Generator Set Installation Manual

Generator Set Installation
Manual
Generator Set Installation Manual

Version Date Author Reviewer Notes
V1.0
© 2017 ZTE Corporation. All rights reserved.

ZTE CONFIDENTIAL: This document contains proprietary information of ZTE and is not to be disclosed or used
without the prior written permission of ZTE.
Due to update and improvement of ZTE products and technologies, information in this document is subjected to
change without notice.
ZTE Confidential Proprietary 1

TABLE OF CONTENTS
1 Preface............................................................................................................................... 5
2 Preparation....................................................................................................................... 5
2.1 Installation Tools................................................................................................................ 5
2.2 Installation Material............................................................................................................6
2.3 Foundation Building...........................................................................................................8
3 Outdoor Genset Installation.........................................................................................9

3.1 Genset Lifting..................................................................................................................... 9
3.2 Genset Mounting............................................................................................................. 10
3.3 External Fuel Tank.......................................................................................................... 12
3.4 ATS Cabinet Installation................................................................................................. 14
3.5 Cables Layout.................................................................................................................. 15
3.6 Wiring.................................................................................................................................18
3.7 Grounding System...........................................................................................................18
4 Indoor Genset Installation..........................................................................................19

4.1 Genset Room Design Criterion..................................................................................... 19
4.2 Genset mounting............................................................................................................. 21
4.3 Auxiliary Installation.........................................................................................................21
4.3.1 Fuel Refilling System Installation.................................................................................. 21
4.3.2 Exhaust System Installation...........................................................................................22
4.3.3 Ventilation......................................................................................................................... 23
4.3.4 Cooling Radiator.............................................................................................................. 24
4.3.5 Battery Start System....................................................................................................... 25
4.3.6 Electric System Connection........................................................................................... 25
5 Making Installation Record........................................................................................ 26
2 ZTE Confidential Proprietary

FIGURES
Figure 2- 1 Concrete foundation....................................................................................................... 8

Figure 3- 1 Genset lifting..................................................................................................................10
Figure 3- 2 Draw centre line............................................................................................................ 10
Figure 3- 3 drill holes and fix bolts..................................................................................................11
Figure 3- 4 Integrated Genset.........................................................................................................11
Figure 3- 5 Integrated Genset control system.............................................................................. 12
Figure 3- 6 Water-fuel separator installation................................................................................ 13
Figure 3- 7 Fuel inlet and outlet connection..................................................................................13
Figure 3- 8 Fuel pipe connection.................................................................................................... 14
Figure 3- 9 Outdoor ATS Cabinet...................................................................................................14
Figure 3- 10 Indoor ATS cabinet.................................................................................................... 15
Figure 3- 11 Cables layout.............................................................................................................. 15
Figure 3- 12 Digging trench.............................................................................................................16
Figure 3- 13 Laying pipe.................................................................................................................. 16
Figure 3- 14 Backfill operations...................................................................................................... 17
Figure 3- 15 Paving gravel and concrete...................................................................................... 17
Figure 3- 16 Terminal....................................................................................................................... 18
Figure 3- 17 Grounding system...................................................................................................... 18
Figure 3- 18 Grounding lug..............................................................................................................19
Figure 4- 1 Ventilation arrangement.............................................................................................. 24
Figure 5- 1 Genset nameplate........................................................................................................ 26
Figure 5- 2 Engine and alternator nameplate...............................................................................26
TABLES
Table 2- 1 Installation tools................................................................................................................5

Table 2- 2 Installation material.......................................................................................................... 6

