SECTION 1 - Safey Precautions

Before operating any generator system, read the Operator's Manual to become familiar with your
equipment. Safe and efficient operation can only happen if the equipment is properly operated
and maintained.
No generator manufacturer or installation contractor can anticipate every potential hazard
involved with the installation and use of these type of systems. The warnings, decal and labels
attached to the equipment and used in this Manual can not cover all hazards. Use of methods or
procedures other than those recommended by the equipment manufacturer must satisfy you that
it is safe for you or others to follow.
The following symbols are highlighted to alert you of conditions that are potentially dangerous to
the operator, installation/service/repair personnel, or the equipment.
1-1. General Safety Precautions

This symbol warns of hazards which will result in severe or lethal

DANGER
personal injury.

This symbol refers to a hazardous or unsafe practice which has

WARNING the potential to result in personal injury or product/property
damage.

This symbol warns of immediate hazards which will result in

CAUTION
severe or lethal personal injury.

• Keep equipment clean and properly maintained. Normal maintenance and servicing of
equipment is a prerequisite to a functional, safely operated machine.
• Use common sense, read the instructions and information in this manual carefully, and
check for other local safety rules that require compliance.
1-2. Installation Precautions
• Be safety conscious. Read all operational, safety and installation information before
attempting to install or operate any generator equipment.
• This equipment should be installed, operated, serviced, and repaired by qualified
personnel only. The installation and interconnection of this equipment to facility wiring
and other equipment must be done by a competent, qualified craftsperson who is familiar
with applicable standards and codes governing the installation.
• Installation methods, practices, or procedures that are unauthorized or done improperly
are dangerous and could result in serious personal injury or damage to property and
equipment.
• Installation, operation, servicing and repair of electrical power generators and their
related equipment must be done in accordance to applicable codes, standards, regulations
and laws. The National Fire Prevention Association (NFPA), National Electric Code
 (NEC), Occupational Safety and Health Administration (OSHA) regulations, local
industrial codes and requirements must be complied with in the use and servicing of this
equipment.

FUEL AND FUMES ARE FLAMMABLE. A fire or explosion could

WARNING
result from violation of recommended practices or procedures

• An open flame, smoking, or welding near a generator is a potential fire hazard. Internal
combustion engine fuels are flammable.
• Ensure all fuel fittings are properly connected and not leaking. Periodic inspection is
required to ensure no leaks develop over time.
• Fuel connection at the engine should be made with an approved flexible fuel line. Use of
copper piping for flexible lines is not recommended as copper work hardens and becomes
brittle.
• Never fill fuel tanks while the engine is running, unless tanks are outside the engine
room. When fuel comes in contact with a hot engine or exhaust system, there is
possibility of a fire or explosion.
• Under certain conditions storage batteries will expel explosive hydrogen gas. Do not
allow smoking, welding or sparks in the vicinity of any storage battery. Adequate
ventilation must be provided around batteries. Battery racks must also be grounded to
minimize static charges.

DANGER EXHAUST GASES ARE LETHAL

• Ensure the exhaust system is installed properly and adequate ventilation is provided.
Exhaust gases must be safely piped away from the unit to an area not used by people. The
engine consumes oxygen and the exhaust given off by the engine contains carbon
monoxide gas. Carbon Monoxide is a deadly, lethal gas.
• The installation must have adequate ventilation.

DANGER MOVING PARTS CAN KILL

• While equipment is running, stand clear of moving parts.

• When in service certain automatic start units are capable of starting at anytime. Disable
control and power switches before maintaining, servicing or repairing these units.
• Before starting work on a self-starting generator, disconnect the starting battery.
Disconnect the negative (-) battery cable first to prevent accidental shorting.
• Ensure all fasteners are secure. Tighten hardware and keep all guards in position over
fans, impellers, or other moving parts.
 • If adjustments must be made while the unit is running, use extreme care around moving
and hot parts. Hot parts include engine and exhaust system, muffler, pipes, flexible
exhaust pipe section, etc..

ELECTRICAL SHOCK CAN CAUSE SEVERE INJURY OR

WARNING
DEATH

• Wire gauge sizes of electrical wiring, cables, and facility circuits must be of sufficient
size to handle the maximum electrical current (ampacity) of circuits. Refer to generator
system's User Manual to determine appropriate cable/wire size.
• Remove electrical power before removing any generator's protective panels or touching
any electrical components.
SECTION 2 - Locations
The location for a generator is dependent on applicable codes and associated support systems for
the generator such as ventilation, wiring, fuel, and exhaust.
The following factors should be considered:
• The ideal location for any generator is away from extreme ambient temperatures and
where the generator is protected from adverse weather conditions. It is recommended that
generator be as close to the load it is supporting as possible.
• The structure the Gen-Set (Generator Set) will be set upon must be strong enough to
support the weight of the Gen-Set, its' auxiliary equipment, and other equipment mounted
on the structure.
• The structure must meet a 1 hour non-combustion fire rating.
• The installation site must be clean, dry and not subject to flooding.
• Because of excessive ambient temperatures associated with the use of stand-alone metal
sheds from exposure to sunlight, a concrete pad with a supported roof and an outside
security enclosure (fence) to protect the unit from vandalism, birds, rodents, and other
small animals is recommended.
• The Gen-Set generates heat while running. Installing the Gen-Set in a tightly enclosed
building or shed is not recommended. The site must provide for adequate cooling and
ventilation with a minimum of duct work. Adequate ventilation for a generator is
specified in cubic feet per minute.
• The site must permit engine exhaust gases to be piped away to an area that is uninhabited
by people or animals. Care must be given to ensure that exhaust gases do not re-enter an
occupied area.
• The site must provide adequate acoustical noise and vibration isolation.
• The outside site must provide access to the generator to allow for maintenance, service,
and repair. A three foot (.914 meter) service clearance around the unit is recommended.
• Fuel supply and ease of refueling must be taken into consideration.
• Adequate normal and emergency lighting must be provided in any installation.
 • When mounting a generator outside on a roof or next to a building the generator must be
at least 3 feet from any combustible wall and 5 feet from any opening(i.e. doors,
windows, vents, & ducts).
2-1. Ground/Floor Loading
The foundation for the generator must support the total weight of the generator. This includes
fuel, oil, and the weight of any associated support systems.
Plan for 3 feet (1 Meters) of access around the generator for maintenance, service and repair.
When calculating the floor loading, ensure the fuel weight, cooling system fluids (where
applicable), piping, pumps, power cables/runways and supporting structures are included in the
calculations. Most user's manuals do not include the weight of the fuel tanks since most are sold
less tank.
SECTION 3 - Mounting
A concrete foundation with anchored mounting bolts, is recommended. Steel Beams are an
acceptable alternative. Foundations help in the servicing and repair of Gen-Set's and protect the
unit from moisture that could occur from seepage. The concrete base that the generator is
mounted to should be separate and independent from the surrounding structure.
The following applies to concrete bases:
• A Single (See Figure 1)or Double (See Figure 2) pedestal base may be used. A height of
at least 6 inches higher than floor level is recommended.

Figure 1- Single Pedestal Concrete Mount

 Figure 2 - Double Pedestal Concrete Mount

• A double pedestal base allows easier cleaning under most generator's.

