ISX-GEN-ATS_Reference Manual_990-1846A
Contents
1. level 15 Replacing the filter 16 Changing the 16 InfraStruXure Generator Overview gt un 4 24 an 17 Coolant type a Dn en ee ar 17 Coolant capacity 17 Draining cleaning flushing and refilling the coolant 18 Fuel A AAA SRA RES 19 OVervieW es er he ee 19 Problems with diesel fuel 19 Preventing potential problems with diesel fuel 20 Fuel specifications 21 Fuel tank size 2 02 aa Ba 21 Fuel monitoring runtime calculation 22 Generator runtimes and fuel consumption 22 E SlOp BUTTON 2 A estes eo tee tee See ara aan 23 Overview ee ae eee Bs et eet 23 Stopping the generator using the E stop button 23 Resetting the E stop button to return the generator to automatic operation 24 Clearing a Shutdown Fault 25 BatleneS cine he a EHER ee is 26 Replacement 26 Keeping the batteries clean 26 Charging the batteries 26 Block Heater Serena ae rn 28 5 aaa ae a a e ea 29 Warr2. 10 Manual start of generator 11 Menu selection button 10 O O Manual Auto switch location 10 Oil 15 16 location of components for maintenance 7 9 reading the dipstick and changing 16 type capacity and level 15 Operation warnings 3 Outlet box location 7 9 Output circuit breaker 7 9 InfraStruXure Generator P Panel lamp button 10 Physical specifications 29 S Safety instructions and symbols 1 Service obtaining 34 Shutdown faults clearing 25 indicator lights 11 Specifications 29 Starting the generator manually 11 T Turbo charger 7 9 U Updates to this manual 1 W Warnings 2 6 Warranty 31 35 www apc com APC Worldwide Customer Support Customer support for this or any other APC product is available at no charge in any of the following ways e Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests www apc com Corporate Headquarters Connect to localized APC Web sites for specific countries each of which provides customer support information Wwww apc com support Global support searching APC Knowledge Base and using e support Contact an APC Customer Support center by telephone or e mail Regional centers Direct InfraStruXure Customer Support Line 1 877 537 0607 toll free APC headquarters U S Canada 1 800 800 4272 toll free Latin America 1 401 789 5735 USA
3. Europe Middle East Africa 353 91 702000 Ireland Japan 0 3 5434 2021 Australia New Zealand South Pacific area 61 2 9955 9366 Australia Local country specific centers go to www apc com support contact for contact information Contact the APC representative or other distributor from whom you purchased your APC product for information on how to obtain local customer support Entire contents 2005 American Power Conversion All rights reserved Reproduction in whole or in part without permission is prohibited APC the APC logo and InfraStruXure are trademarks of American Power Conversion Corporation and may be registered in some jurisdictions All other trademarks product names and corporate names are the property of their respective owners and are used for informational purposes only an 0
4. paraffin wax content Note InfraStruXure Generator Fuel 5 Fuel must be dry Keep the fuel tank full to reduce the air space above the fuel in the tank Have the generator s fuel filter water separator serviced annually 6 Do not add new or used engine lubricating oil to the fuel as it could reduce engine performance 7 Do not mix gasoline gasohol or alcohol with diesel fuel as it creates an extreme fire and explosive hazard 8 Have the fuel tested for water content and microbial contamination at least annually or when new fuel is added or fuel is suspect If microbial contamination has occurred after it has been remedied use Fleetguard s Fleet Tech Microbicide fuel additive to prevent the future growth of microorganisms If water in the fuel is a persistent problem Fleetguard s Fleet tech Winter Conditioner can be used to prevent fuel line freeze up Fuel specifications When adding diesel fuel to your generator be sure that it adheres to the following specifications Viscosity 1 3 to 5 8 centistrokes 1 3 to 5 8mm per second at 104 F 40 C Cetane number 40 minimum above 32 F 0 C 45 minimum below 32 F 0 C Sulfur content Not to exceed 0 5 mass percent Active sulfur Copper strip corrosion not to exceed Number 2 rating after 3 hours at 122 F 50 C Water and sediment Not to exceed 0 5 volume percent Carbon residue Not to exceed 0 35 mass