1 Preface
This installation manual will guide you to the factors to be considered in the installation of
diesel generator system, correct installation and debugging will play an important role to
last Generator Set (Genset) life, keep Genset running reliable and stable. It discusses
location and mounting of the Genset, size of room, ventilation and air flow; engine
cooling water supply or radiator location, exhaust outlet, fuel tank and fuel transfer
system.
Before Genset installation, user needs to acknowledge Genset clearly and consult with
manufacturer.
2 Preparation
2.1 Installation Tools
Table 2- 1 Installation tools
NO. Item Picture
Tool box:
 Slot screwdriver
 Cross screwdriver
 Diagonal pliers
 Square mouth tongs
 Sharp nose pliers
1  Riveter
 Monkey wrench
 Cutter
 Saw
 Hammer
 Socket wrench
 Level ruler
 Mark pen
Electric drill
2
Churn drill

NO. Item Picture
3 Open end wrench
4 measuring tape
5 Multi-meter
2.2 Installation Material
Table 2- 2 Installation material
NO. Item Picture
Copper lug
1
self-tapping screw
2 Expansion Bolt

NO. Item Picture
3 Sealant
4 PVC Pipe
5 PVC Elbow
6 binding
7 Fuel pipes
8 fuel pipe connector
9 Cable
10 fuel-water separator

NO. Item Picture
11 Thread seal tape
12 electrical tape
2.3 Foundation Building
Concrete base of foundation (not less than C15) should have enough space and weight
(1-2 times of Genset wet weight) to load Genset and absorb vibration. Genset concrete
base with base frame should be 150-300mm higher than ground. Concrete base depth,
length and width depend on Genset power system, weight and soil conditions
(0.15-0.25MP), generally 500-1100mm depth is enough. While making concrete base, no
reservation for bolts is needed, but drill a hole for bolts to fix on the base is necessary
during installation.
Figure 2- 1 Concrete foundation

3 Outdoor Genset Installation
3.1 Genset Lifting
The Genset base frame is specifically designed for ease of moving the set. Improper
handling can seriously damage the generator and components. Using a forklift, the
Genset can be lifted or pushed/pulled by the base frame. Gensets and electrical
equipments have packages, generally is wooden case, pay much attention to lift at
suitable position, and check any wreckage, loose screws, and suspend safely. Do not lift
Genset in strong wind. Make sure Genset is laid on flat and loadable place.
Warning:
! Keep human away from the Genset bottom while lifting;
! Lift ring must be used with helicopter.
When Genset arrives at station, it should be stocked in room. If no Genset room is

available, and Genset is placed outdoor, canopy should be considered to avoid weather
damages.
For Genset is large and heavy, transport circuit have to be designed before installation,
esp indoor type. Enough space has to be reserved for Genset in. If the door is not large
enough, it should be demolished for move and mended after location. There is a special
design for Genset move, wrong action will damage Genset. When move Genset by a
forklift, pay attention to lift slowly and push or pull carefully at gravity. If Genset need to
move at times, lubricated wheels at bottom are preferred with forklift groove and lift hole.
Some small Gensets have fitted wheels at bottom when ex factory.
Warning:
! Don’t lift by engine and alternator stationary rings.
! Make sure the lift equipment is in good condition with enough load capacity.
! Keep human away while lifting;

Figure 3- 1 Genset lifting
In some countries without good transportation system, so maybe we need manual

transportation. We must carefully about it, to avoid Genset damage during transportation.
3.2 Genset Mounting
Find centre line of cleared concrete base, Genset and vibration damper according to
drawing, Genset should be placed in the middle of concrete platform. Then use electric
mallet drill holes in the marked places and fix Genset with expandable bolts and lock it,
keep at same level (parallel with cabinet if near cabinet). Installation precision is 0.1mm
each meter vertically and horizontally.
Figure 3- 2 Draw centre line

Figure 3- 3 drill holes and fix bolts
There is new type integrated Genset, it comprises imported engine, alternator,

soundproof canopy, control panel, ATS, enlarged fuel tank and fuel sensor, it reduces
installation space, minimize wiring and piping connection. So we need not install external
fuel tank, ATS cabinet, and fuel pipe layout.
Figure 3- 4 Integrated Genset

Figure 3- 5 Integrated Genset control system
3.3 External Fuel Tank
（1） Fuel tank should be located in the middle of platform.
Fuel inlet and outlet side should be in the opposite of Genset fuel inlet and outlet side. It
should be fixed with expandable bolts and keep the same level (parallel with Genset if
near Genset).
（2） Water-fuel separator installation
Clear the separator in and out, if some separator “IN” can’t meet fuel tank “OUT”, remove
the 4 screws on separator and turn the bracket to another direction then fasten the
previous 4 screws.

