AVK|SEG (UK) LTD

Generator Installation Guide

A - UNLOADING AND HANDLING

I - UNLOADING
A - UNLOADING SAFETY
In order to remove the generating sets from their transport with optimum safety and efficiency, you must
ensure that :
- The hoisting devices are appropriate for the required tasks.
- The slings are correctly positioned in the lifting lugs provided or the fork lift arms are positioned centrally
under the frame.
- The ground is able to withstand the weight of the generating set and its hoisting device (if not, sturdy planks
must be laid).
- The set is lowered as close as possible to its service or transport position in an open and easily accessible
area.
B - EXAMPLES OF EQUIPMENT
- Crane, slings, spreader, lifting hook and shackles.
- Lift truck.
C - UNLOADING INSTRUCTIONS
1 - Slinging
- Attach the hoisting device slings to the generating set lifting
lugs designed for this operation.
- Slowly tighten the slings.
- Make sure the slings are evenly attached and strong enough.
- Slowly hoist the generating set.
- Move the set to the chosen site and place in position.
- Bring it down slowly while maintening it in the right position.
- Loosen the slings, unhook and remove the shackles.
- Use at least 2 people.
2 - Lift truck
- Position the arms of the lift truck under the frame, making
sure only the mainframe is resting on the arms.
- Lift and handle the equipment slowly.
- Set down the generating set in its final position.
- Use at least 2 people, one of whom is the lift truck operator.

II - HANDLING
A - HANDLING INSTRUCTIONS
Chock the generating set at the aiternator end.
Slightly lift the generating set at the engine end with two jacks
and slide two tubes under the frame.
- Let the frame rest on the tubes and move the generating set
into the room by pushing it manually or pulling it with a winch
or pulley system attached to the bedframe.
- As the generating set moves along, take the free tubes and
slip them back under the frame.
- When it gets to its final location, position the generating set,
chock and jack it up.
- Remove the tubes and lower the generating set ensuring it
remains in the correct position and remove the jacks.
B - EXAMPLES OF EQUIPMENT
- 2 jacks, three 60 mm thick walled tubes, the same width as the
frame and 1 winch or pulley system.
- Manpower : at least 2.

Unloading and handling_______________________________________________________________________________________________________________________________________

- If ground is uneven or the hauling distance too far, use a lift truck
with arms longer than the f rame width.
- Manpower : at least 2, one of whom is a lift truck operator.

- Once you are in the engine room you have the use of a crane rail
and a travelling block, follow the instructions in Section 1-C-1.

B - INSTALLING PERMANENT GENERATING SETS

PREPARATION :
The installation of a generating set must follow certain rules, which must be strictly adhered to in order to get equipment to
operate properly.
The whole equipment is liable to sustain damage and abnormal wear if these basic principles are not followed.
This manual lists the main installation requirements for a "conventional" generating set built with an I.C. engine, a generator
and a control panel. In case of special applications our Technical Department will advise you and study your specific needs.
The regulations provisions and laws in effect on the installation premises should also be complied with.

_______________________________________________________________________________________________________________________________________Unloading and handling

I - SITE
A - LOCATION
It should be decided by the application. There are no special rules in selecting the location, other than the proximity
of the control panel and the noise reduction. Nevertheless, fuel supply, correct ventilation of the site, exhaust gas,
direction of radiator hot air and noise must be taken into account.
Do not wait until the last moment to plan the installation of the generating set. It should not be forgotten that a
generating set may be the most important piece of machinery designed to back up faulty mains supply and to ensure
the continuing operation of the vital fonctions of a company, factory or hospital.
The choice of positioning should be based on a well planned site.

1m
minimum

Incorrect exhaust and ventilation

Fuel refill impossible

Incorrect base

Incorrect ventilation and exhaust

openings

Undersized access

Door opening, maintenance and

repair are impossible

Installing permanent generating sets__________________________________________________________________________________________________________________________

B - DIMENSIONS AND LAYOUT

Depends on two types of requirements :
1 - Static
These requirements relate to the size of the equipment installed with its peripherals, namely : daily tank, control
panel, exhaust muffler, batteries, etc.
CAUTION : PLEASE CONTACT OUR DESIGN OFFICE FOR CERTIFIED DIMENSIONS.