5. When replacing generator batteries be sure to use the same number and type of battery as the original The generator uses 12V 225 1400 cold cranking amps sealed lead acid batteries Keeping the batteries clean Ensure that the batteries remain clean by wiping them with a damp cloth whenever dirt appears excessive Charging the batteries The InfraStruXure generator is equipped with a battery charger to continuously charge the batteries and ensure reliable operation Refer to InfraStruXure Generator Components on page 7 for the location of the battery charger on your InfraStruXure generator model You can tell if your generator s batteries are charging by looking at the battery charger If the battery charger is charging the batteries correctly the green Power On LED will be lit In addition the voltmeter will indicate the voltage at the battery and the DC ammeter will show the charger output current which should be between 0 and 2 amperes when the battery is at its float voltage The illustration on the following page shows battery charger and the location of these items For proper operation the On Off switch of the battery charger should always be in the On position unless you are installing or replacing the batteries If you are installing or replacing the batteries ensure that the battery charger s On Off switch is in the Off position The illustration on the following page shows the location of the On Off switch on the
6. generator s battery charger 26 InfraStruXure Generator Batteries Voltmeter Ammeter NS DC VOLTS AMPERES Off Power On LED On Off switch Ensure that the battery charger is plugged in to one of the 120 VAC receptacles on the generator If the On Off switch is in the On position but the batteries are not charging check that the charger is plugged into the correct receptacle The following illustration shows the proper receptacle for the battery charger If the charger is plugged in to the correct outlet and the On Off switch is switched to On but the batteries are still not charging call customer service at a number listed on the back of this manual Plug the battery charger into one of these two standard 120V receptacles Do not plug the charger into one of the GFCI receptacles For more information on the location of the outlet box see InfraStruXure Generator Components on page 7 InfraStruXure Generator 27 Block Heater Checking the block heater 28 The block heater reduces wear of generator s motor and should be plugged in at all times Check the operation of the block heater by verifying that it is warming the coolant Ifthe block heater is not working it will cause an alarm on the ATS indicating that the engine temperature is too low If this alarm occurs check that the b
7. load and the remaining fuel in the tank Once a new fuel level point is reached the value ofthe calculated fuel used is reset and the consumption begins again The Fuel Level and Runtime Estimate are displayed on the Generator Status screen on the ATS display interface and you can set the following Fuel Alarm Limits in the Alarms menu of the display interface Percent Fill If the amount of fuel as a percentage falls below this value an alarm condition exists Runtime If the estimated runtime falls below this value an alarm condition exists Generator runtimes and fuel consumption 22 The following table provides the estimated runtime ofthe generator based on the load capacity when there is a full tank of diesel fuel Load Capacity 80kW 125kW 200kW At full load 12 hours 12 hours 12 hours At 3 4 load 22 7 hours 14 5 hours 17 3 hours At 1 2 load 31 1 hours 19 8 hours 23 7 hours At 1 4 load 47 4 hours 33 0 hours 37 6 hours The following table provides the fuel consumption of the generator based on the load capacity Load Capacity 80kW 125kW 200kW At full load 6 1 gal hr 9 5 gal hr 17 3 gal hr At 3 4 load 4 8 gal hr 7 5 gal hr 11 8 gal hr At 1 2 load 3 5 gal hr 5 5 gal hr 7 8 gal hr At 1 4 load 2 3 gal hr 3 3 gal hr 4 3 gal hr InfraStruXure Generator E Stop Button Overview The E stop button allows you to immediately stop the generator in the event that it requires an emergency shutdown After the generat
8. observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Do not lay tools or metal parts on top of batteries The electrolyte is a diluted sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water If electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon 4 liters of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried InfraStruXure Generator 5 Warnings Lead acid batteries present risk of fire because they generate hydrogen gas The following precautions are to be followed DO NOT SMOKE near batteries DO NOT cause flame or spark in battery area Discharge static electricity from body before touching batteries by first touching a grounded metal surface InfraStruXure Generator InfraStruXure Generator Components Overview The seven doors of the generator provide access to