• Double pedestals provide better access for inspecting for oil or fuel tank leaks.
• The generator should be retained to the pedestal base with fasteners that are
recommended by the generator set manufacturer.
• The concrete base should extend beyond the generator's "Footprint" by at least 12 Inches
(305 mm) on all sides.
• The higher the mounting base is made, the easier the unit will be to work on when
performing maintenance, service, or repairs. Typically bases are required to be raised at
least 6 inches (153 mm) above floor level. Placing the unit higher than 6 inches
sometimes has the advantage of making it easier to change the unit's oil.
• Passing fuel lines and electrical conduit for a "stub-up" through the concrete base is a
standard practice of gen-set installers.
• Concrete foundations are typically mixed by volume. The typical ratio of cement, sand,
and aggregate is 1:2:3 with a maximum 4 inch (102 mm) slump and 28 day compressive
strength of 2500 psi (173 kPa).
• A generator can typically be mounted to a combustible floor or roof, dependent upon
code, however, the surface beneath the engine and beyond the engine to a minimum
distance of 12 inches (305 mm) must be covered with a non combustible insulation and a
minimum of 24 gage sheet metal between the insulation and the generator. See Figure 3.

Figure 3. Combustible Floor and Roof

 • Optional vibration isolators beyond those already built in the generator also help reduce
transmitted noise, however, it is recommended that one verify that the generator
manufacturer recommends the use of an isolator.
• Insulation must be a non-combustible material, typically a Fiberglas mat.
SECTION 4 - Ventilation
4-1. Outdoor Installations - Air Cooled Units
• Air cooled unit draws cooling air from different ends of the unit to cool the system,
dependent upon the units cooling system design. Check with the generator's manufacturer
to determine the optimal cooling method for the system. Factors such as climate and
direction of prevailing winds must be considered in an outdoor installation.
• If your generator is expected to be in temperatures lower than -20oF(-29oC) consult the
generator sets factory, a cold weather package may be required.
The following general rules apply:
• Where strong prevailing winds are anticipated, face the engine end away from the wind.
• Plan the installation carefully to prevent the cooling air vents on the generator from
becoming clogged by leaves, grass, snow, etc.
Figure 4 . Typical Outside Small Generator Installation
4.2 Indoor Installations - Air Cooled Units
When a generator is installed and operated in an indoor environment, adequate ventilation for
heat dissipation and combustion is required. Ventilation is typically done through the use of an
air inlet, air outlet/exhaust fan, and/or other ventilation openings.
The following rules apply:
• When ever possible, face the generator air inlet openings away from the wind. The wind
can prevent the air intake louver from opening on start up.
• The air inlet must be capable of moving enough air through the room to provide the
correct minimum CFM (cubic feet per minute) cooling for generator as specified by the
generator's manufacturer. (This means the generator's air inlet opening size will be greater
than the generator's room exhaust fan outlet.)
• Locate air inlet, ventilation and air outlet openings in a structure so that already
exhausted air will not be drawn back into the building.
• Louvers, screening, expanded metal and other materials used to cover air openings are a
restriction to air flow. This restriction must be compensated for by making the air opening
size proportionally larger.
• When possible, position the engine end of air cooled generators in line with the air inlet
per the manufacturer's recommendation.
 • When possible, position liquid cooled engines with the engine end in line with the
exhaust outlet per the manufacturer's recommendation. The reason or this
recommendation is that the air moving through a liquid cooled system is typically pulled
past the engine and through the generator's radiator. The generator's radiator is placed so
that the air is ducted out of the generator's room.
4-3. Ventilation Exhaust Fans and Air Inlet Louvers
Some indoor installations may require the use of one or more exhaust fans, to provide adequate
ventilation during generator operation.
The following rules apply:
• Exhaust fans must have the proper capacity for the specific application. In addition, the
fans must be located so that engine exhaust gases will not re-enter the building.
• Power is required to operate the exhaust fan. Typically, AC is provided from an DC/AC
inverter or UPS to operate the exhaust fan and open air inlet louvers.
4-4. Ducting of Air
The engine cooling fan moves a large volume of air during operation. This heated air must be
expelled to the outside of any structure housing a generator.
The following rules apply to the ducting of heated engine air out of a building:
• Whenever possible, use no ductwork at all. Simply position the inlet air duct so that air
will be drawn directly over the generator and expelled horizontally to the building
exterior (outdoors).
• If duct work must be used between the generator installation location and the building air
outlet opening, keep such ductwork as short as possible with a minimum number of
bends.
• Construct air outlet duct work of self-supported sheet metal.
• Never locate the air outlet opening of a structure close to adjacent buildings or walls as
noise is amplified when air is expelled in large volumes.
Figure 5. Typical Indoor Ventilation Duct
Figure 6. Typical Small Generator Indoor Installation
 Figure 7. Typical Indoor Larger Generator Installation

Roof mount radiators on liquid cooled units is sometimes done where the installation location of
the unit can not dissipate the heat generated by the unit during operation. Roof mount radiators
is beyond the scope of this publication.
4-5. Louvers, Screening And Expanded Metal
When louvers, screening or expanded metal are used to cover air openings in buildings housing
generators, consideration must be given that these materials do not restrict the free flow of
cooling air. Any restriction must be compensated for by making the actual opening size
proportionately larger.
Louvers: Either fixed or movable louvers may be installed on the air openings in a structure that
houses a generator. The installer must make sure that the total square inches of free air inlet
opening is sufficient to limit the heat rise in the room to prevent the room temperature from
exceeding the generator 's operating temperature.
Figure 8. Louver

Find the actual free air opening as follows:

• Multiply the height of a single louvered opening by its width, to find the opening area of
one louvered opening.
• Multiply the opening area of the single louvered opening by the total number of louvered
openings to find total free air inlet area.
Figure 9. Screening and Expanded Metal
Screening and Expanded Metal: Screening and expanded metal may be used to cover air inlet
and outlet openings in a structure that houses the generator. These materials also offer a
restriction to the free flow of cooling air, which must be compensated for by making the actual
air opening in the structure proportionally larger. Screening and expanded metal are usually
assigned a "free air inlet area" value by the manufacturer, which is given as a percentage.

To find the actual size of the air inlet opening needed, proceed as follows:
• Find the area of the generator's inlet air duct, by multiplying the air duct height by its
width.
• Divide the inlet air duct area by the percentage of free air inlet area for the particular
screening or expanded metal to be used. The result is the required size of the air inlet
opening in the building.
Example 1: If the required inlet air opening area on a particular generator is 400 square inches
and the building air opening is to be covered with screening having a 70% "free air inlet area":
Divide 400 square inches by 0.70, to obtain 576 square inches. Actual air inlet opening size in
the building should be equal to or greater than 576 square inches. (An opening that measures 24
X 24 inches (576 square inches) would be adequate in this case to achieve the required 1125 Cu.
ft/minute (31.86 Cubic Meters/Min.).
Example 2: The required inlet air opening area on a particular generator is 500 square inches and
the building air opening is to be covered with screening having a 70% "free air inlet area":
Divide 500 square inches by 0.70, to obtain 714 square inches. Actual air inlet opening size in
the building should be greater than 714 square inches. (An opening that measures 27 X 27 inches
(729 square inches) would be adequate in this case to achieve the required 2000 Cu. ft/Minute
(39 Cubic Meters/Min.).
SECTION 5 - Fuel
5-1. Gasoline
For gasoline egine generators, Unleaded or Regular gasoline with a lower octane rating than
85((RON/MON)/2) may cause pre-detonation (knocking) which can damage the engine. Regular
gasoline can be used, however, unleaded gasoline is preferred because it reduces pollution and
combustion chamber deposits. See the generator's engine owner's manual for fuel information or
contact the generator set's manufacturer.