Height
>1,5m

2 - Dynamic
These requirements relate to the space around each set to
allow for maintenance and
possible removal.
A 1 m clearance around the generating set must be
considered as the minimum requirement for problem free
maintenance. Make sure the doors of the canopy can be
opened completely, the equipment is easily accessible for
maintenance and the generating set can be removed from
the room.
3 - Building
Various room layouts can be considered for housing the
generating set.
- If sound level and start up speed are not important the set
can be instalied under a simple shelter to protect it from the
weather (snow, rain, thunder, etc.).
- If a lower sound lever and a rapid start up is essentiel (e.g.
emergency set or noise sensitive area) special care should
be taken to build the room with at least 20 cm cast
concrete, covered with absorbent fireproof insulating
material such as rockwool.
NOTE : Fire resistance must comply with the legislation
related to the type of building used.

T h e
slab,
door
exhaust outlet, air intake
and exhaust, must be built according
to the dimensions given by our
design office.

4 - Generating set foundation

A generating set in operation produces a certain amount of
vibration which makes its way towards the concrete slab, via
the frame. Our generating sets are supported on inbuilt
rubber mounts and not normally require a special slab. The
slab should be level and smooth after casting and isolated
from the building.
Sample size of a generating set room for a set without a
canopy.
The slab, door exhaust outlet, air intake and exhaust, must
be built according to the dimensions given by our design
office.
5 - Openings
A generating set room must have a number of openings
essentiel for its operation.
5.1 - A door in line with the generating sety plinth to move
the generating set and accessories in and out.
5.2 - Ventilation openings (fresh air inlet, warm air outlet)
sited so that the air blows in the Alternator Engine
direction. The size depends on the power of the generating
set to be installed, general weather conditions, selected
cooling system and possible soundproofing system.
5.3 - Exhaust pipe, fuel lines and electric cables.
6 - Hoisting
Normally the hoisting equipment should be part of the
building and should comprise a moving block on an I beam
rail sealed into the walls and ceiling. This will make handling
easier and is usually installed above, along the axis of the
set, towards the door.

(designed to suit the

weight of the
generating set)
______________________________________________________________________________________________________________________________Installing permanent generating sets

7 - Soundproofing
The best quality / price ratio is achieved when soundproofing is part of the initial design of the room. On the other
hand if soundproofing is added to an existing room, it will inevitably be more expansive and not as good. Two
techniques should be used to soundproof the genset room.
7.1 - Insulation
Its purpose is to prevent sound travelling through the walls by providing mass and adequate thickness.
7.2 - Absorption
Sound energy is absorbed by specialist materials and reduces reverberation. For a soundproofed room the openings
have to be larger and carefully designed to provide adequate ventilation without allowing excessive noise to pass
through the openings. A properly designed soundproofed door is also needed.
General
- Building structure: cast concrete or concrete blocks, min. 20 cm thick.
- Anti-vibration mounts under the generating set, when installed close to sensitive areas.
- Walls and ceiling may be lined with absorbent materials such as rockwool.
- Selection of one or more suitable exhaust mufflers.
- When required soundproof doors should be fitted to reach the required sound level.
- Noise attenuators mounted in the air inlet and outlet openings.
EXAMPLES : Measures to be taken.
- Basic noise level of genset : 105 to 11 ODBA 1m.
*Non sensitive areas
Generating set soundproofing by means of a canopy bringing the noise down to 85dBA at 1 m (useful for low and
medium powered sets), or Room soundproofing : noise attenuator on air inlet, about lm long, soundproofed access
door, 30dB exhaust muffler. Outside noise level : 75dBA about 1m.
* Noise sensitive areas (in town, close to houses)
Noise reduction depends on the distance between the noise
source and the sensitive areas 6dB on average every time
you double the distance : 1m (0); 2m (-3dB); 4m (-12dB); 8m
(-18dB).
Tnis caiculation done, the following elements must be
specified :
- From 60 to 70dBA at about 1m

NOISE ATTENUATORS

40 AND 19 dB MUFFLERS IN SERIES

NOISE
ATTENUATORS

- walls and ceiling made of 20 cm concrete blocks or cast

concrete,
- noise attenuators about 1.80 m long,
- high efficiency soundproof door,
- 40 and 19dB mufflers in series
- From 40 to 60dBA at about 1m
noise attenuators (about 2.50 m) with baffles in ventilation
shafts if possible.
SOUNDPROOF
DOORS
- inside walls and ceiling lined with absorbent material.
- soundproof door and airlock.
- floating slab beneath the generating set (vibration).
- 40 and 30dB mufflers in series. Sometimes 40dB and 19dB mufflers are sufficient.
or generating set soundproofed by means of a canopy, in which case, the sound traps are smaller and the airlock
unnecessary.
When lower noise levels are required a special study must be carried out.
SOUND LEVEL REGULATIONS
Please refer to appropriate regulations in your area.