9. spontaneously lights the fuel Do not let your diesel engine run out of fuel A diesel engine may not restart when refilled if it runs out of fuel To avoid this situation ensure that your generator s fuel never reaches below a half a tank Diesel engines run more efficiently when they are loaded Always attempt to run the generator with a 30 load or higher Diesel engines burn less fuel per watt generated if they are generating near their full potential Diesel engines do not regulate the intake air but rather they regulate the amount of fuel injected to the cylinders Unlike gasoline engines which run best at a fixed air fuel ratio diesel engines run with essentially the same air but add more fuel when they require more power InfraStruXure Generator Maintenance Overview You should establish and follow a maintenance schedule that works with your particular application and its environment APC recommends quarterly service visits for generator maintenance Ifthe InfraStruXure Power Generation System will be subjected to extreme operating conditions reduce the service intervals accordingly The following factors may affect the maintenance schedule Use of the generator for continuous duty prime power Extremes in ambient temperature Exposure to severe weather Exposure to salt water Exposure to dust sand or other airborne contaminates This manual outlines the basics of generator maintenance In most cases
10. surrounding area clean and free from obstructions Remove any debris from the set and keep the floor clean and dry Do not work on this equipment when mentally or physically fatigued or after consuming any alcohol or drug that makes the operation of equipment unsafe Substances in exhaust gases have been identified by some state and federal agencies as causing cancer or reproductive toxicity Take care not to breathe ingest or come into contact with exhaust gases InfraStruXure Generator Warnings Do not store any flammable liquids such as fuel cleaners oil etc near the generator A fire or explosion could result Wear hearing protection when going near an operating generator To prevent serious burns avoid contact with hot metal parts such as radiator turbo charger and exhaust system Caution batteries Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from the batteries When replacing batteries use the same number and the following type of batteries 12V 225A 1400 cold cranking amps sealed lead acid e Do not dispose of batteries in a fire The battery is capable of exploding Do not open or mutilate the batteries Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A battery presents a risk of high short circuit current The following precautions are to be
11. the different engine components for service and maintenance This section lists the parts found behind each door for the three different generator models 80kW InfraStruXure Generator Generator controller battery charger Door not used for engine access in this model generator Oil drain oil level sensor air filter change indicator block heater 120 VAC outlet box Oil filter turbo charger Coolant drain coolant overflow receptacle oil fill point fuel pump Fuel sensor visual fuel gauge air filter oil dipstick Main output circuit breaker 120VAC outlet box also has two 2 GFCI receptacles These receptacles are for customer use and should not have the battery charger or the block heater connected to them InfraStruXure Generator 7 InfraStruXure Generator Components 125kW InfraStruXure Generator e Generator controller battery charger Door not used for engine access in this model generator Oil drain point oil level sensor block heater air filter change indicator 120 VAC outlet box Turbo charger oil filter Coolant drain coolant overflow receptacle oil fill point fuel pump Oil dipstick fuel sensor visual fuel gauge air filter Main output circuit breaker 120VAC outlet box also has two 2 GFCI receptacles These receptacles are for customer use and should not have the battery charger or the block heater
12. to the previously viewed main menu O The E stop button allows you to perform an emergency shutdown of the generator set For more information refer to E Stop Button on page 23 The generator s indicator lights provide a visual indication of the generator status and any warnings present For more information refer to Indicator lights on page 11 The generator s O Manual Auto switch should be in the Auto position when the InfraStruXure Power Generation System is running in automatic operation and should be in Manual when the generator must be started manually The manual run stop button starts and stops the generator set locally The O Manual Auto switch must be in Manual to enable this button The panel lamp and lamp test button allows you to test all panel LEDs and to turn the control panel lamps ON or OFF The fault acknowledge reset button allows you to clear faults once they have been corrected InfraStruXure Generator Generator Control Panel Indicator lights The indicator lights on the generator controller provide information about the status of the generator and any current generator faults O Running CO Remote Start O Not in Auto O Low Oll Pres Waming OD High Engine Temp Warning O Low Oll Pres Shutdown OD Overspeed Shutdown O Fall to Start Indicator Light Color Description Running Green Indicates that the generator is running Remote Start Green Indicates that th