WARNING ENGINE FUEL can cause fire or explosion.

• Do not operate the engine without the cranking battery connected.

• Do not disconnect the cranking battery while the engine is running.
• Stop engine by turning the Key Switch to OFF before checking oil or adding fuel.
• If fuel is spilled, clean up immediately and dispose of contaminated materials properly.
• Do not refuel if engine is hot or running.
• Do not refuel near sparks or open flame.
• Do not smoke while refueling.
• Do not fill fuel tank to the top; allow room for expansion.
• Fuel consumption varies from one engine to another. Different brands of fuel, operating
conditions, condition of engine, etc., also affect the fuel consumption.

CAUTION POOR QUALITY, LOW OCTANE FUEL can damage the engine.

IMPORTANT:
• Use clean, fresh, unleaded gasoline with at least 85 octane rating.
• Do not mix oil with the gasoline.
• Do not use gasohal or gasoline alcohol fuel blends.

5-2. Gaseous Fuels

Typically on LP Gaseous or Natural Gas powered unit the unit will run on either vaporous fuel
source. Most gaseous fuel units are set up for a specific number of ounces of line pressure (a.k.a.
as a corresponding number Inch Water Column) with some type of threaded pipe hook up. Note:
Use of gaseous fuels decrease the amount of total power the generator is capable of producing by
as much as 20 percent, dependent upon thermal content of fuel in your specific area. Refer to
Section 8 for Gaseous Fuel Systems.
5-3. Diesel Fuel Piping and Filtration
The basic requirements of a diesel engine fuel system are adequate piping, proper selection of
filters for the application and completely air-tight joints, with a minimum number of fittings to
prevent air from entering the fuel lines, especially in installations where the fuel tank is lower
than the pump.

5-3. A. Piping to the Tank

Vacuum at the transfer pump inlet must be avoided. If an auxiliary pump is used, pressure at the
transfer pump must not be less than 0 p.s.i. nor greater than 5 p.s.i.(typical). Pressure after the
return line connector assembly must not exceed 5 p.s.i. unless called for in the pump or system
specification.
NOTE: The return line must never be piped back to the transfer pump inlet side. Both supply and
return line should be connected to standpipes in the tank with the opening for each 2 inches
minimum from the bottom of the tank to allow space for water and sediments to settle and to
eliminate siphoning problems.
5-3.B. Filter Requirements
1. A pleated paper type filter with large area and minimum pressure drop capable of filtering
out 75 - 80% of five micron particles should be used. A Master Filter is recommended
since it provides sufficient area for long life and two stage filtration for maximum
protection.
2. Where water in the fuel is known to be a problem, a Master Separator is recommended.
Contact the generator manufacturer for a recommended filter.
5-3.C. Maximum Pressure Drop
Pressure drop across clean filters should not be more than 2.5 inches of mercury (1.2 p.s.i.) at full
load. Pressure drop in the supply system exceeding 10 inches of mercury (4.9 p.s.i.) because of
dirty filters or other restriction usually will affect pump and engine performance, (erratic
operation, low power, engine stall).
5-4. Fuel Consumption
Fuel consumption is typically specified in the generator's user manual and is specified in a
quantity of fuel consumed per hour based on a specified load. Refer to the generator's user
manual for expected fuel consumption, which is based upon a specific load. While the
generator's manufacturer may not be able to predict the consumption for your site because of the
differences in the typical load, by site, an estimate a full load is typically given.
A simple fuel consumption model that is a "ball park" predictor of fuel consumption is as
follows:
Based on experience, a generator at no load typically uses about half of the fuel of a generator at
full load. The ratio of output power from a generator to the amount of fuel consumed is almost
linear. Consumption on diesel fueled generators is somewhat less than gasoline.
Fuel Consumption = (Estimated Load/Maximum Generator Power Output) X .5 X Maximum
Fuel Consumption + 50% of Maximum Fuel Consumption
Assuming Maximum fuel consumption = 1 Gallon/Hour
Minimum fuel consumption = .5 Gallon/Hour
At a 50% load, Fuel Consumption = (((50 Amps/100 Amps) X .5 Gallon) + .5 Gallon) = (((.5) X
.5) + .5) = .75 Gal./Hr.
Other factors that need to be taken into account are the temperatures of the areas where the fuels
are stored are as follows:
• Diesel gels at lower temperatures. It is advisable to use the lowest temperature rated fuel
all year around. The reason for this is that the generator will typically run only at
scheduled maintenance test times. If higher temperature rated fuel is used, by time the
lower temperature fuel is put into the tank, the fuel blend will be less than desired at the
time you need the lowest temperature rating.
• Use of LP is a problem at lower temperatures. At 20oF the amount of fuel in an LP tank
that is available to vaporize decreases dramatically. Rule of thumb for LP is that the
amount of fuel available is about 50 percent of the amount of fuel in the tank. In short, at
cold temperatures, only 50 percent of the fuel in the tank is available for the generator.
• At -36oF, LP does not vaporize. This means no fuel will be available for use.