Figure 3- 6 Water-fuel separator installation
（3） Fuel inlet and outlet connection
Glue and thread sealing tape is opted for metal accessories connection to avoid any
leakage; while waveform tube and PVC pipe should be outside winded for fuel inlet and
outlet pipes. Any pipes knot, distortion or non-natural bent should be avoided. Pay much
attention on float ball direction and pipes tie-in while installation.
Figure 3- 7 Fuel inlet and outlet connection
（4） Fuel pipe connection
Remove factory fitted fuel in and out connection, and install parts accompanied with
Genset.

Figure 3- 8 Fuel pipe connection
3.4 ATS Cabinet Installation
ATS Cabinet have outdoor or indoor type, generally indoor type is wall-suspended, while
outdoor stand which need base platform.
Outdoor ATS Cabinet is mounted on concrete foundation.
Figure 3- 9 Outdoor ATS Cabinet
In general, indoor ATS cabinet is suspended on the wall, place the ATS bottom at 1.4m
level from the ground and keep parallel with ground. Make sure ATS door can be opened
freely after installation.

Figure 3- 10 Indoor ATS cabinet
3.5 Cables Layout
Confirm the distance and route from the Genset to the load first (reasonable
arrangement route ),and dig trench for cables and pipes.
Figure 3- 11 Cables layout
（1） Digging trench
Cable trench shall have 150mm width and 200 to 300mm depth. If dig trench near by the
house, must be keep distance to the wall, prevent loose the earth to destroy the wall.

Figure 3- 12 Digging trench
（2） Laying pipe
Power cable and control cable must protect with protection tube. In general, PVC pipe
ф50mm could be opted when cable is laid underground. All cables should be marked
before cover PVC pipes for identification.
Figure 3- 13 Laying pipe
Electric isolate pipe installation Claims:
 Keep straightness when lay the PVC pipe, orifice should be flat and smooth. The
connection of Pipe to Pipe or Pipe to Box, which use socket model, must strong and
sealed with professional glue bond.

 Must give protection for the fest pipe, which outlet from the floor or ground, to avoid
mechanical hurt.
 Cable duct’s bend radius shall not less than the cable’s minimum allowed bending
radius.
（3） Backfill operations
Backfill soil into cables pipe ditch and pun soil.
Figure 3- 14 Backfill operations
Figure 3- 15 Paving gravel and concrete

3.6 Wiring
Connect all cables (including power cables, control cables) correctly and fasten bolts
according to terminal mark.
Figure 3- 16 Terminal
3.7 Grounding System
Genset and distribution devices must be grounded to avoid any damages caused by
electricity leakage. Grounding devices play an utmost important role which can avoid any
damages by electricity faulty or electricity misuse. Grounding devices include ground
body and ground cable laid on underground or upper ground.
Figure 3- 17 Grounding system

Grounding claims:
1) Genset’s grounding cable diameter shall more than 16mm2.
2) Cable lugs of grounding shall use Hydraulic tong, the screw and washer to lock on
the grounding bar, and make it tighten.
3) Grounding cable connection port is at base frame end, if no suitable cube cable
grounding pad, grounding lug should be opted. Must drill holes on steel grounding
lug, and connect the grounding cable on it with bolts.
4) Grounding cable of equipment’s resistance must less than 4Ω.
Figure 3- 18 Grounding lug
User should keep reasonable grounding and all devices safe, and make maintenance
strictly according to instructions.
4 Indoor Genset Installation
4.1 Genset Room Design Criterion
For indoor type Genset, factors to be considered in the installation of Genset.
（1） Genset layout in room