Installing permanent generating sets__________________________________________________________________________________________________________________________

II - EXAMPLE OF GENERATING SET INSTALLATION

A - EXAMPLE OF INSTALLATION
(indoor fuel tank and control panel)

AIR EXHAUST
Air is discharged by the
radiator through teh masonry
wall. The opening in the wall
must have the same dimensions
as the radiator and be fitted with
a rainguard louvre. Seal the wall
and the radiatior with neoprene or
flexible canvas duct.

EXHAUST GASES
DISCHARGING OUTSIDE
THE ROOM
When the original pipework must
be extended. It should be mounted on
an efficient suspension bracket, fitted with
an expansion joint between piping and muffler
(on engine). It must never rest on the engine or
muffler. The exhaust pipinq must be able to move
freely across the walls.

SOUNDPROOF DOOR

FUELSTORAGE
Storage must comply with the
appropriate regulations. The
retaining tank may be made of
metal sheeting or concrete.

AIR INLET
Air inlet louvre on door or wall.
AIR INLET SURFACE :
- minimum X 2 the air exhaust.

ELECTRIC CABLES
Cables may follow a channel (15cm x
15cm) in the floor or at high level. In
this case they must be installed on
cable trays

FUEL PIPES
Fuel supply and return i
15cm x 15cm floor channel.

GENERATING SET
BOLTED TO
THE SLAB

EARTH TERMINAL

______________________________________________________________________________________________________________________________Installing permanent generating sets

B - EXAMPLE OF INSTALLATION (control panel, muff ler and Tank under canopy. Soundproof type room and
underground fuel storage tank).

AIR EXHAUST
Hot air from the generating set is discharged
from the room through a hot air duct
(optional) fitted in an opening in the wall the
same size as the duct. The hot air discharge
opening is protected from any obstruction,
penetration or infiltration of foreign elements
by a metal louvre.
Use a neoprene foam to seal the hot air
discharge duct in the wall. The exhaust pipe
is fitted in the hot air discharge duct. Hot air
from the radiator passes through the canopy
roof.

SOUNDPROOF DOOR

ELECTRIC CABLES
Cables may follow a
channel (15cm x 15 cm)
or a high level path in
this case they must be
installed on cable trays.

AIR INLET
Air inlet louvre on door
or Wall.
AIR INLET SURFACE
- minimum x 2 the
exhaust air area.

GENERATING SET BOLTED

TO THE SLAB
EARTH TERMINAL

EXHAUST GASES DISCHARGE

OUTSIDE THE ROOM
When the original piping must be extended,
should be mounted on an efficient suspension
bracket fitted and muffler expansion joint between piping
and muffler (or engine). It must never rest on the engine or
muffler.
FUELSTORAGE
Storage must comply with the appropriate regulations.
FUEL PIPES
Fuel supply and returri in 15cm x 15cm channel.

Installing permanent generating sets______________________________________________________________________________________________________________________________

III - VENTILATION
An I.C. engine generates considerable heat which must be discharged from the room to ensure operation.
Heat is released from a number of sources :
- radiator cooling,
- engine, exhaust pipework and radiator,
- alternator cooling.
If its necessary to fit the room with air inlets and outlets specifically designed for the cooling system and local
operating conditions. Insufficient ventilation will cause an increase in room temperature, which will lead to an engine
power loss or the set stopping (in some cases auxiliary fans will be required). The cooling air should sweep the
generating set room in the direction AlternatorDEngineDRadiator. This not only allows for the discharge of the heat
produced by the generating set, but also supplies the fresh air required for combustion. The openings will have to
be large.
The air inlet and outlet should be as direct as possible. The cooling system should be tightly connected to a
ventilation shaft or the outlet duct to avoid hot air recirculating.
Examples of air inlet and outlet layouts
G and R type frames to be sealed.