SECTION 6 - Electrical System

There are a number of different generator systems and typical loads in the context of electrical
systems. Most systems, unless they contain automated swtich gear, have a means of disconnect
between the generator and the load. This is typically a transfer switch or disconnect. Ensure the
contacts on the switch are rated for the size of your system. System schematics are beyond the
context of this tutorial at this time.
6-1. General (Electrical System)
Generators are rated for a maximum current in Amps and power output in Kilowatts. Typically
power outputs can vary between different models. The output is dependent upon fuel type,
ambient temperature and altitude of the installation.
Of same model types using different fuels, Gasoline units will have the highest output followed
by gaseous fuels (Natural Gas and Liquid Petroleum(Vapor withdrawal). LP is about 95% of that
of gasoline and natural gas at about 85% of gasoline. These units typically derate at about 3% per
1,000 ft (334 meters) starting at about 3,000 feet (1,000 meters) and an additional 1% for every
10 degrees over 78 degrees F. This is fairly common for all asperating engines.
Diesel units derate more for temperature and altitude. Diesels typically derate at about 4% per
1,000 ft (334 meters) starting at sea level and an additional 1% for every 10 degrees over 78
degrees F. At higher elevations, this power loss can be significant.
Circuits to carry power from the generator needs to be sized accordingly. Distance of the
generator to the load (Typically a UPS) will also effect wire size. The conduit entryway for the
generator is typically specified for a nominal size and may need to be increased in size if you are
required to go to the maximum wire size. Flexible liquid tight metallic conduit should be used.
Direct Current (D.C.) Generators typically require a significantly larger cable size from the
generator to the load (typically UPS batteries) in order to compensate for voltage drop. Voltage
drop is a function of the resistance of the wire over the distance from the source to the load. The
typical recommedation for D.C. generators is to keep the generator as close to the load as
possible. Refer to the generators manufacturer's recommendations. Refer to N.F.P.A. 70, also
known as the National Electric Code (NEC) for cable sizing tables.
When mounting electrical panels, a 3 foot clearance is required and the use of an emergency light
to illuminate the unit during operation is typically required. Power for the emergency light
should be from both the primary utility and the generator. This is highly recommend so that in
the event of a malfunction there is a light source to see to work on the unit. Refer to your local
building and electrical codes to ensure compliance.
Use of powered exhaust fans and powered louvers for ventilation is typical for indoor
installations. Emergency power will be needed operate the auxillary devices. Make sure the
generator is sized large enough to cover the load and the auxillary equipment.
6-2. Conductor Sizing Connection
This information is dependent upon your generator output and intended load. When connecting
cables to the generator, unless instructed differently by the equipment manufacture, make
connections at the generator first. Make the connections at the load last. Failure to do so may
constitute a fire or safety hazard.
All ampacities are typically calculated at 75 o C (Celsius)(167 o F(Fahrenheit) in the conductor
size charts. Building wire conductors should be rated at 90oC(194oF) to allow for different
ambient temperatures that these conductors may pass through.
All conductors are typically required by electrical code to be copper. The recommended
conductor sizes are based on maximum current. Ampacities are found in NEC Article 310, Table
310-16. Conductor resistances are found in NEC Table 8 "Conductor Properties".
Direct Current (D.C.) generators require larger output power cables than comparable A.C.
generators due to voltage drops in the cable caused by increased resistance.

Most A.C. Generators require the use of transfer switches. Refer to manufacturer's installation
instructions and recommendations.

Return to Table of Contents

Go to Section 7
Tips on Hooking up a Generator (genset) to a Uninterruptible Power System (UPS)

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SECTION 7 - Exhaust System
7-1. General (Exhaust System)
Generator engines give off deadly carbon monoxide gas through their exhaust systems.
Carbon monoxide gas, if breathed in sufficient concentrations, can cause unconsciousness or
death. Exhaust gases must be piped safely away from any room or enclosure that houses a
generator and to a well ventilated area where people will not be endangered.
Besides the possibility of carbon monoxide poisoning, exhaust piping becomes extremely hot
during operation and remains hot for a long time after shutdown. For that reason, the following
precautions are necessary:
• Avoid contact with hot engines, exhaust manifolds, exhaust piping and mufflers. Any of
these can cause severe burns.
• Where piping must pass through combustible walls or ceilings, special precautions must
be taken to prevent fire or heat damage such as using heat thimbles through walls and
ceilings.
7-2. General Rules for Exhaust Systems
When installing an exhaust system for a generator, the following rules should be considered:
• Exhaust piping should be of wrought iron or steel having adequate strength and
durability.
• Exhaust fittings may be of cast iron. A 9 inch spacing (10 inches (250mm) recommended)
from the exhaust pipe and walls is also required by most local codes.
• Low points in horizontal runs of piping should be provided with condensation traps, as
well as condensation drains.
• Piping and mufflers must be properly supported and connected.
• A flexible length of exhaust pipe is required between the engine exhaust manifold and
rigid exhaust piping.
• Exhaust piping must be terminated safely outside a structure that houses a generator, in
such a way that hot gases and sparks will be discharged harmlessly and will not blow
against any combustible surface or material.
• Exhaust piping must not terminate under loading platforms, structures, or near any
opening in a building.
• Where necessary, exhaust piping must be guarded and/or insulated to prevent burns.
• Provide a clearance of at least 9 inches (229mm)(10 inches (250mm) recommended)
between exhaust piping and any combustible material.
• Keep exhaust piping well clear of fuel tanks, fuel lines, etc.
7-3. Routing Exhaust Piping Through Combustible Walls
• Exhaust piping that passes through any combustible wall or partition must be guarded at
the point of passage by:
• A ventilated metal thimble that is at least 12 inches in diameter larger than the piping, or
• Metal or burned fire clay thimbles built in brickwork that provides not less than 8 inches
of insulation between the clay thimble and any combustible material.
• Thermal insulation or protective guards are typically required for exhaust pipes/system
by national and local codes to protect users from burns.
Figure 10. Wall Thimble
7-4. Routing Exhaust Piping Through Combustible Roofs
Exhaust piping that passes through any combustible roof must be separated from the roof by a
ventilated metal thimble that is at least 6 inches in diameter larger than the piping. The thimble
must extend at least 9 inches (229mm)(10 inches (250mm) recommended) above and below roof
construction.
 Figure 11. Roof Thimble

7-5. Rain Cap

A rain cap is recommended on the end of the exhaust pipe. The rain cap is attached to the end of
the pipe and opens due to the pressure from the exhaust discharge force. The rain cap protects the
exhaust system from the environment when the system is not running.

7-6. Spark Arrestor

Use of a spark arrestor is required by the U.S. Department of Forestry if located on lands under
their jurisdiction. The spark arrestor is recommended in areas where combustible materials may
ignite such as dry grass, leaves, or other combustible materials.
7-7. Exhaust Back Pressure
The exhaust back pressure of the generator when measured at full load must not exceed the
manufacturer's recommendations. The size of exhaust pipe, number and type of ends and fittings
together with the selection and location of muffler determine exhaust back pressure.
A typical 90 degree bend in an exhaust system is equal to adding 8 feet (2.67 meters) of pipe.