The distance between Genset and wall should be not less than 1.5m except the coolant
radiator side to make sure enough space for handle, operation, maintenance and move.
Exhaust pipes suspend in a space 2.2m higher than the engine. Genset room is required
not less than 4.5m high, and space between roof and Genset should be not less than
1.5m, that’s the reasonable requirement for Genset maintenance and repair. For large
Genset, hoist tackle need to be considered, and the rooftree should carry 3 times Genset
weight, 16-20# I-beam needed if necessary. Cables, water and fuel pipe will be buried in
ground groove whose depth is about 0.5-0.8m with a slope to remove seeper and
steel/fireproof wood/concrete cover plate.
If there are several Gensets in one room, attention:
 Gensets should not be laid in line array. but parallel in enough space for easy
maintenance and radiation. Specific space should consult manufacturer before
design.
 Carefully consider the cable length and layout to avoid any cross.
 Genset room should be firm and safe with excellent radiation and ventilation system.
 Lighting, hot insulation and fire fighting system in room is necessary.
 Room space should be designed according to Genset power output and expansion.
 Complete feed and drainage system is needed.
（2） Noise reduction and vibration damper
In order to reduce exhaust system noise, industrial silencer is needed. If customer need
less noise, residential silencer can be fitted. Then reduce the whole Genset noise, that’s
to fit soundproof canopy in case outdoor type. If Genset is installed indoor, room noise
treatment is necessary, noise absorption materials would be fitted on door, roof and
holes. Vibration dampers are fitted to reduce the shake.
（3） Ventilation and radiation
Ventilation system is necessary for Genset room in order to emit energy, smoke and frog
and feed enough fresh air for ignition, Genset room should be 18-30 ℃ temperature.
Genset axis should be at the same direction as air inlet and outlet holes, fresh air flows

from Genset end through control panel, alternator, engine, radiator, and released by fan.
The minimum air inlet capacity must meet engine ignition, engine cooling (including
radiator), and alternator cooling.
4.2 Genset mounting
The set may be located in the basement or on another floor of the building, on a balcony,
in a penthouse on the roof or even in a separate building. Usually it is located in the
basement for economics and for convenience of operating personnel. The generator
room should be large enough to provide adequate air circulation and plenty of working
space around the engine and alternator.
It is recommended that the Genset be mounted on vibration isolation pads to prevent the
set from receiving or transmitting injurious or objectionable vibrations. Rubber isolation
pads are used when small amount of vibration transmission is acceptable. Steel springs
in combination with rubber pads are used to combat both light and heavy vibrations. On
smaller Gensets, these isolation pads should be located between the coupled
engine/alternator feet and the base frame. The base frame is then securely attached to
the floor. On larger sets the coupled engine/alternator should be rigidly connected to the
base frame with vibration isolation between the base frame and floor. Other effects of
engine vibration can be minimized by providing flexible connections between the engine
and fuel lines, exhaust system, radiator air discharge duct, conduit for control and power
cables and other externally connected support systems.
4.3 Auxiliary Installation
4.3.1 Fuel Refilling System Installation
For different Gensets, the fuel tank can be separated one or base frame type or customer
designed, anyhow, the basic principle should as follows:
Fuel tank should be stored in safe and fire-proof place and keep a certain distance from
Genset, exhaust pipes, vibration sources and any smoke is prohibited. For diesel fuel will