Air inlet and outlet must never be located close to each other.

Type : G

Type : R

Hole

Air inlet and outlet rainguard Louvre

The following table indicates the pressure loss through the Louvre
(in dPa).
The air velocity (in m/s) refers to the rated section (H X L).
Pressure losses related to H x L

1.5

2.5

3.5

4.5

Pressure loss for use air inlet

0.3

0.7

1.2

1.9

2.7

3.7

4.8

6.1

7.5

Pressure loss for use as air

0.35

0.9

1.5

2.3

3.3

4.5

5.8

7.4

Air velocity

CDO Dimensions

______________________________________________________________________________________________________________________________Installing permanent generating sets

IV - FUEL
Diesel fuel is classified as a "Dangerous product" and storage and distribution are subject to a number of rules
and regulations. Please refer to the local legislation.
On permanent installations it is usual to fit a day tank and a main storage tank. These two tanks can be combined
into one if the fuel requirements of the generating set are low.
A - TANK WITH MANUAL FILLING
This is convenient for a manual start generating set which is visually
checked.
Often part of the generating set assembly this tank is fitted either with
a dipstick or fuel level gauge, a filler, breather and drainage outlet.
The required tank capacity may be calculated on the
basis of an estimated consumption of 0.2 litres/kW/hour.

B - TANK WITH AUTOMATIC FILLING LOCATED INSIDE THE ROOM

This is recommended for automatic start generating sets. The tank is refilled automatically by an electric pump from
the main storage tank.
This type of equipment is subject to regulations. It must be equipped with a fuel tank bund having the same capacity
as the tank for collecting any fuel leakage. A waste pipe returning to the main tank must be installed, with a section
of at least twice the fuel supply pipe (supply 20/27 mm, return 33/42 mm typically).
The tank is mounted slightly higher than the diesel engine crankshaft (except in covered parking areas) in order to
keep the pump primed.
This tank must be fitted with a fire valve controlled from outside the room.
For safety purposes the supply and should run smoothly from the main tank to the daily tank so that no airlocks exist
which would slow down supply to the daily tank. If the storage tank is located higher than the daily tank a safety
valve and an anti-syphon device must be installed on the pipeline with the daily tank.
The tank should not be at a level higher than lm above the diesel engine crankshaft. If the tank is located at a lower
level than the engine the suction head should not exceed 1 metre.
Main fuel tank, dally service tank and sedimentation tank
- Double wall main fuel tank
- Leakage sensor cell
- Refili opening
- Police fuel shut off point
- Fire fighter fuel shut off point
- 600 litre sedimentation tank
- 500 litre daily service tank
- Gauge with level contacter
- Manual pump
- Electric pump
- Generating set
- Air vent
- Police fuel valve
- Fire fighter fuel valve
- Earth point
- Electric fuel level gauge sender
- Foot valve and screen
- Concrete base
- Anchoring bolts
- Excavation
- Pipe duct
- Inspection plate
- Drains
- Minimum diameter 0,7 x 0,7 metres
- Type and capacity label

TO ELECTRICA CABINET

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Fuel supply
Fuel return
Electrical wiring
Mechanical wire

V - EXHAUST GAS
A - GENERAL
The design of the exhaust pipe from the generating set is a serious matter and should calculated carefully. If you
need assistance please consult us.
A number of constraints must be taken into account such as pressure loss, insolation, suspension, noise level and
air pollution.
Please note that the more bends the higher the pressure loss, there fore a larger diameter pipe should be used.
NOTE : Generating sets equipped with built in mufflers must be fitted with an exhaust expansion joint. This expansion
joint or flexible exhaust should be mounted on the canopy exhaust outlet.
Installing permanent generating sets______________________________________________________________________________________________________________________________

B - MAIN COMPONENTS

1 - Exhaust pipe
2 - Elbows
3 - Expansion joint
4 - Condensation drain
5 - Wall and roof seals
6 - Exhaust outlet
7 - Suspension device
8 - Support frame
9 - Pipe stand
10 - Muffler suspension system
11 - Heat insolation
12 - Muffler

C - PIPING
- Item 1 : Pipe
We recommend using unwelded pipe: for weight reasons, however,
rolled sheet piping may be convenient (helicoval from Vallourec or
Cofratol). In any case, welding seams must be avoided inside the
conduit ( p increase).
- Item 2 : Elbows
Elbows must have a minimum bend radius of 6-8 x D, in one element
if possible. If the elbow is made of welded sheet, make sure it
comprises 2 to 4 sections for a 90 elbow.
- Item 3 : Expansion and flexible exhaust
- Flexible exhaust : allows for sideways deflection, but little
longitudinal movement.
- Expansion exhaust : absorbs mainly longitudinal movement due to
expansion.
Reminder : the following table gives the expansion in mm per metre
os an exhaust when it is heated.
- For stainless steel multiply by 1.5
This comportent must not support exhaust pipe weight; make sure it
is in perfect alignment to prevent breakage.

