noise and exhaust away from occupied areas.
* Space and equipment to extinguish a fire. Minimize the possibility of fire
danger.
* Remember, GenSets move on their vibration mounts. Allow clearance to compensate
and use flex-joints on all lines and connections.
EXHAUST SYSTEMS
The exhaust system may need to be covered with insulated material to prevent
fire resulting from contact with combustible materials. We recommend a heat
blanket over exhaust outlets to reduce the heat radiated from the exhaust and
to ensure personal safety. Some insulation materials are best left to professionals
with the proper equipment. Keep all piping away from combustible materials including
walls. A seamless, stainless steel flexible joint must be used between the generator
set and the exhaust system to prevent metal fatigue. Do not use the exhaust
manifold to support the exhaust system because the weight will cause manifold
failure. Exhaust pipe hangers are readily available and inexpensive.
FUEL SYSTEM
Extreme care should be taken in designing and installing the fuel system to
prevent fire danger. Fuel lines should have as few connections as possible and
be routed to prevent damage. Keep lines away from hot engine or exhaust components.
The lines should be no smaller than the inlet and outlet on the engine. Support
fuel lines with clamps, as needed, to help prevent metal fatigue from vibration.
The fuel tank should be level with or below the set to prevent siphoning in
the event of a line failure. Remember to check the lift capacity of the engine
fuel pump and stay within its limits. If the set is higher than the tank, an
auxiliary fuel pump may be required.
To prevent water ingestion, fuel should be drawn out of the top of the tank
with the pick-up extending to no more than two inches from the bottom. Fuel
storage tanks must have leakage protection and many jurisdictions require spill
basins. Above ground tanks are recommended and cheaper but you must check your
local codes before installing a tank. The safest tanks are double walled with
alarms. These alarms are simple and well worth the investment to avoid a possible
fuel spill, and significant clean-up costs. If the tank is mounted above the
generator set, use a fuel shut-off valve, so that you can work on the fuel system
without the fuel-siphoning out. It also allows you to cut-off fuel flow in the
event of line breakage.
A high quality, fuel/water separator filter should be mounted as close to the
generator set as possible. Because of its explosive nature, gasoline fuel systems
have special requirements; see your tank supplier for complete information.
COMBUSTION AND COOLING AIR
The generator set requires air for combustion and cooling. A radiator and a
“pusher” engine fan cool the generator engine temperature. Your
car or truck will normally operate with a “puller” fan. An internal
fan cools the generator.
OUTDOOR MOUNTING
GenSets that are housed in weather-protective enclosures are designed for installation
out-of-doors. Typically a cement pad is placed in a suitable location, out of
sight but with easy access for maintenance and fueling. The generator is secured
to the pad. Choose a site close to the electric service and fuel supply lines
(natural gas, propane, or diesel). The image below shows a typical natural gas
installation. The main distribution panel, transfer switch and sub-panels are
inside the building in this example, but more often the distribution panel,
sub-panels and transfer switch are outside. You should make sure that 110v power
is available at the generator for battery charging.
The GenSet must be a minimum of 3 ft from combustible material (NFPA 37). Leave
at least 3 ft (or more if the housing and instructions for your particular unit)
all around the GenSet enclosure for access to the inside (NEC Art. 110-26a,
Art. 110-26b). The GenSet must be at least 5 ft from any opening (window, door,
vent, etc.) in a wall, and the exhaust must not be able to accumulate in any
occupied area. See figure below.
INDOOR MOUNTING
We do not recommend locating generator sets indoors in residential applications
and small commercial and industrial applications. The primary reason to avoid
indoor installation is safety. Carbon monoxide gas is odorless, colorless and
can accumulate in closed spaces. You can walk into a room full of carbon monoxide
and be overcome. A gas leak in space attached to your home can kill you and
your family.
In addition to safety, it costs more to install a GenSet indoors than for the
same GenSet provided with the factory weatherproof housing. When a GenSet is
installed indoors, the building must be designed carefully to handle ventilation
to remove heat and any fumes due to fuel, exhaust, lubrication and starting
batteries. The radiator must be provided with a duct adapter that interfaces
properly with louvers on an outside wall of the building. Adequate air intake
flow must be available not only for the radiator fan but also for cooling the
alternator. The engine exhaust piping and muffler must be tight to prevent any
leaks that would allow dangerous carbon monoxide to accumulate inside the building.
Generally, the room or space in which the generator operates, should not exceed
100 F. We recommend keeping it under 85 F if possible. Generator installations
require an intake of cool, clean air and an outlet vent for hot air. Whenever
possible the cool air should be drawn over the alternator (or generator end)
to help keep the alternator cool. The size of the space affects the room temperature
(the smaller the space the generator runs in, the higher the room temperature
is likely to be), smaller spaces may require ducting. The size of the generator
and the outside air temperature or climate must be considered. In an indoor
installation, increasing these vent sizes may cool the room down to acceptable
levels and ensure “positive” airflow. Positive airflow is cool,
clean air in and hot air out, as opposed to circulating hot air inside the room.
Generator cooling fans move moisture as well as air. Moist air is corrosive
to a GenSets copper windings, so make sure air inlets are positioned to minimize
moisture intake.
Automatic fire suppression systems may also be required. Check with your local
fire codes. You should also contact your fire insurance provider to determine
if an indoor GenSet is even permitted.
Installation engineered to meet all the above requirements and all safety codes
can still become a hazard later. For an installation to remain safe, it has
to be regularly inspected and maintained to ensure that leaks or other dangerous
conditions do not develop with age or use. Sites that do not have a knowledgeable
maintenance staff trained to support an indoor generator set should not install
a unit inside a building.
Another factor is the initial cost. It is impossible to construct a building
to house a GenSet at a cost as low as the factory housing that can be ordered
with the GenSet. And even if the building already exists, the design expense
and costs to adapt it for a generator set installation usually will exceed the
enclosure cost available from the GenSet manufacturer. For a small GenSet the
cost of an open unit with duct adaptor and exhaust pipe kit is as little as
$600 less than the same GenSet with the factory weather housing. The additional
costs for just the exhaust thimble and louvers exceed that savings.
Please read Policy, Warranties and Disclaimers. You as the buyer and user of
generators sold by GeneratorJoe assume all risk and liability in connection
with all equipment purchased.
AC CONNECTIONS
Connecting the generator to your electrical distribution system is a job for
a qualified, licensed and bonded electrician who is familiar with local building
codes. Electricity is dangerous, respect it.
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TRANSFER SWITCHES & SWITCHGEAR
All generator systems require a circuit breaker and a distribution panel. The
circuit breaker protects the generator set from short circuit and unbalanced
electrical loads. The distribution panel divides and routes the connected loads
and includes circuit breakers to protect these loads. Stand-by systems also
require a main circuit breaker between the utility source and the transfer panel.
The transfer panel switches power from the utility to the GenSet and back so
that both aren't on at the same time. Residential, commercial and industrial
generators are equipped with auto-start to allow connection to auto-transfer
switches.
Unless you have no other electric service (utility power), you must install
a transfer switch. Normally the transfer switch must be the same size as the
service panel or a sub-panel off the service pane. The transfer panel switches
power from the utility to the GenSet and back so that both aren't on at the
same time. Auto-start, auto-transfer systems are available and are relatively
inexpensive. We can help you determine what you need. For more information about
transfer switches and how they work see: Small Transfer Switch Information and
for large switches see: Transfer Switches. . GeneratorJoe can help you determine
what you will need, call us.
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