13. 3 2 x 40 0 x 108in 2367 x 1016 x 2743 mm 98 4 x40 x 108in 2499 1016 x 2743 Shipping 98 x 46 x 118in 2489 x 1168 x 2997mm 103 5 x 46 x 118in 2629 1168 x 2997 mm Weight Generator 42101b 1914kg 41601b 1891 kg 52591b 2390kg Shipping 43001b 1955kg 450010 2045kg 56751b 2580kg Environmental 80kW 125kW 200kW Operating Temperature 22 to 40 30 to 40 C 5 to 100 RH 12 800 ft 3900m 1330BTU min 75dbA at 7m Operating Relative Humidity 5 to 100 RH 12 800 ft 3900m Thermal Dissipation full load 1386 BTU min 75dbA at 7m Operating Elevation Audible Noise Emission 5 to 100 RH 12 800ft 3900m 2680BTU min 75dbA at 7m Compliance Approvals UL cUL 2200 Tier 2 EPA Emissions certified InfraStruXure Generator 29 Warranty APC warrants that all components of the InfraStruXure system will be free from defect in material and workmanship for a period of two years from the date of start up when start up has been performed by APC authorized service personnel If assembly services are included in the original purchase and are also performed by APC authorized service personnel APC offers an additional year of parts warranty and the first year of on site coverage at no additional charge In the event that the system fails to meet the forgoing warranty APC shall repair or replace at its sole discretion any such defective parts Under this warranty APC will ship all parts to you
14. HETHER SUCH DAMAGES ARISE IN CONTRACT OR TORT IRRESPECTIVE OF FAULT NEGLIGENCE OR STRICT LIABILITY OR WHETHER APC HAS BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES InfraStruXure Generator Life Support Policy American Power Conversion Corporation APC and its affiliates and subsidiaries worldwide do not recommend the use of any of their products in life support applications where failure or malfunction ofthe APC product can be reasonably expected to cause failure of the life support device or to significantly affect its safety or effectiveness APC does not permit the use of any of its products in direct patient care APC will not knowingly sell its products for use in such applications unless the life support system or direct patient care device is part ofa whole facility building into which the UPS is integrated and unless APC receives in writing assurances satisfactory to APC that a The UPS system will be configured in a manner that will provide N 1 power redundancy to the critical load b The end user customer assumes all risks and signs the APC System Configuration and Use Form and c The customer and operators ofthe APC UPS system agree to indemnify and hold APC and its affiliates and subsidiaries harmless for any and all claims arising out of the systems use in such applications The term life support device includes but is not limited to neonatal oxygen analyzers nerve stimulators whether used for anesth
15. addition if a summer blend fuel is used in the winter the paraffin wax can gel turning the fuel into the consistency of jelly If this occurs the fuel pump will not be able to draw the fuel and the generator will not start InfraStruXure Generator 19 Fuel Water Water can enter the fuel system through either the fuel itself or through condensation of the moisture normally in the air above the fuel Water in diesel fuel is normally present as both free and emulsified water Free water settles to the bottom of the fuel tank Emulsified water stays suspended in the fuel the way that oil and vinegar separate in salad dressing and can enter the fuel lines fuel pump and injectors From there it can cause corrosion and failure ofthe fuel pump and injectors In addition emulsified water can freeze at low temperatures and the resulting ice crystals can clog the fuel filter This clog can prevent the generator from starting or cause the generator to stall after it has started Microbial contamination Microorganisms primarily bacteria and fungi exist harmlessly in moisture free fuel However in the presence of water these microorganisms can grow and reproduce In turn they can clog your fuel filter and prevent the generator from starting or cause the generator to stall after it has started Cetane number Cetane number is a measure of the starting and warm up characteristics of a fuel A minimum number of 40 is required In cold we
16. anty aa a aa RA ia a AY wht tS ea ais 31 Life Support 33 SOIVICO Ai 34 InfraStruXure Generator Safety Save these instructions This manual contains important instructions that must be followed during installation operation and maintenance of the InfraStruXure Generator Safety symbols used in this manual Indicates an electrical hazard which if not avoided could result in injury or death i gt Electrical Hazar Indicates a hazard which if not avoided could result in severe personal injury or gt substantial damage to product or other property DANGER Indicates a potential hazard which if not avoided could result in personal injury or gt damage to product or other property Caution Indicates a heavy load that should not be lifted without assistance Indicates important information i gt Note Cross reference symbols used in this manual Indicates that more information is available on the same subject in a different section of this manual ES Indicates that more information is available on the same subject in a different manual See also InfraStruXure Generator 1 Warnings The components in the InfraStruXure Power Generation System and UPS power distribution system can pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of the dangers and act safely Read and f
