INSTALLATION MANUAL

INSTALLATION

2.1 SELECTION OF SITE

� Proper space should be there for placement and opening of doors of the Silent DG Set.

� There should be at least 2 meter free space around the DG Set for proper access to initial

product delivery and installation, operation, service i.e. for general maintenance and

inspections and working space for major work such as overhauls or component

removal/replacement.

� There should be cross ventilation and free flow of cool, clean and fresh air flow from

alternator end to engine to ensure proper cooling of DG Set. Exhaust gases and hot air

discharge should not re-circulate inside the acoustic enclosure (canopy).

� For basement installations, supply of fresh air and forced ventilation through air ducts is

required to remove heat.

� There should be no restriction for fresh air suction and hot air discharge. If 02 DG sets

are installed at the site, ensure that hot air outlet of the one DG set does not become the

fresh air intake of the 2nd DG set.

� A low height shelter for the Silent DG set should be avoided. It should not obstruct the

hot air outlet.

� It is preferable to install the DG Set in an open area. No shade (roof) is required over it.

However, if the AMF Panel is outside the Acoustic Enclosure, then a shelter is

recommended for the Panel.

� For Roof Top Installation, ensure that the civil structure is capable to bear the static and

dynamic load of DG set. The load of the Silent DG set should be borne by Columns and

Beams of the building.

� Proper space should be there for earthing.

� If there are no space constraints, the DG set should be placed near the distribution

panel.

� The DG set should be located away from polluted surrounding such as corrosive fumes,

cement dust, fibres, cotton and toxic chemicals to avoid overheating of the DG set.

� For Humid / Coastal atmospheric applications, anti condensations heaters are mandatory

for alternator.

2.2 FOUNDATION DETAILS AND GUIDELINES

A. Ground base Foundation (RCC/PCC)

� The length and width of the Foundation should be at least 200mm to 400mm more than

Acoustic enclosure length and breadth respectively.

� Check the base/foundation level diagonally as well as across the length for even flatness

and same should be within ± 0.5 degree of any horizontal plane.

� Ensure that the concrete is completely set and hardened before positioning the enclosure

� Do not install acoustic enclosure on lose sand or clay.

� A rigid foundation ensures the least vibration. Sand Filling should be there around the

foundation. Rubber matting can also be used over the foundation to minimize the

vibration effect and noise leakage.

� Please refer to the dimension of DG set for deciding the foundation length, width and

depth.

Note: Please ensure that the foundation should not be made over any basement,

Water tank or Sewer line.

B Roof Top Foundation

� The weight of Silent DG se should be on Column and Beam through proper foundation.

� The RCC foundation should be on the Beam or supported on two Beams.

� ISMC Channel or MS "I" Section may also be used to cater the load of the DG set with

the canopy. Load of ISMC Channel or MS "I" Section should be on the column of the

building.

� M.S. Sheet is to be provided at the bottom of the base frame of the Silent DG set for roof

top installation.

� Whenever seismic events are a consideration, a qualified structural engineer should be

consulted.

Note: An inadequate foundation may lead to excessive genset vibrations resulting in

Radiator leaks, failure of the auto electric and safety system, or failure of gauge,

Coupling or other engine parts.

2.3 EARTHING SYSTEM

� An Earthing system is required for the protection of equipment and human being, as per

Indian electricity Rules 1956.Grounding should be done in accordance with applicable

National, local code or regulation.

� Separate earth should be used for body and neutral earthing.

� 4 Nos. earthing pits are required for DG set, 2 each for neutral & body.

� The min. distance between 2 earthing pits should be 2.0 meters.

� An earth pit cover should be provided.

� A watering pipe of 19mm with a funnel should be provided for each pit, wherever depth

of the earthing pit is not at water level.

� Earthing system should be checked with meagre and maximum 1.0 ohm resistance

should be ensured.

� The earthing plate/pipe and strip should be selected as per the rating of the DG set.