SECTION 8 - Gaseous Fuel Systems

8-1. General (Gaseous Fuel Systems)
Some generators are equipped with fuel systems that utilize Liquefied Petroleum (LP) or Natural
Gas as a fuel.
Local fuel gas codes may vary widely. For that reason, it is recommended that a local gas
distributor or installer be consulted when installing a gaseous fuel supply system. In the absence
of local fuel gas codes and regulation, booklets published by the National Fire Protection
Association (NFPA) may be used as sources of information.
The installer must ensure that the correct fuel delivery system is installed, and that applicable
standards and codes are strictly complied with.
8-2. Advantages of Gaseous Fuels
Use of Natural and LP gas as a fuel may result in a slight power loss. However, that disadvantage
is usually compensated for by the many advantages of gaseous fuels. Some of the advantages of
gaseous fuels are:
Low residue content, resulting in minimum carbon formation.
• Reduced sludge build-up in engine oil.
• Reduced valve burning, as compared to gasoline.
• No "wash down" of engine cylinder walls during start up.
• No tetra-ethyl lead to foul spark plugs and other engine parts.
• Excellent anti-knock qualities.
• Reduced amounts of contaminated residues.
• A nearly homogeneous mixture in engine cylinders.
• Fuel can be stored for long periods without breakdown.
8-3. Gaseous Fuel System Variations
Any one of four different types of gaseous fuel systems may typically be installed by the factory
on your generator system, dependent upon the model. These are:
• Liquefied Petroleum (LP) gas vapor withdrawal.
• Liquefied Petroleum (LP) gas liquid withdrawal.
• Natural Gas.
• Dual Natural and LP gas (Additional regulator and hardware are not standard on most
generators Contact the generator's manufacturer if you need this option).
• Combination Gas-Gasoline systems (Additional regulator and hardware are not standard
on the generator systems. (Contact the manufacturer if you need this option).
8-4. Properties of Gaseous Fuels
Natural Gas: Is lighter than air and tends to settle in high places. Natural gas is found in the
gaseous state only at normal ambient conditions. Natural gas is highly explosive and
accumulations of the gas can be ignited at the slightest spark. For that reason, adequate
ventilation is absolutely essential and fuel lines must be free of leaks. Local fuel/gas codes
usually dictate the maximum pressure at which natural gas can enter a structure. A primary
regulator is required, to reduce the pressure of the delivered gas to the reduced pressure required
by code.
LP Gas: Is heavier than air, tends to settle in low places. The gas is highly explosive and the
slightest spark can cause an explosion. LP gas is usually supplied in pressure tanks as a liquid,
but is found in gaseous form at normal atmospheric temperature and pressure. It may consist of
(1) butane, or (2) propane, or (3) a mixture of these two gases. Fuel suppliers may fill the supply
tank with a mixture made up primarily of butane in warm weather. Butane may not provide
sufficient vapor pressure in colder weather and more propane may have to be added to the
mixture. The ratio of butane to propane is especially important when a large outdoor supply tank
is used. LP gas must be converted to its vapor state before it enters the engine carburetor.
8-5. Natural Gas Fuel System
The maximum pressure at which natural gas can enter the building is established by code and
may vary from area to area. The gas distribution company will usually provide piping from the
main distribution line to the standby generator site. A primary regulator is needed to reduce gas
supply pressures to the required safe level before the gas enters a building. Such a regulator may
or may not be provided by the gas supplier. It is the responsibility of the gas supplier to ensure
that sufficient gas pressure is available to operate the primary regulator.
Gas outlet pressure from the primary regulator to the standby generator's shutoff valve should
typically not exceed approximately 0.50 pounds per square inch (psi), or 14 inches of water
column. Optimum supply pressure to most small generator's shutoff valve is 11 inches of water
column. Depending on the characteristics of the specific shutoff valve in use, the valve may or
may not open at supply pressures greater than 0.50 psi (14 inches water column).
Install a flexible length of fuel line between rigid piping and the Generator engine's natural
gas connection point.
Natural gas is delivered to the primary regulator. From the primary regulator, in most
installations, the gas flows through a solenoid operated fuel shutoff valve, a pressure reducing
valve and the engine's natural gas carburetor. The shutoff valve is electrically energized open
during startup and running, is de-energized closed on shutdown. The carburetor measures engine
air flow and meters gas to the engine based on throttle setting and load. The carburetor also
provides a positive gas shutoff.
8-6. LP Gas Vapor Withdrawal System
This type of system utilizes the vapors formed above the liquid fuel in the supply tank.
Approximately 10-20 percent of the tank capacity is needed for fuel expansion from the liquid to
the vapor state.
Ambient temperatures around the supply tank must be high enough to sustain adequate
vaporization or the system will not function properly. In addition to the cooling effects of
ambient air, the vaporization process itself provides an additional cooling effect. Vapor
withdrawal systems are generally more suited for smaller engines that need less fuel.
When ambient temperatures are low and fuel consumption is high, the vapor withdrawal system
may not function efficiently. This is particularly true with larger engine machines.
Many LP gas and Natural Gas vaporous fuel systems are identical as a demand regulator is used
to provide fuel to the engine.

8-7. LP Liquid Withdrawal System

This type of system delivers gas in liquid form to a generator. The liquid fuel must then be
vaporized before it is delivered to the engine carburetor.
Liquid withdrawal (LP) gas systems usually employ a "vaporizer-regulator" to convert the liquid
to its vapor state. A "vaporizer-regulator" is mounted in the air flow of the engine to provide heat
to the regulator for fuel vaporization.
LP liquid withdrawal is typically used for equipment used in remote locations where size and
availability of refilling the tank is limited. Liquid withdrawal is also used for trailered and
construction site equipment.
8-8. Dual Natural/LP Gas Fuel System
In some areas, the cost of Natural gas may be reduced considerably by procuring the gas on
"interrupted service" rates. Such "interrupted service" can be obtained by using LP gas as an
emergency fuel whenever Natural gas is not available.. Automatic changeover is accomplished
by using two regulators - a line pressure regulator for natural gas and a vacuum operated
regulator for LP gas. The differences in pressures compensates for the greater BTU value of LP
gas.
During operation on Natural gas, a 5 inch (water column) (typical) pressure exists in the common
line to the carburetor. This pressure closes the LP gas regulator. Loss of Natural gas pressure
causes loss of pressure in the line; the LP gas regulator then opens to admit LP gas into the
system. A separate power mixture adjustment in the LP gas line provides precise setting of
air/fuel ratios for each of the two fuels. Changeover is automatic with the engine operating.

8-9. Gaseous Fuel System Piping

The following general rules apply to piping used in gaseous fuel systems:
• Piping should be of black iron.
• Piping should be rigidly mounted and protected against vibration.
• Install an approved length of flexible hose between the generator fuel line
connection point and rigid piping.
• Piping must be of the correct size to maintain required supply pressure under varying
conditions, especially when fuel in gaseous form is being supplied (Natural gas and LP
gas vapor withdrawal).
• Installed piping must be properly purged and leak tested, in accordance with applicable
standards.
NOTE: In the absence of local purging and leak test standards, NFPA No. 54 may be used as a
guide.

8-10. Gaseous Fuel Pipe Sizes

A "Gas Flow Pipe Sizing Chart" (Table 8-1) is provided below. Use the chart to determine the
correct piping diameter in gaseous fuel systems (such as Natural gas and LP gas vapor
withdrawal type).
To find the proper pipe diameter, the installer must know (a) the length of the gas piping run, and
(b) the cubic feet of gas needed by the generator when under full load.
First, find the length of the piping run on the chart.
From the pipe length figure on the chart, move horizontally across the chart until you reach a
number that is just higher than the cubic feet of gas needed under full load. From the cubic feet
of gas figure, move straight up vertically in the chart to the pipe diameter given in that vertical
column. This is the pipe size required.
LP Gaseous Fuel Example: A small 16 horse power generator when operating at full load
requires a supply of 51 cubic feet per hour of LP gas. Length of the piping run from the supply
tank is 60 feet. Propane gas having a specific gravity of 1.5 and with a multiplier of 0.633 is used
(Table 8-2). From the pipe length in the chart, trace horizontally across to "86" (the first number
larger than 51 cubic feet). Moving vertically upward in the chart, a 3/4 inch pipe is needed.
Applying the chart conversion factor (86 x 0.633=54.44) and the 3/4 inch pipe is still adequate.
Natural Gas Example: A small 16 horse power generator operating at full load requires 115
cubic feet per hour of Natural gas. Length of the piping run from the supply tank is 75 feet.
Natural gas having a specific gravity of 0.65 and with a multiplier of 0.962 (Table 8-2) is to be
used. From the pipe length in the chart, trace horizontally across to "155" (the first number larger
than 115 cubic feet). Moving vertically upward in the chart, a 1 inch pipe is required. Apply the
conversion factor (155 x 0.962=149.1) and the 1 inch pipe is still adequate.