17. application Type of filter 80kW or 125kW generator Fleetguard LF3349 or equivalent 200kW generator Fleetguard LF3000 or equivalent To replace the generator s oil filter 1 Fill the filter with clean lubricating oil 2 Apply a light film of oil to the gasket sealing surface of the filter 7 LF3000 oil filter has two gaskets Lubricate both of the gaskets Note 3 Install the filter on the generator according to the manufacturer s instructions Changing the oil Handling and disposing of used oil is subject to federal state and local regulations Use authorized waste disposal facilities Ifin doubt contact your local Note EPA authorities for guidance as to proper handling of used oil E For detailed instructions on changing your generator s oil refer to the Cummins Qe Engine Operation and Maintenance manual included with your generator See also 16 InfraStruXure Generator Coolant Overview The diesel engine of the generator requires a balanced coolant mixture of water antifreeze and coolant additives You can check the coolant level of your generator through the ATS display interface To check the coolant level using this method select Generator Status and then Engine Parameters from the Generator screen en For more information about the Generator screen on the ATS see Generator under the Display Interface chapter of the ATS with Power Distribution Operation manual See al
18. ather or in service with prolonged low loads a cetane number of 45 is desired Fuel with a cetane number greater than 55 may cause increased torque peak smoke Viscosity Viscosity is a measure of the fuel s pumping and lubricating characteristics Low viscosity causes rapid wear of the fuel pump and injectors High viscosity causes hard starting white smoke when cold and failures of the fuel injector train Fuel quality Use of fuel that does not meet all of the fuel specifications may cause problems with the generator See Fuel specifications on page 21 for generator specific specifications Preventing potential problems with diesel fuel Follow these suggestions to help prevent any of the potential diesel fuel problems and help ensure your generator s reliability 1 Only purchase premium diesel fuel from a qualified diesel distributor 2 Ifthe generator is located in an environment with temperatures 20 F 7 C and above only purchase ASTM D975 No 2 D diesel fuel with a minimum cetane number of 40 If the generator is located in an environment with temperatures below 20 F 7 C only purchase Winter Blended 50 ASTM D975 No 1 D 30 No 2 D with a minimum cetane number of 45 4 If the generator is located in an environment with temperatures below 20 F 29 C a fuel filter heater is required 7 ASTM D975 No 1 D fuel is less dense than ASTM No 2 D fuel and has a lower 20
19. back cover of this manual InfraStruXure Generator i Contents Safety an nen der 1 Save these instructions 1 Safety symbols used in this manual 1 Cross reference symbols used in this manual 1 234 0 Da a A AA 2 The InfraStruXure Power Generation System is an Optional Standby System 2 Fuel and fumes are flammable 2 Exhaust gases are deadly 3 Moving parts can cause severe personal injury or death 3 Do not operate in flammable and explosive environments 3 Electric shock can cause severe personal injury or death 4 General safety precautions 4 5 InfraStruXure Generator Components 7 OVERVIEW a een eier 7 80kW InfraStruXure Generator 7 125kW InfraStruXure Generator 8 200kW InfraStruXure Generator 9 Generator Control 10 Special Features of Diesel Generators 12 Maintenance 13 Maintenance Checkpoints 14 Olle es ee Lee Ae 15 2 iD PR Gre AA ae ee 15 capacity rein a a re 15 Engine
20. connected to them 8 InfraStruXure Generator InfraStruXure Generator Components 200kW InfraStruXure Generator gt me BR Bar Generator controller battery charger Door not used for engine access in this model Oil dipstick 120 VAC outlet box Turbo charger block heater oil filter coolant filter Fuel pump oil drain point coolant overflow receptacle Oil fill point fuel sensor visual fuel gauge air filter Main output circuit breaker 120VAC outlet box also has two 2 GFCI receptacles These receptacles are for customer use and should not have the battery charger or the block heater connected to them InfraStruXure Generator 9 Generator Control Panel The generator s control panel connects to the ATS monitoring unit for communication purposes At the generator controller you can clear alarms perform an emergency stop ofthe system clear a shutdown fault and manually start the generator The following illustration shows the InfraStruXure Generator s control panel O The home button brings you back to the main menu screen from any other screen The menu selection button allows you to step through the various menu items and adjust parameters The digital display allows you to view menus faults and shutdown messages An asterisk before a listed fault indicates that it is an active fault The previous main menu button brings you