2.4 VENTILATION AND COOLING:

� The radiated heat given off by the engine, generator and exhaust piping can result in a

temperature high enough to adversely effect operating and maintenance personal or the

performance of the genset. Locate the genset in a room or area that will provide or allow

sufficient ventilation to remove this heat as well as the heat radiated from the engine

cooling water by the radiator.

� If the enclosures are placed in an enclosed place, ensure that enclosure is well ventilated

and exhaust gases are driven out of the enclosure.

Points to remember in any type of installation:

� Ensure that hot air is positively discharged from the building by fitting a flexible

connection between the radiator and duct.

� The size of the openings should be calculated to ensure that excessive restriction is not

imposed on the flow of cooling air. Openings should atleast be as big as the radiator core

area but, as a guide, an area on 150% of the core area of the radiator should be allowed

for.

VENTILLATION SYSTEM FOR LIQUID COOLED/WATER COOLED DG SETS

2.5 EXHAUST PIPING

The exhaust system is used to direct exhaust gases to non-confined areas and reduce the noise

to tolerable levels. The exhaust system must be designed to keep the resistance to hot gases

(back pressure) as low as possible. Excessive back pressure in exhaust system will create horse

power loss and increase the engine operating temperature and emissions.

The following may please be noted.

� The load of the extended exhaust pipe/silencer should not be on the engine manifold.

� There should not be any load or stress on the exhaust below.

� A uniform gap has to be maintained between bellow flange and exhaust pipe flange.

� There should be proper support for the exhaust pipe if required dampers are used at

points of high vibration & pipes should be extended through proper flanges only.

� At points where the piping passes through a wall or roof, a metal thimble guard 300mm

in diameter slightly larger than the pipe should be installed.

� When bends are required in an exhaust system, always make the radius atleast 150% of

the inside diameter of the pipe. The exhaust pipe should be routed in a path that offering

the least amount of turns or bends so not to increase back pressure more than 50 mm of

Hg.

� Short bends should be avoided.

� Exhaust pipe outside the enclosure should be wrapped with high temperature insulation

along with aluminum sheet cladding or installing fitted insulated sections will aid in

preventing excessive heat radiation with in room.

� Always use proper size M.S. pipes (G.I. pipe and bend should not be used in exhaust

piping).

� Exhaust outlet should be in the direction of prevailing winds.

� There should be rain trap to avoid rain water entry. If rain cap is used the distance

between exhaust pipe and rain cap should be higher than diameter of the pipe. It is also

recommended that horizontal run of exhaust piping should slope downwards away from

engine to the condensate trap. Silencer should install with drain plug at bottom.

� Each genset installation should have its own exhaust system and should not be

connected to a system accommodating more than one genset as the possibility of

exhaust gas and condensation backflow may cause permanent damage to an idle engine.

EXHAUST PIPING EXTENSION

Note: Health Warning: Inhalation of exhaust fumes is potential lethal. Correct installation of

exhaust systems to prevent accumulation of exhaust gas cannot be over emphasized.

Air Cooled

Description Unit 15 KVA - 35 KVA 40 KVA - 62.5 KVA 75 KVA

Exhaust pipe Dia mm 63 76 100

Water cooled R- Series

Description Unit 15 KVA - 35

KVA

40 KVA - 62.5

KVA

75 KVA 100 KVA-125

KVA

Exhaust pipe

Dia

mm 63 76 100 125

SL Series

Description Unit 140 KVA - 250 KVA

Exhaust pipe Dia mm 125

K Series

Description Unit 275 KVA 320KVA 400KVA-625 KVA

Exhaust pipe Dia mm 125 150 2 x 150

2.6 FUEL SYSTEMS

The fuel system must be capable of delivering to the engine a clean and continuous supply of

fuel. When designing a fuel system, always incorporate the requirements of Local, State, or

National Codes, which may pertain to either the fuel system or the electrical apparatus utilized

by the system.