0
0

10 15 20 25 30 35 40 45 50 55 60 65

70 75 80 85 90 95

0,00 0,06 0,12 0,18 0,24 0,31 0,37 0,43 0,49 0,55 0,61 0,68 0,74 0,81 0,87 0,93 0,99 1,06 1,12 1,19

100 1,25 1,32 1,38 1,45 1,52 1,59 1,65 1,72 1,78 1,85 1,92 1,99 2,06 2,13 2,19 2,26 2,33 2,40 2,47 2,54
200 2,61 2,65 2,75 2,83 2,90 2,97 3,04 3,12 3,19 3,26 3,33 3,41 3,48 3,56 3,63 3,71 3,78 3,86 3,93 4,01
300 4,08 4,16 4,23 4,31 4,38 4,46 4,54 4,62 4,69 4,77 4,85 4,93 5,01 5,09 5,17 5,25 5,33 5,41 5,49 5,57
______________________________________________________________________________________________________________________________Installing permanent generating sets

- Itern 4 : Condensation and rainwater drain.

Must be fitted at the lowest point of the installation and at any
horinzontal / vertical path change, in order to protect the exhaust
muffler and the engine.

- Item 5 : Wall seals and roof outlet

To be installed at each wall piercing and on the roof outlet.

- Item 6 : Exhaust outlets

The exhaust outlets are used to discharge into the atmosphere and to
protect the inside of the pipes from bad weather.

D - PIPES AND MUFFLERS, MOUNTING AND SUSPENSION

The useful life of an installation depends on correct design and
appropriate pipe supports
- Item 7 : Pipe Support System
Made of a flat iron clamp secured to the ceiling, the suspension
system is designed to allow for a free expansion of the pipes.

- Item 8 : Guide frame

For vertical sections the guide frame is designed to allow the piping
to expand while maintaining it laterally.

- Item 9 : Pipe stand

The pipe stand is designed to support the weight of the
vertical piping.

- Item 10 : Muffler suspension

The muffler suspension is designed to support the weight
of the muffler. It may be vertical or horizontal.

E - HEAT INSULATION (item 11)

Depending on the type of installation it may be necessary to insulate the pipes. The heat emitted by the exhaust
pipe(s) inside the room may affect the cooling system, it may also be dangerous for the safety of the maintenance
staff.
Once insolation is complete the surface temperature must not exceed 70 C, the material used for the insolation
being rockwool (excluding asbestos). This may be covered with thin aluminium in order to improve the appearance
and support the insulating material.
A 50 mm thick glass wool layer should be considered as a minimum requirement.
F - MUFFLERS (Item 12)
- General
Reduces noise by absorbing the sound wave or reacting with it (refer to manufacturers instructions : BOET,
BURGESS, MANNING, LUCHAIRE).
The exhaust pipe should be properly suspended, brackets must not be mounted on the generating set (except for
original assemblies). An exhaust expansion coupling should be fitted on the engine outiet. The pipe diameter should
never-be smaller than the generating set exhaust outlet (please consult us for lengths longer than 6 m).
If the exhaust pipe has to be extended for installation reasons an expansion bellows must be fitted between the
generating set and the pipe.
The piping should be installed so that its weight does not press on the flexible bellows, the latter must be perfectly
in line (any misalignment will cause the bellows to crack).
- 'Mounted' mufflers
A "mounted" muffler is mounted directly on the
generating set or the canopy. The brackets are fitted
on the generating set and an expansion bellows is
fitted between the silencer and the engine.

- Absorption mufflers
The gases pass through a muffler made of highly efficient
sound absorbing material and protected with perforated
sheet sometimes called a straight through muffler.