21. d by a qualified licensed electrician Lock out and tag open switches to avoid accidental closure Hazardous voltages can flow from the generator into the utility line This creates a potential for electrocution of service personnel or property damage DO NOT CONNECT GENERATOR DIRECTLY TO ANY BUILDING ELECTRICIAL SYSTEM CONNECT ONLY TO THE AUTOMATIC TRANSFER SWITCH General safety precautions e Coolants under pressure have a higher boiling point than water DO NOT open a radiator heat exchanger pressure cap while the engine is running or hot Allow the generator to cool and bleed the system pressure first Used engine oils have been identified by some state and federal agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to ingest oil breathe the fumes or contact used oil Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires combustible and flammable liquid fuels and gaseous fuels Class C fires live electrical equipment ref NFPA No 10 Make sure that rags are not left on or near the engine Make sure generator is mounted in a manner to prevent combustible materials from accumulating under the unit Remove all unnecessary grease and oil from the unit Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard Keep the generator and the
22. e generator is receiving a start signal remotely from the ATS Not in Auto Red Flashes continuously when the Low Oil Pres Warning High Engine Temp Low Oil Pres Shutdown Overspeed Shutdown Fail to Start O Manual Auto switch is not in the Auto position Yellow Indicates that oil pressure is lower than the normal range of operation Yellow Indicates the engine temperature is higher than normal range of operation Red Indicates that the engine has shut down due to low oil pressure Red Indicates that the engine has shut down because of excessive speed Red Indicates that the engine has failed to start How to clear a shutdown fault See Clearing a Shutdown Fault on page 25 for instructions How to manually start the generator on how to start the InfraStruXure Power Generation gt For detailed directions lt System manually refer to the ATS with Power Distribution Operation manual See also 990 1845 InfraStruXure Generator 11 Special Features of Diesel Generators Differences between diesel engines and gas engines Before operating the generator it is important to be aware of the differences between diesel engines and gasoline engines Some of the most notable differences between the two are Diesel engines do not have spark plugs Unlike a gas engine a diesel engine takes in air compresses it and then injects the fuel into the compressed air The heat of the compressed air
23. enter APC SHALL NOT BE LIABLE UNDER THIS WARRANTY IF ITS TESTING AND EXAMINATION DISCLOSE THAT THE ALLEGED DEFECT IN THE PRODUCT DOES NOT EXIST OR WAS CAUSED BY PURCHASER S OR ANY THIRD PERSON S MISUSE NEGLIGENCE IMPROPER INSTALLATION OR TESTING UNAUTHORIZED ATTEMPTS TO REPAIR OR MODIFY OR ANY OTHER CAUSE BEYOND THE RANGE OF THE INTENDED USE OR BY ACCIDENT FIRE LIGHTNING OR OTHER HAZARD THERE ARE NO WARRANTIES EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTHERWISE OF PRODUCTS SOLD SERVICED OR FURNISHED UNDER THIS AGREEMENT OR IN CONNECTION HEREWITH APC DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY SATISFACTION AND FITNESS FOR A PARTICULAR PURPOSE APC S EXPRESS WARRANTIES WILL NOT BE ENLARGED DIMINISHED OR AFFECTED BY AND NO OBLIGATION OR LIABILITY WILL ARISE OUT OF APC S RENDERING OF TECHNICAL OR OTHER ADVICE OR SERVICE IN InfraStruXure Generator 31 Warranty 32 CONNECTION WITH THE PRODUCTS THE FOREGOING WARRANTIES AND REMEDIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REMEDIES THE WARRANTIES SET FORTH ABOVE CONSTITUTE APC S SOLE LIABILITY AND PURCHASER EXCLUSIVE REMEDY FOR ANY BREACH OF SUCH WARRANTIES APC S WARRANTIES RUN ONLY TO PURCHASER AND ARE NOT EXTENDED TO ANY THIRD PARTIES IN NO EVENT SHALL APC ITS OFFICERS DIRECTORS AFFILIATES OR EMPLOYEES BE LIABLE FOR ANY FORM OF INDIRECT SPECIAL CONSEQUENTIAL OR PUNITIVE DAMAGES ARISING OUT OF THE USE SERVICE OR INSTALLATION OF THE PRODUCTS W