FUEL SYSTEM LAYOUT

A. Diesel Fuel Bulk Storage

Bulk fuel storage is the most preferable method of providing fuel supply. This method allows

bulk fuel purchases which will minimize dirt and contamination possibilities, especially when the

fuel is seldom used. The bulk storage tank may be located either above or below the ground. A

vent must be installed on the main tank to relieve the air pressure created by filling the tank as

well as preventing a vacuum within tank as fuel is consumed. The tank bottom should be

rounded and placed on a 2 degree tilt to assure a concentrated settling of both water and

sediments. At the low point of the tank a drain valve should be installed to remove water that

may accumulate due to condensation.

Underground tanks must be pumped periodically to remove this water. This is best done by

placing a tube through the filter pipe to the low end of the tank. For these reasons it is

imperative that the tank be placed in or on stable ground to assure that eventual settling does

not change the location of the low point of the tank. Burying the tank below the frost line will

help in avoiding seasonal settling. Another consideration to be made when locating the main

tank is the height difference between it and the auxiliary tank (day tank). The maximum vertical

lift capability of a standard electric motor driven fuel transfer pump is 5m. Do not place either

tank at a level that would exceed the pump lift capabilities. Also keep in mind the possibilities of

pressure drop created by excessive horizontal distances and pipe work bends. The fuel delivery

line carrying fuel to the engine and the fuel return line for carrying excessive fuel back to the

tank should be no smaller than the fitting sizes on the engine. For longer runs or extremely low

ambient temperatures increase the size of these lines to ensure adequate flow. The fuel lines

can .be made of any fuel compatible material such as steel pipe or fuel line tube that will

tolerate ambient conditions. Overflow piping should be of the same material and one size larger.

The fuel return line should enter the tank at the top and contain no shut-off valve. This line

should be designed with a minimum amount of bends or dips to prevent an air lock in the

system. The fuel delivery line should pick up the fuel from the point no lower than 20mm from

the bottom of the tank. If at all possible locate this line at the end of the tank opposite that of

the return line and at the high end of the tank. Flexible fuel lines should be used at a point

between the tank and engine (preferably adjacent to the genset) to avoid the potential damage

that could be created by vibration.

B. Day Tanks

Auxiliary tanks or day tanks as they are commonly referred to are recommended. All standard

gensets with acoustic enclosure are provided with tank fitted in the base frame. This day tank

will produce a ready fuel supply.

2.7 LUBRICATING SYSTEM

The engine's lubricating system is designed to:

� Reduce friction

� Cool

� Seal

� Scavenge

� Dampen shocks

Lub oil specifications:

The operating life of an engine depends on the use of the correct type of lub. oils. To ensure

this, oils recommended by the engine manufacturer should be used. Oil confirming to IS: 496(

1979 HD type 5 or U.S. Military standard MIL-L-2104-C must be used for industrial/ automotive

naturally aspirated and turbo charged diesel engines.All standard lubricating oils have a brand

name and the SAE number. The brand name indicates the oil specification. The SAE number

denotes the oil viscosity. Oil viscosity is selected according to the ambient temperature as

shown below:

Temperatures above 45° C SAE 40

Temperatures 10° C to 45° C SAE 30

Temperatures -5° C to 10° C SAE 20 W

Temperatures -15° C to -5° C SAE 10 W

Where the temperature variation between minimum and maximum is very wide, multigrade oils

should be used. Also multi-grade oil is better than mono-grade oil.

Example : SAE 20W40 is a multi-grade oil and can be used where atmospheric temperature is

between -5° C to 45° C and above. (Which is applicable to normal Indian climatic condition.)

KOEL recommends to use K-Oil which confirms to the following specifications:

US Military: MIL- L-2104C. Indian Std.: IS: HD type 5 OR IS: E-DL3. API: SC/CD

Recommended for all types of NA & Turbocharged Diesel Engines.

� KOEL recommends to use K-Oil

� A premium quality heavy duty multi-grade 20W40 Engine Oil which exceed specification

of US MIL-L-2104C/APSC/CD & IS 13656 EDL-3. MACK T-7 Engine Test

Approved.

� Recommended for all types of NA & Turbocharged Diesel Engines.