Table 8-1. Gas Flow Pipe Sizing Chart

Length 1-1/4 1-1/2 2-1/2
1/2 In. 3/4 In. 1 In. 2 In. 3 In. 4 In. 6 In. 8 In.
of In. In. In.
(12.7m (19.05 (25.4m (50.8m (76.2m (101.6 (152.4 (203.
pipe (31.75 (38.1m (68.5m
m) mm) m) m) m) mm) mm) 2)
(FT/M) mm) m) m)
7900
15/4.57 76 172 345 750 1220 2480 3850 6500 13880 28700
0
5585
30/9.14 52 120 241 535 850 1780 2750 4700 9700 27370
0
45/13.7 4560
43 99 199 435 700 1475 2300 3900 7900 23350
2 0
60/18.2 3950
38 86 173 380 610 1290 2000 3450 6800 19330
9 0
75/22.8 3530
70 155 345 545 1120 1750 3000 6000 17310
6 0
90/27.4 3225
77 141 310 490 1000 1560 2700 5500 15800
3 0
105/32. 2985
65 131 280 450 920 1430 2450 5100 14620
00 0
120/36. 2798
120 270 420 860 1340 2300 4800 13680
58 0
150/45. 2500
109 242 380 780 1220 2090 4350 12240
72 0
180/54. 2280
100 225 350 720 1120 1950 4000 11160
86 0
210/64. 2110
92 205 320 660 1030 1780 3700 10330
01 0
240/73. 1974
190 300 620 970 1680 3490 9600
15 0
270/82. 1861
178 285 580 910 1580 3250 9000
30 0
300/91. 1766
170 270 545 860 1490 3000 8500
44 0
450/137 1442
140 226 450 710 1230 2500 7000
.16 0
600/182 1248
119 192 390 900 1030 2130 6000
.88 0
Table 8-2. Chart Conversion Factors
Specific Specific Specific
Multiplier Multiplier Multiplier
Gravity Gravity Gravity
0.50 1.100 0.700 0.926 1.200 0.707
0.55 1.040 0.800 0.867 1.400 0.655
0.60 1.000 0.900 0.817 1.500 0.633
0.65 0.962 1.000 0.775 1.700 0.594
Note 1: Use of elbows increases pressure drop on fuel lines. A 90 degree elbow adds 3 to 8 feet
of equivalent length to your pipe estimate.

Note 2: Typical Specific Gravity for Natural Gas is 0.65.

Note 3: Typical Specific Gravity for LP is 1.5.

Back to Table of Contents

Go to APPENDIX A - Applicable Codes
Tips on Hooking up a Generator (genset) to a Uninterruptible Power System (UPS)

Introduction
There are many people in the generator and UPS industries that have tried to operate engine
driven alternating current (A.C.) generator sets (gen-sets) and uninterruptible power systems
(UPS) together. Although some systems are successful, there are problems that can occur. This
article should provide insight into the problems of using a gen-set to power a UPS as well as
provide enough information to possibly save the reader from a problem installation.
Achieving and maintaining adequate control of frequency and line noise is a common issue in
generator design and use. Unless the gen-set is sized 2 to 3 times the size of the UPS, and the
UPS is about 75 percent loaded, the UPS may never switch from the inverter (battery power) to
generator power. Another factor is that there is a great deal of line noise from small generators
compared to utility line power. This can also cause the UPS to stay on inverter until the batteries
go dead. To address these problems, Best Power Technology, Inc., a fairly well known U.S. UPS
supplier, started a DC generator product line. They have since dropped that product line due to a
take over by a UPS competitor who did not want to be in the generator business.
When preparing to connect a gen-set to a UPS, first check with the UPS manufacturer for
recommendations on using their UPS with a generator. Sizing and compatibility issues should be
addressed before even considering hooking a gen-set to the UPS. Loading and the ability of the
generator to regulate the load, possibly the hardest issues to deal with, should be considered.
In addition, the type of power plant and alternator used in the gen-set can effect whether the
equipment will work together or not. For instance, Diesels/turbine engines work better than
gasoline/liquid propane (LP) and Natural gas (NG) engines. It has been noted on gen-sets that
single-phase alternators work better than three phase alternators. Turbo-charged engines work
better than normally aspirated engines, as well as being better at higher altitudes. Fuel injected
engines work better than engines with carburetors (Aspirated engines use carburetors). See
Figure 1 below for a block diagram of a typical gen-set/UPS installation.
 Figure 1. A Typical Generator - UPS Installation
[Back to Index]
Sizing Considerations
Tables 1 and 2 provide generator sizing and loading recommendations for various sizes of UPSs.
These recommendations are based on UPSs and gen-sets from several manufacturers, and are
more rules of thumb based on experience with connecting gen-set and UPSs together than
absolute rules. The two tables differ in the fuel type of the gen-sets engines.
The reason that a background load is shown in the tables is two fold. First, the additional load
helps the generator regulate better. Second, in an emergency situation, it is always a wise move
to put in emergency lighting, and is an electrical code requirement. Caution is advised when
operating fluorescent lights from the UPS for emergency lighting. Preferably, power the
fluorescent lights from the generator and have some incandescent emergency lights running from
the UPS. Fluorescent lights will sometimes flicker, especially if the UPS is one that is a double
conversion unit that uses a Ferro-resonant transformer. As improvements in UPS and generator
technologies take place, these recommendations may become less relevant.
Gasoline/LP/NG Fuel
Gasoline/LP/NG Gasoline/LP/NG
Background Background
Single Phase Three Phase
UPS Load Load
Generator Generator
KVA KW KVA KW KW KVA KW
0.5 to 3.5 10 12 2 10 12 2
4 10 12 2 10 15 2
5 13 16 2 15 19 2
7 16 20 3 19 24 2
10 24 30 4 29 36 4
12 30 38 5 36 45 6
18 46 57 7 55 68 8
Table 1. Gasoline/LP/NG Fuel Gen-sets
Diesel Fuel
Diesel Diesel
Background Background
UPS Single Phase Three Phase
Load Load
Generator Generator
KVA KW KVA KW KW KVA KW
0.5 to 2 5 7 1.5 5 7 1.5
2.5 to 3.5 5 7 1.5 6 8 1.5
4 6 8 1.5 8 10 1.5
 5 8 10 2 10 13 2
7 10 12 2 13 16 2
10 14 18 2.5 19 24 3
12 18 23 3 24 30 4
18 28 34 4 37 46 6
Table 2. Diesel Fuel Gen-sets
From Tables 1 and 2, note that the size of the gen-set is significantly larger than the UPS. There
are a number of reasons. Besides the obvious losses due to line loss, there are inefficiencies
involved every time another piece of equipment is brought into the equation. One of the biggest
factors is that the generator needs to be sized to handle the start up of the largest load, not just the
continuous load. Based on calculations and manufacturers specifications, the gen-set
recommendations look like they are larger than needed. However, if the generators engine can't
get up to speed and running, for any reason, the system will fail.