24. esia pain relief or other purposes autotransfusion devices blood pumps defibrillators arrhythmia detectors and alarms pacemakers hemodialysis systems peritoneal dialysis systems neonatal ventilator incubators ventilators for adults and infants anesthesia ventilators infusion pumps and any other devices designated as critical by the U S FDA Hospital grade wiring devices and leakage current protection may be ordered as options on many APC UPS systems APC does not claim that units with these modifications are certified or listed as hospital grade by APC or any other organization Therefore these units do not meet the requirements for use in direct patient care InfraStruXure Generator 33 Service How to contact APC Customer support for this or any other APC product is available at no charge in any of the following ways e Visit the APC Web site to access documents in the APC Knowledge Base and to submit customer support requests www apc com Corporate Headquarters Connect to localized APC Web sites for specific countries each of which provides customer support information Www apc com support Global support searching APC Knowledge Base and using e support e Contact an APC Customer Support center by telephone or e mail Regional centers Direct InfraStruXure Customer Support Line 1 877 537 0607 toll free headquarters U S Canada 1 800 800 4272 toll f
25. he Cummins Engine Operation and Maintenance manual included with your generator InfraStruXure Generator Fuel Overview The InfraStruXure generator runs on diesel fuel The fuel is one of the most critical components of your generator s reliability Unlike on road diesel engines which continuously use up the fuel in their tanks the fuel in a standby generator sits in the tank for an extended period of time Diesel fuel that sits unused for a period of time can present problems This section describes some of the problems that may occur and offers recommendations for preventing these problems Adhere to the recommendations provided in this section to increase the probability of reliable operation for your generator a Refer to the Cummins Engine Operation and Maintenance manual for complete fuel system maintenance instructions See also Problems with diesel fuel The following list addresses some issues that can lead to problems with diesel fuel especially when it will be sitting in a standby state for an extended period of time 1 Temperature Diesel fuel naturally contains paraffin wax In warm temperatures this wax is in a liquid state and is suspended throughout the fuel When the temperature drops below 20 F 7 C the wax crystallizes causing the fuel to cloud up These wax crystals can clog your fuel filter and can prevent the generator from starting or cause the generator to stall after it has started In
26. level either at the generator or through the ATS Checking the oil level at the ATS For convenience you can check the oil level through the ATS display interface To check the oil using this method select Generator Status and then Engine Parameters from the Generator screen gt For more information about the Generator screen on the ATS see Generator Se under the Display Interface chapter ofthe ATS with Power Distribution Operation See also manual InfraStruXure Generator 15 Oil Checking the oil level at the generator If checking the oil level at the generator make sure that the oil level is as close to the high mark on the dipstick as possible without exceeding it Do not operate the generator ifthe oil level is above the high mark on the dipstick or below the lt High mark low mark Refer to InfraStruXure Generator Components on page 7 for the location of the oil dipstick for your specific generator model lt __Low mark L Do not operate the generator if the oil level is too low or too high Operating the generator with too much oil can cause foaming or aeration Operating the generator Caution With too little oil may cause loss of oil pressure Replacing the oil filter Your InfraStruXure Power Generation System s generator has a six cylinder engine Refer to the following table for the type of replacement filter that you will need for your particular application Type of
27. lock heater is operating correctly At the generator feel the block heater with your hand If it is warm to the touch then it is operational If the block heater is cool to the touch and should be running check to ensure that it is properly plugged in to one of the 120 VAC receptacles on the generator s outlet box Plug the block heater into one of these two standard 120V receptacles Do not plug the heater into one of the GFCI receptacles Refer to InfraStruXure Generator Components on page 7 for the location of your generator s block heater and outlet box InfraStruXure Generator Specifications Electrical 80kW 125kW 200kW Output Power kW kVA 80 100 125 156 200 250 Power Factor 1 0 0 8 1 0 0 8 1 0 0 8 Alternator Alternator Temperature Rise 257 F 125 C 257 F 125 C Alternator Insulation Class Class H Class H Voltage 120 V 208 120 V 208 V or 277 V 480V Output Type 4W G 4W G 208V 3W G or 4W G 480V Frequency 60 Hz 60 Hz Battery Charger Output 10A at 12V 10A at 12V Battery Charger Input 120V at 200W 120V at 200W Coolant Heater 120V at 1125 1500W 120V at 1125 1500W Brushless 4 pole drip proof revolving field 12 lead with separately excited PMG 221 F 105 C Class H 120 V 208 V or 277V 480V 4W 208V 3W or 4W 480V 60Hz 10A at 12V 120V at 200W 120V at 1125 1500 W Physical 80kW 125kW Dimensions H x W x D 200kW Generator 9