The oil sump is usually fitted on the lowest part of the engine. It is provided with a drain plug to

Enable oil draining. Oil sumps are of two types: Standard Sump - for stationary applications.

Deep sump - for industrial automotive applications.

LUBRICATING SYSTEM

The dipstick measures the quantity of oil in the sump. It is usually grooved with low and high

markings to help users maintain the correct oil level in the sump.

DIPSTICK

CAUTION: Oil level to be checked when the engine is in cold condition.

2.8 Filters and Traps

Clean fuel will aid in attaining maximum engine life and dependability. Primary filters are

recommended for use between the engine filters and the transfer pump. Water and sediment

traps should also be included upstream of the transfer pump. However, on border line pump

installations do not increase fuel line restrictions to a point exceeding the capabilities of the

pump.

2.9 FIRE PRECAUTIONS

When designing a genset installation the following points should be noted:

– The room should be designed so that there is an easy escape route for operating personnel in

the event of fire within the room.

– A recommended type of fire extinguisher or fire extinguishing system should be provided to

fight the fire.

– Gravity operated fire valves operated by fusible links, mounted above the engine, can be

installed in the fuel lines.

– The room should be kept clean and free from accumulated rubbish which can be a fire hazard.

2.10 ELECTRICAL CONNECTION

Only fully qualified and experienced electrical technicians should be allowed to carry out

electrical installation work. The electrical connection to the genset should be made with flexible

cable to prevent the transmission of vibration and possible damage to the alternator or circuit

breaker terminals If it is not convenient to use flexible cable throughout then a link box can be

installed close to the set with a flexible connection between it and the set. The cable may be laid

in a duct or on cable tray. When bending cable reference must be made to the recommended

minimum bending radius. No rigid connection should be made between the set and the cable

support system, e.g., cable tray. When single core cables are used the gland plates must be of

non-ferrous material, e.g., aluminum, brass or a non-metallic material such as Teflon. The cable

must be suitable for the voltage being used and adequately sized to carry the rated current with

allowances made for ambient temperature, method of installation, proximity of other cables,

etc. All electrical work should be carried out in accordance with any applicable National, Local

Standards, Codes or Regulations. All connections should be carefully checked for integrity. Phase

rotation must be checked for compatibility with the installation. This is vitally important when

connection is made to an auto transfer switch, or if the machine is to be paralleled.

NOTE: A. correct size Cable glands should always be used for holding the cable.

B. Control Wiring should always be done with 2.5sq.mm copper cable.

2.11 BATTERY CHARGING PROCEDURE

A. Battery charging procedure

� If dry battery is supplied along with the DG set then initial charging of the battery is

required.

� Please get initial charging of the battery done from an authorized service dealer of the

battery manufacturer.

� The initial charging process is of 72 hours.

� Specify gravity of acid inside the battery should be 1.23 to 1.28 kg/liter.

B. Method to use charged battery

� If charged battery has been provided along with the DG set, and the DG set is not in use

then ensure that at positive terminal battery lead is not connected. It should be

connected at the time of the commissioning of the DG set.

� Charged battery may be used for commissioning of DG set within 15-20 days; else re-

charging of charged battery is required.

� Always connect the battery with the proper battery charger. The battery should be

connected to the battery charger, which is connected with 230V AC supply.

� The Battery charger is provided with an AMF Panel (Auto Mains Failure Panel) under the

standard scope of supply. 230V AC supply is essential for battery charger operation.

Note: Battery charger is not supplied with a standard manual Panel. So, it is

Suggested that the DG set must run once a day for 15-20 minutes so that

Battery is charged by engine dynamo/ charging alternator.

C. Precaution to be taken during handling of battery.

� Do not charge the battery at a wet a place.

� Flame, Candle and matchbox should not be used near charged battery.

� Use hand gloves while handling the charged battery.

� Electrolyte level should be below the neck.

� Always switch off the charger first before disconnecting the battery from the DG set.

� Never put tools etc. on the battery.