[Back to Index]
Start Up Load / In Rush Current
When a gen-set is being used to put power directly into the battery bank of the UPS, as shown in
Figure 3, the load can exceed the gen-sets ability to supply power. The UPS, in holding the load,
starts to deplete battery power immediately, at the start of the outage. By the time the gen-set is
up and running, and prepared to go on-line, the battery bank has lost a considerable amount of
power. At the instant power is provided to the battery charger, the charger is trying to power a
battery bank that acts like a very large capacitor and the in rush of current into the batteries takes
all the power available from the battery charger. This has been known to stop the engine on some
gen-sets. This has also been known to start a "stop-restart cycle" where the gen-set never gets
running to power the load and the UPS batteries finally run down and the UPS shuts down.
A work-around for the current in-rush problem is to limit the amount of current the batteries can
draw from the charger. Putting a Current Shunt in-line with one of the battery leads can do this.
Another option is, if the gen-set has the capability of auto-start from sensing the UPS battery
bank float voltage, set the float voltage on the battery bank at a higher voltage to get the gen-set
to start sooner also may help.

[Back to Index]
Other Generator Tips
Other gen-set related caveats that allow the gen-set to work with the UPS are as follows:
1. If installing a three-phase generator, install the UPS across the generator phase that is
monitored by the generator's voltage regulator.
2. Adjust the governor of the generator so that the line frequency doesn't deviate by more than
plus or minus 3 hertz.
3. Install additional ballast loads such as emergency lighting that are equal to 15% of the KW
rating of the gen-set. The ballast loads share the generator with the UPS and stabilize the
generator so that the frequency is less erratic. The loads should be stable and continuous such as
lighting or electric heaters. In other words, do not use air conditioners or air compressors for a
background load. See Figure 2 below.

Figure 2. Adding Background Load as a Ballast to Improve Regulation

[Back to Index]
UPS Tips
In hooking a UPS to a gen-set, the following should be reviewed and considered:
1. When connecting a generator to the UPS, make sure that there is a disconnect switch between
the UPS and generator. A disconnect switch is usually required by code as well as a serviceability
and safety factor. In most cases, a means of disconnect is required. If soft wired, you may be able
to get away with a plug and socket (i.e. Anderson Connectors); however, check with the
authority having jurisdiction.
2. Ensure that the UPS has enough power to operate any ventilation fans or other required
peripheral emergency equipment connected to the UPS during an outage. It is common for the
gen-set ventilation fans and/or powered intake louvers to be powered from the UPS.
3. When using an existing generator with a UPS, the UPS may not run on the generator's power
because the UPS's software is telling the UPS that it has poor input power. Gen-set power
compared to most commercial utility power, is very erratic. Before giving up, look into buying a
battery charger and hook the battery charger directly into the UPS's battery bank. See item #4
below.
4. When hooking power from a battery charger directly into the UPS battery bank, make sure to
check with the UPS manufacturer to find out if the UPS's inverter is rated for continuous duty.
There is nothing worse than burning up the UPS inverter because it was only designed to run as
long as the manufacturers factory installed internal batteries would carry it. Always verify with
the UPS manufacturer that their units have been rated for continuous duty. At this time, I know
that the UPPIand Best Power Ferrups units have been rated for continuous duty, however, it is
always a good idea to confirm that your particular unit is rated for it. Due diligence has saved a
number of people a lot of time, money and warranty head aches from their power equipment
suppliers. See Figure 2 below.

Figure 3. Using a Battery Charger to Avoid Generator Regulation Issues.

5. If using a battery charger that is powered from a generator, ensure that the battery charger
provides the correct voltage for the UPS battery bank, and is large enough to handle the load.
This means that the battery charger has to produce enough power out to handle the UPS input
requirements as well as to compensate for any other inefficiency.
[Back to Index]
Other Alternatives
If a UPS and gen-set still do not operate correctly, there may still be a way to salvage the project,
depending upon whether the generator has sufficient power to hold the load and whether the
problem is a regulation issue. The first alternative is to simply add additional (background) load
to the gen-set. This will help to tighten regulation, though this is not always effective.
The second alternative is more expensive. This alternative requires some retrofitting expertise to
replace the governor on the generator with a better grade governor or an electronic controller
such as a Barber-ColmanTM. The generator supplier may have an alternative governor available,
though most small gen-sets typically do not. Some mechanical engineering work may also be
required to fit an electronic controller onto the gen-set if the supplier doesn't have an off-the-
shelf solution.
[Back to Index]
UPS's for Sale
For those looking for a UPS or Power Conditioner:

Click here to use the UPS/Power Conditioner Quote Request / Sizing - Applications Assistance
Contact Form to obtain help sizing a Uninterruptible Power Products or Best Power UPS for your
needs from Uninterruptible Power Products, Inc..

GENERATOR OPTIONS, CONTROL PANELS, REMOTE MONITORING, AND

ATTACHMENTS
Cat Electric Power provides a full line of options and attachments to customize your Caterpillar Generator Set to fit your
exact needs.
For a complete list and specifications, please contact your Cat Dealer.

Generator Options Include:

• Anti-Condensation Heater
• Excitation System
• Permanent Magnet Generator
• Voltage Regulator

Generator Control Systems & Monitoring Options Include:

• Auto-start Control Panel
• Auxiliary Controls
• Digital Control Panel
• Electronic Governor
• Key start Control Panel
• Load Sharing
• Remote Annunciator
• Remote Monitoring Software
• Shunt Trip
• Single / Dual Circuit Breakers
• Speed Control

Generator Accessories Include:

• Battery Heater
• Coolant Heater
 • Engine Exhaust System
• Exhaust Silencer / Muffler
• External Fuel Tank
• High Output Battery
• Integrated Fuel Tank Base
• Lube Oil Drain Pump
• Lube Oil Sump Heater
• Seismic Vibration Isolator
• Sound Attenuated Enclosure
• Static Battery Charger
• Sub-base Fuel Tank
• Weatherproof Enclosure

DIESEL GENERATOR SET FEATURES & SPECIFICATIONS

Cat Diesel Generator Set Features:

• Ratings from 12kW to 17,460kW
• Emissions compliance with most worldwide regulations
• Simple to specify and purchase
• Easy to install and operate
• Wide range of factory-designed options
• Low life-cycle costs
• Excellent transient response and steady state performance
• World-class fuel efficiency
• Single source for complete power solutions

• Turnkey support from the Cat® Dealer network

Generator Options Include:

• Anti-Condensation Heater
• Excitation System
• Permanent Magnet Generator
• Voltage Regulator

SWITCHGEAR OPTIONS
The benefit of Caterpillar's vast experience in power generation is fully realized in its generator switchgear offering. Available
from 600V through 15 kV, Cat® switchgear provides a harmonized system solution by being able to integrate all elements of
monitoring and control of a Caterpillar® generator set in a single-source package.
For integration of Caterpillar generator sets into a customer's facility, Caterpillar offers switchgear suitable for applications
ranging from single standby/load management to multi-unit utility paralleling installations. In any of these cases, Caterpillar
switchgear can offer remote communication capabilities for monitoring and control of your total system.
Caterpillar switchgear employs a feature rich microprocessor based control system that is combined with an easy to use
touchscreen operator interface panel. The entire system can be controlled from the switchgear-mounted touchscreen, or it
can be controlled/monitored from a remote site through a personal computer.
Caterpillar offers three standard switchgear products that can support a wide variety of applications or can provide a custom
designed system to meet your specific site's needs as required. Our XLM series products supports transfer between the
utility source and generator bus, as well as affording capability for parallel operation with the utility for load management
applications. The EGP series supports paralleling on an isolated generator bus and is commonly used in prime power or
emergency standby systems. Finally, our LM series supports single unit paralleling with utility for load management and
peak shaving applications.