be vaporized above 65 ℃ and can’t start engine any more. Vibration may mix the
contamination in fuel and block fuel way.
After fuel tank is located, the fuel level should not be 2.5m higher than base frame. If
exceed 2.5m, additional day fuel tank should be fitted. The lowest fuel level should not be
lower than 1m of fuel pump mouth while fuel pump mouth to the bottom of fuel tank not
less than 100mm to avoid water or contamination injected into engine.
Fuel leakage must be avoided during fuel system installation. Fuel tube have to use ring
band for winding instead of iron wire, fuel pipes can use black iron pipe or steel wire pipe.
Fuel-water separator can bring big benefit. For water in fuel is dangerous to engine,
which makes engine rusty and damages injector mouth.
4.3.2 Exhaust System Installation
Engine exhaust must be directed to the outside through a properly designed exhaust
system that does not create excessive back pressure on the engine. A suitable exhaust
silencer should be connected into the exhaust piping. Exhaust system components
located within the engine room should be insulated to reduce heat radiation. If the
building is equipped with a smoke detection system, the exhaust outlet should be
positioned so it cannot off the smoke detection alarm.
The function of exhaust system is to emit smoke or others safely outdoor and keep away
from building and human. Attention:
 Exhaust pipe should connect flexible stainless steel waveform type. Waveform pipe
can’t be used as elbow or appendix for fuel pipe.
 Silencer and exhaust pipe should be supported by bracket rather than exhaust pipe
or it will be damages.
 Heat insulation is suggested to silencer and exhaust pipe to avoid any accidental fire
or extinguish equipment error.
 Distance between tinder and exhaust pipe should be at least 290mm (9 inch). Anti
flaming materials or heat insulation gloves will be opted if exhaust pipe have to pass
through ceiling and wall.

 The end of exhaust system should be away from building and air inlet to avoid
pollution. It’s better to install exhaust system at the back of building.
 Exhaust pipe outdoor should be 60°bent to ground if horizontal design or rainproof

cover in addition if vertically design.
Exhaust pipe backpressure can’t exceed instruction limitation. High backpressure may
cause high temp. Exhaust air and dust which will hurt engine. As a result, it’s necessary
to test Genset backpressure at full load before get into use. To reduce backpressure,
exhaust pipe is better to be shorter, and straighter, if bending; the semi diameter should
be 1.5 times of pipe diameter.
Warning:
！Exhaust air may hurt human body.
！All indoor Genset should exhaust through non-leakage pipe, the installation must apply
to relevant regulations, standards and other requirements.
！ Silencer, exhaust pipe and turbo charger may cause high temperature; human must
keep away from them.
！Avoid exhaust smoke and air to be the public hazard.
4.3.3 Ventilation
Any internal combustion engine requires a liberal supply of cool, clean air for combustion.
If the air entering the engine intake is too warm or too thin, the engine may not produce
its rated power. Operation of the engine and alternator radiates heat into the room and
raises the temperature of the room air. Therefore, ventilation of the generator room is
necessary to limit room temperature rise and to make clean, cool intake air available to
the engine
Good ventilation requires adequate flow into and out of the room and free circulation
within the room. Thus, the room should be of sufficient size to allow free circulation of air,
so that temperatures are equalized and there are no pockets of stagnant air.

To bring in fresh air, there should be an inlet ventilator opening to the outside or at least
an opening to another part of the building through which the required amount of air can
enter. In smaller rooms, ducting may be used to bring air to the room or directly to the
engine's air intake. In addition, an exit ventilator opening should be located on the
opposite outside wall to exhaust warm air.
Both the inlet and exit ventilators should have Louvers for weather protection. These may
be fixed but preferably should be movable in cold climates. For automatic starting
Gensets, if the louvers are movable, they should be automatically operated and should
be programmed upon starting the engine.
Figure 4- 1 Ventilation arrangement
4.3.4 Cooling Radiator
An important advantage of a radiator cooling system is that it is self-contained. If a storm

or accident disrupted the utility power source, it might also disrupt the water supply and
disable any Genset whose supply of raw water depended upon a utility.
The common component of cooling system is radiator. When the radiator is at the end of
Genset, location should be reasonable to make it near the exhaust hole. If above location
is not feasible, another exhaust slot is needed, whose min across sectional area should
be the same as radiator cooling area, canvas wind slot with steel-made flanges is
generally used to connect radiator and exhaust shutter.