- Absorptive reactive muffler

Before the gases go through the absorbing soundproof section they
enter into an expansion chamber filled with reactive baffles.

VI - STARTING
Starting an engine is easy when it succeeds, but may cause untold
problems when unsuccessful.
The operation of highly complex equipment may depend on the
reliability of the genset particularly in applications such as hospitals,
factory processes and building protection systems.
That is why there are many starting processes and devices on a generating set to ensure reliable starting every time.
We make a distinction between a manual start procedure and an emergency start procedure, which is triggered by
the failure of the mains supply (generally in automatic mode three 5 second cranks are provided).
The starting system design depends on the engine temperature. For a start in very cold temperatures it is sometimes
necessary to use starting aids, such as heating the intake air, heating the fuel, injecting ether into the air intake. As
well as these the engine coolant is heated, and in very cold conditions also the oil is kept warm.
Generating sets can be provided with three types of start systems
- Electric starting : This is the most widely used system and consists of a 12V or 24V starter motor supplied by
one or more lead acid, or in exceptional cases, alkaline batteries.
The starter motor rotates the ring gear of the engine flywheel moving on receiving the signal from an electric contact.
Once the diesel engine has started and the flywheel has run up to its required speed, the starter motor pinion
disengages automatically from the ring gear. The batteries are recharged automatically by an alternator or static
charger.
- Pneumatic starting : Pneumatic starting relies on an air starter that is operated by a flow of compressed air from
one or two compressed air bottles and an air compresser.
The engine is started in the same way as for electric starting.
The air bottles and air compresser are located as near as possible to the generating set.
- Mechanical starting : Several mechanical starting system exist, i.e. spring, crank, inertia etc. All of these are only
used with low power generating sets.
The three systems above can be coupled to each other in the following way:
- electric/pneumatic starting
- electric/mechanical starting.

VII - ELECTRIC SYSTEM

A - CONNECTIONS - General
Just as for low voltage electrical equipment installation and maintenance must comply with the regulations standard
or equivalent.
B - POWER CABLES
May either be of the single core or multi core type according to the generating set power.
Power cables should be type installed in a duct or a cable tray designed for that purpose.
The following table will help you determine the minimum section reciuired for your generating set power.
REMINDER : Current is calculated as follows :
1 phase KVA x 1000 = A
where A = amperes
3 phase KVA x 1000
system
V
kVA = genset output
system
3V
V = single phase voltage
400
= 231V
Note : if 3 phase voltage is 400V, then 1 phase voltage is
3
Quick calculation for 3 phase (A) = kVA x constant (C)
415

400

380

346

220

WHERE C = 1,39

1,44

1,52

1,67

2,62

VOLTAGE

C - BATTERY CABLES
Install the battery(ies) near the electric starter. The cables shall be directly connected between the battery terminais
and the starter terminais. The first thing to watch is to make sure you match the + and - polarities on the battery and
on the starter. The minimum cable section shall be 70 mm2. This varies according to the generating set size but also
the distance between the batteries and the generating set.

Installing permanent generating sets______________________________________________________________________________________________________________________________

D - REMOTE CONTROL CABLES

They usually are multi core cables installed as the power cables in a duct or on a cable tray.
Their minimum sections are given for a maximum length of 4 m between generating set and panel :
- Safety . . . . . . . . . . . . . . . . .1,5 mm2
- Starting control . . . . . . . . . .4,0 mm2
- Battery voltage supply . . . .4,0 mm2
- Fuel solenoid . . . . . . . . . . .4,0 mm2
- Heating . . . . . . . . . . . . . . .2,5 mm2
For longer cables please consult our Technical Department.
E - AUTOMATIC START GENERATING SET
In this case do not forget to connect :
- The main voltage sensing or the remote control signal for starting the generating set.
- The power supply for the plant auxiliary equipment (fuel pump, charger) should be taken from the load side of the changeover
panel. This power supply should be protected by a fuse or MCB.
Earth connections shall comply with the local standards. Similarly, make sure the generating set neutral rating is identical to the
one used in your equipment.
Your equipment should also be protected against lightning.
F - CABLE SELECTION TABLE (duct installation)
Acceptable amperes for ambient temperature of :

CABLE SECTION H07RNF OU PRC

5x16mm2
5x25mm2
1x25mm2
1x35mm2
1x50mm2
1x70mm2
1x95mm2
1x120mm2
1x150mm2
1x185mm2
1x240mm2
2(1x35mm2)
2(1x50mm2)
2(1x70mm2)
2(1x95mm2)
2(1x120mm2)
2(1x150mm2)
2(1x185mm2)
2(1x240mm2)

Multi-core
Multi-core
per single Core phase
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

...

per single Core phase

...
...
...
...
...
...
...
...
...
...
...
...
...
...