AUTOMATIC TRANSFER SWITCHES (ATS)

50/60 Hz 600 V Class, 40-4000 Amps
Caterpillar® offers a broad range of automatic transfer switch products that are positioned to support virtually any type of
emergency power application from simple, single ATS installations to highly complex, multi-ATS/generator switchgear
systems. Today every standby generator set that is sold requires at least one ATS, and some cases require multiple units.
Available in sizes ranging from 40 through 4000A, there is a Cat switch to suit every project's needs.
Consider:
• CTX series for residential and light commercial applications.
• CTG series for overall general applications with limited attachments
• CTS series for applications a wide range of attachments and configurations.
CTG Series & CTS Series meet the requirements of NFPA 110, 99, and 70.

Automatic Transfer Switch Features Include:

• Mechanically held contactor
• Available in 2, 3, and 4 pole versions
• Rating range from 40 to 4000 Amps
• UL, IEC, and CSA listed
• NEMA 1, 3R, 4, 4X, and 12 enclosures

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UNINTERRUPTIBLE POWER
SYSTEMS (UPS)
Caterpillar knows the importance of quality power to your operation. Whether
supporting critical processes or defending servers from harmful power problems,
Caterpillar's uninterruptible power supply systems will provide years of low maintenance
protection. Yielding the lowest operating costs in the industry, Caterpillar's UPS system
will provide the peace of mind that comes from knowing that Caterpillar is standing
beside you in your efforts to grow your business.
Currently offering uninterruptible power supply systems from 150kVA to multi-megawatt
solutions, Caterpillar integrates a battery free UPS with its market leading generator
sets, switchgear and automatic transfer switches to deliver a world class integrated
system.
Caterpillar's world wide dealer network makes service and support locally available and
timely. Click here to find a Caterpillar Dealer near you or use the left navigation to learn
 more about the Cat UPS, the uninterruptible power supply with the highest power
density in the world.

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Change over switch allows switching between mains supply and standby generators for emergency services
and remote locations
Question : I have bought a generator, and would like to connect it to my house in case of
mains failure. What do I need to do?

• Answer : When using a generator as an alternative supply to the mains, there are
several precautions that must be observed.

• It is vital that the generator is completely isolated from the mains supply. This
ensures that the generator is not attempting to power up the whole neighborhood,
but also ensures that it does not electrocute a utility worker trying to restore the
mains supply.

• To achieve this, a double-pole, break-before-make, changeover switch must be

installed by a qualified electrician. The Briggs & Stratton manual transfer switch is
ideal for this application.
• This should be fitted between the electricity meter and the building consumer unit.
The switch connects the building to either the mains supply or to a lead which can be
plugged into the generator.

• Most buildings now have an RCD built into the consumer unit. This is configured to
operate from the mains supply with an earthed neutral, and not from a generator
with a floating earth. To utilize this protection device, it is necessary to modify the
generator so that it is configured in the same way as the mains supply.
 • This is a simple modification for a qualified electrician, involving adding a link wire
from the neutral terminal to the earth terminal. It is recommended to make this
connection in the plug that is to be used to connect to the generator. This ensures
that the generator is unmodified when it is disconnected from the house, and
therefore remains safe.

• The plug should be labeled “Do not connect to mains: Neutral-Earth link fitted”. The
lead between the generator and the transfer switch is not protected by the RCD, it is
therefore recommended to use a steel armored cable for this connection. Finally a
local low-impedance earth spike needs to be installed

Q & A of the Day - Temporary genset earthing and protection

2007-11-14

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Our Voltimum Experts answer your questions on a daily basis in our Technical Expertise area.
This first Question of the Day, on BS 7671 Section 551 - temporary genset earthing and
protection, is answered by SELECT:

Genset in cellar - install to BS 7671 Section 551.

Question: I've been asked whether it is possible to install a 5KVA backup generator to supply
emergency power during power outages.
The supply is single-phase PME taken from a three-phase service head in an outbuilding/workshop.
The supply then runs under the drive via 25mm two-core SWA (with earthed sheath) cable to a cellar. In
the cellar, the earth is not connected to the MET of the house, which has an earth rod and a 100mA
Type-S RCD. I believe that this is because the Ze reading at the house end of the SWA is over 1.5ohm.
My thinking was to connect the generator to a break before make switch, connect the neutral to an
earth rod installed beneath the SW and feed the SWA via an 30mA RCD and a fused isolator to the
house CU. Can you see any problems with this approach?

Answer: The arrangements you describe appear to be generally satisfactory provided you meet the
requirements of BS 7671 Section 551. The following are some particular points to note:
• Ensure the earth electrode resistance is satisfactory - It should be less than 200ohm where
possible.
• The changeover switching arrangement (double-pole) should meet the requirements of
Regulation 551-06-01.
• To prevent danger or damage to equipment, ensure that the requirements of Regulation 551-
02-03 are met.
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Alternator control system

Document Type and Number:
United States Patent 5754032

Abstract:
A control system for controlling an alternator driven by an engine, for generating electric power, has a changeover
switch for selectively switching destination of electric power generated by the alternator to a plurality of electric loads
having respective different load voltage values. An ECU controls switching operation of the changeover switch and
controls the alternator electric power, according to a direction in which the changeover switch has been switched. The
ECU detects voltage of the alternator electric power when the destination of the alternator electric power is to be
switched from a first electric load having a higher load voltage value of the plurality of electric loads to a second
electric load having a lower load voltage value of the same, and causes the changeover switch to switch the
destination of the alternator electric power from the first electric load to the second electric load after it is determined
that the voltage of the alternator electric power has been changed from a predetermined higher voltage value to a
predetermined lower voltage value

Brushless alternator
Document Type and Number:
United States Patent 4647806

Abstract:
A brushless alternator consisting of interconnected stator coils disposed in stator plates and surrounding the main
winding of the rotor and including rectifiers coupled to the stator coils. The rotor is on a shaft supported within the
housing of the alternator, and includes an exciter with shaft-mounted rectifiers for supplying a DC voltage to the main
winding of the rotor. The exciter field coil is spool wound on a cylindrical core that is contained within the exciter
stator, that is attached to thealternator housing. The field coil has a concentric opening for slidably receiving the rotor
shaft. The exciter rotor armature does not rotate, but is affixed to the alternator housing and surrounds the outer
periphery of the exciter field coil. The main winding of the rotor has a cylindrical sleeve extending from one end to
engage and support the exciter rotor armature in alignment with the exciter stator.