For calculating air inlet or air outlet area, we suggest to keep the air inlet area twice of
radiator area, outlet area is 1.2 times radiator area.
Whether the radiator is mounted on the Genset or mounted remotely, accessibility for
servicing the cooling system is important. For proper maintenance, the radiator fill cap,
the cooling system drain cocks, and the fan belt tension adjustment must all be
accessible to the operator.
4.3.5 Battery Start System
Normal voltage for engine start system is 12V or 24V, standard configuration includes
battery bracket and battery cables. Battery can be acid-lead type or free maintenance
type, the former need to add electrolyte before usage while the latter can be used directly.
Notice for installation:
 Keep clean surface and around.
 Open the filling hole and add electrolyte, keep the level 10-15mm higher than
battery panel. New added electrolyte is easy to be absorbed by battery panel,
regular complement is necessary. Due to electrolyte is heating, it’s necessary to
keep it stand still after filling.
 Connect battery panel correctly.
 Charge battery shortly after discharging to avoid panel sulfating. While charging,
make sure the polarity is correct.
4.3.6 Electric System Connection
Genset has configured control panel, complete cable devices, input and output terminals
etc. Cables Connection could refer to outdoor Genset.

5 Making Installation Record

When the installation is complete, must record all the information on nameplate for the
acceptance inspection and maintenance later.
Figure 5- 1 Genset nameplate
Figure 5- 2 Engine and alternator nameplate

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© 2017 ZTE Corporation. All rights reserved.

ZTE Confidential Proprietary 1

3 Outdoor Genset Installation.........................................................................................9

4 Indoor Genset Installation..........................................................................................19

5 Making Installation Record........................................................................................ 26

2 ZTE Confidential Proprietary

Figure 2- 1 Concrete foundation....................................................................................................... 8

Table 2- 1 Installation tools................................................................................................................5

ZTE Confidential Proprietary 3

Table 2- 2 Installation material.......................................................................................................... 6

4 ZTE Confidential Proprietary

2.1 Installation Tools

Table 2- 1 Installation tools

NO. Item Picture

ZTE Confidential Proprietary 5

NO. Item Picture

3 Open end wrench

2.2 Installation Material

Table 2- 2 Installation material

NO. Item Picture

6 ZTE Confidential Proprietary

NO. Item Picture

8 fuel pipe connector

ZTE Confidential Proprietary 7

NO. Item Picture

11 Thread seal tape

2.3 Foundation Building

Figure 2- 1 Concrete foundation

8 ZTE Confidential Proprietary

3 Outdoor Genset Installation

3.1 Genset Lifting

! Keep human away from the Genset bottom while lifting;

! Lift ring must be used with helicopter.

When Genset arrives at station, it should be stocked in room. If no Genset room is

! Don’t lift by engine and alternator stationary rings.

! Keep human away while lifting;

ZTE Confidential Proprietary 9

Figure 3- 1 Genset lifting

In some countries without good transportation system, so maybe we need manual

3.2 Genset Mounting

Figure 3- 2 Draw centre line

10 ZTE Confidential Proprietary

Figure 3- 3 drill holes and fix bolts

There is new type integrated Genset, it comprises imported engine, alternator,

Figure 3- 4 Integrated Genset

ZTE Confidential Proprietary 11

Figure 3- 5 Integrated Genset control system

3.3 External Fuel Tank

（1） Fuel tank should be located in the middle of platform.

（2） Water-fuel separator installation

12 ZTE Confidential Proprietary

Figure 3- 6 Water-fuel separator installation

（3） Fuel inlet and outlet connection

Figure 3- 7 Fuel inlet and outlet connection

（4） Fuel pipe connection

ZTE Confidential Proprietary 13

Figure 3- 8 Fuel pipe connection

3.4 ATS Cabinet Installation

Outdoor ATS Cabinet is mounted on concrete foundation.

Figure 3- 9 Outdoor ATS Cabinet

14 ZTE Confidential Proprietary