30

40

50

60

96
127
142
175
212
270
327
379
435
496
584
297
360
459
555
644
739
843
992

86
114
128
157
191
243
294
341
391
446
525
267
324
413
500
579
665
758
893

77
101
113
140
169
216
261
303
348
397
467
238
288
367
444
515
591
674
794

64
85
95
117
142
181
219
254
291
332
391
199
241
307
372
431
495
564
665

VIII - COOLING
Heat needs to be dissipated from three sources:
- the water used to cool the engine
- the air used to ventilate the engine room
- the exhaust gases.
The systems described below enable this heat to be dissipated or ducted away.
- ENGINE DRIVEN RADIATOR
The engine cooling system is connected to a tube and fin radiator mounted on the chassis.
- This radiator is cooled by the fan driven directly by the engine. The fan often displaces enough air to ensure
adequate ventilation of the engine room on its own.
Air is always blown from the fan to the radiator.
The engine room is cooled by the cold air circulating inside it and air circulation can be controlled in several ways.
- ELECTRIC MOTOR DRIVEN RADIATOR
The engine cooling system is connected to a separate electric motor driven radiator located either inside or outside
the engine room.
- If the unit is inside the room it works in the same way as the engine driven radiator but the fan is driven by an
electric motor.
- When the electric motor driven radiator is located outside the engine room or on a roof top, extra lengths of cooling
water pipe are required. These have to be accurately sized and the room ventilation system will be separate from
the engine cooling system.
Such systems require great care to ensure proper extraction of gases from the engine room.
- WATER HEAT EXCHANGER
This type of cooling system uses a considerable amount of water so extra overheads need to be taken into account.
It is suited when local conditions provide a sufficient flow of water and where proper ventilation cannot be ensured
by an air cooled radiator or air cooling unit system.
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Water cooling systems consist mainly of a tubular heat exchanger connected to the engine cooling system. This
exchanger has an expression chamber and one of its circuits vented to the outdoor air. The water is circulated by
the engine water pump. The exchanger's second circuit is connected between the building water supply system and
the drain. A valve upstream of the exchanger opens or shuts.
- ENGINE ROOM VENTILATION
Exhaust fans and/or blowers can be used to cool the engine and draw fresh air into the engine room and over the
equipment housed there.
If fans are used, more effective temperature control can be achieved with several fans rather than one large fan.
The ventilation of the engine room requires detailed engineering calculations.
- In all the above cases, the system shall be in accordance with the consulting engineer's or manufacturer's drawings,
recommandations and instructions.

IX - SPECIAL PROTECTION
However, the installation of SOULE type 8134 or 8137 variable resistance lightning arresters may be considered,
keeping in mind that these devices do not offer full protection.
We wish to draw your attention to the fact that this protection concerns the power station itself but not the overhead
distribution system that might be connected to it.
This solution may be offered as an option. This type of protection device does not ensure full safety.
A - SOULE LIGHTNING ARRESTER OPERATION
When there is an overvoltage on the lightning arrester, the spark gap is pre-ionized by
the formation of a corona at a voltage much lower than the lightning strike. The gap is
bridged without any noticeable delay whatever the rise time of the lightning. The
discharge current flows to the earth through the Carbosial semi-conductor resistor, the
resistivity of which decreases very rapidly with the applied voltage. A very high current
of 4 to 5 kA may then flow to earth without the instantaneous voltage on the resistor
exceeding 2500V.
When the voltage decreases, after the overvoltage, and gets closer to the normal
operating value, the de-ionization stops almost instantly in the carbosial semiconductor resistor and the current becomes so low that the leakage current is close
to 0 and the arc is spontaneously de-energised in the spark gap.
OUR GENERATING SETS ARE NOT EQUIPPED WITH PROTECTION DEVICES
AGAINST OVERVOLTAGE DUE TO LIGHTNING OR OTHER SIMILAR CONDITIONS.
THE COMPANY IS NOT RESPONSIBLE FOR ANY DEFECTS RESULTING FROM SUCH
PHENOMENA.

Tipo 8134

Tipo 8137

C -TEMPORARY INSTALLATION OF GENERATING SETS ON SITE

I - GENERAL
Apart from the local rules and recommandations for stationary generating sets there are some specific requirements
which should be followed for "WORK SITE" generating sets.

II - SPECIAL PROVISIONS
A base shall be provided to install the generating set.
It must be flat and firm enough to prevent the generating set from sinking. lt may be made of concrete or very large
planks assembled together.
PLEASE NOTE : A generating set that does not rest properly on its bedplate (frame or traiter) will be subjected to
vibration that may cause the equipment to suffer.
The generating set shall be located on the worksite so that it is easy to get fuel to. The operator should have easy
access and the power supply should be easy to distribute to the site operators.
Access to the generating set shall always remain free for safety and maintenance purposes.
The generating set ventilation must not be masked by miscellaneous objects left in the vicinity. It could lead to
dangerous overheating and power loss.
Exhaust gases must escape freely and the exhaust system must not be positioned so that it recirculates into the air
filter or cooling system.
Earthing should be with a metal spike driven deep into the ground.
The set should be protected against bad weather with an adequate shelter (see previous chapters).

Installing permanent generating sets______________________________________________________________________________________________________________________________

D - ROAD TRAILER
I - TRAILER HITCHING
Before hitching the traiter check the tractor tow facility which should fully match the trailer towing eye/hook/ball.
CAUTION :Towing a traiter using illegal rneans is dangerous. Do not use rods, cables and ropes which may cause a serions accident

Also check :
- for signs of breakage or serious wear,
- the locking device is operating correctly.
To hitch the traiter proceed as follows :
- chock the wheels to prevent the traiter from moving,
- lift the rear stands and lock them,
- release the parking brake,
- loosen the tow bar locking levers and adjust the towing head to the same level as the tractor towing eye/hook/bali,
- hitch the trainer remove the wheel chocks and fully lift the jockey wheel using its handle,
- connect the traiter electrics to the tractor,
- hook the handbrake safety cable to the tractor towing eye/hook/ball.

II - PRE-TOWING CHECKS
Carry out the following checks before towing:
- wheel nut tightness,
- traiter and tractor are properly locked together,
- type pressures,
- side, turning and stop lights operate correctly,
- canopy doors are closed,
- parking brake released,
- front jockey wheel and rear stand raised,
- tow bar locking levers tightened and pinned,
- for "Road" type trailers, check the overrun/air brakes,
- install the brake safety cable.

III - DRIVING
- "WORKSITE" Type trailer.
The maximum road speed for a "WORKSITE" type traiter is 27km/h (16mph).
These trailers are not equipped with running brakes and therefore have no braking capability on the road ; the tyres
are designed for a speed of 27km/h. This speed must never be exceeded.
- "ROAD" type trailer.
Driving speed must be adapted to road conditions and traiter behaviour.
Driving at a high speed causes the tyres to overheat; it is advisable to stop from time to time to check them.
Excessive overheating may result in a blow out and a serious accident. When in reverse never forget to lock the
overrun brake.
IMPORTANT NOTE :
Particular attention should be paid to tightening new vehicle wheels. Brake drum heating will cause wheel loosening
during the first few kilometers.
IT IS ESSENTIAL TO TIGHTEN WHEEL NUTS EVERY 10 KILOMETERS UNTIL LOOSENING CAN NO LONGER BE
DETECTED. Wheel tightening should be checked before each towing and during the trip.

IV - TRAILER UNHITCHING
This operation must be done on level ground :
- chock the wheels,
- lower the front jockey wheel,
- lock the handbrake,
- disconnect the traiter electrics,
- raise the traiter hitch with the jockey wheel to disconnect the tow hitch from the tractor towing eye/hook/ball,
- remove the tractor.

V - SETTING UP FOR SERVICE

(Also refer to the relevant section of the generating set installation guide.)
- Make sure the ground is hard enough to prevent the assembly from sinking.
- Using the jockey wheel or stands ensure the generating set is level.
- Lock the handbrake.
- Lower the rear stands and lock them.
Certain special types of traiter may require different manuvering to that described above.
In such cases you should refer to the instructions supplied for operating and manuvering the traiter.
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