28. ollow all of the safety instructions and warnings in this manual and in all of your component manuals The InfraStruXure Power Generation System is an Optional Standby System The Generator and Automatic Transfer Switch ATS that you purchased from APC is classified as an Optional Standby System it provides backup or standby power to data centers in the event of a sustained power failure The InfraStruXure Power Generation System is not to be classified as an Emergency System that is essential for safety to human life e g fire pumps operating room and life support equipment in hospitals as legally required by municipal state federal or other governmental codes The InfraStruXure Power Generation System is not to be classified as a Legally Required Standby System as it s not supplying power to aid in fire fighting rescue operations control of health hazards e g sewage and similar operations as required by municipal state federal or other governmental codes Emergency and Legally Required Systems are not allowed to rely on municipal fuel for operation and municipal water for cooling Emergency and Legally Required Systems require dual fuel systems with one of them being a two hour on site fuel supply Your InfraStruXure Power Generation System is not to be classified as an Integrated Electrical System as an orderly shutdown is not required to prevent damage to the generator The generator is not to be paralleled with anothe
29. or is shut down using the E stop button it cannot be started either at the generator or at the ATS until the button has been reset The following illustration shows the location of the E stop button located on the generator controller E stop button If an emergency power off is performed at the ATS it will automatically trip the E stop button of the generator If this situation occurs the E stop Note button must be manually reset at the generator using the procedure described on the following page Stopping the generator using the E stop button To stop the generator using the E stop button push it in InfraStruXure Generator 23 E Stop Button Resetting the E stop button to return the generator to automatic operation 24 E stop shutdown status can only be reset at the generator control panel Note O Pull the emergency stop button out Turn the generator s Manual Auto switch to O Press the front panel Fault Acknowledge Reset button O Place the O Manual Auto switch on the generator controller to the Auto position fsi Shutdown Warning Warning Fault Acknowledge Reset Fault Acknowledge Reset Panel Lamp Lamp Test Panel Lamp Lamp Test Manual Run Stop Manual Run Stop To ensure that your entire InfraStruXure Power Generation System is configured lt A correctly to run in automatic operation see the Operation section of the ATS
30. percent on 10 volume percent residuum Density 0 816 to 0 876 grams per cubic centimeter g cc at 60 F 15 C Cloud point Temperature at which paraffin crystals form Should be 10 F 6 C below lowest ambient temperature at which the generator is expected to operate Ash Not to exceed 0 02 mass percent Distillation 90 volume percent at 680 F 360 C Lubricity Minimum of 3100 grams SLBOCLE or maximum of 0 45mm wear scar SLBOCLE or HFRR diameter at 140 F 60 C HFRR Fuel tank size For the 80kW and 125kW generator the fuel tank size is 109 gallons 413 liters For the 200kW generator the fuel tank size is 173 gallons 655 liters InfraStruXure Generator 21 Fuel Fuel monitoring runtime calculation Fuel monitoring is a unique feature of the InfraStruXure Power Generation System Fuel level is monitored at the generator if purchased through APC and load is measured at the ATS These measurements are used to calculate runtime as explained in the following paragraph Fuel is monitored by a level sensor in the generator fuel tank calibrated to the bottom of the fuel tank that changes readings every 1 2 inch of fuel level change From these fixed level points the ATS counts the number of gallons or liters of fuel used based on load over time and subtracts this from the fixed level fuel amount to give an accurate estimate of fuel level The remaining runtime is then calculated based on the fuel usage rate at the current
31. r generator Your generator will operate at its rated load without being re fueled for a minimum of six hours and should run for a minimum of 12 hours Fuel and fumes are flammable Fire explosion and personal injury or death can result from improper practices DO NOT fill fuel tanks while engine is running unless tanks are outside the engine compartment Fuel contact with hot engine or exhaust is a potential fire hazard DO NOT permit any flame cigarette pilot light spark arcing equipment or other ignition source near the generator or fuel tank 2 InfraStruXure Generator Warnings Exhaust gases are deadly Ensure exhaust gases are properly discharged away from enclosed or sheltered areas and areas where individuals are likely to congregate Ensure that the unit is well ventilated Engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm Moving parts can cause severe personal injury or death e Keep your hands clothing and jewelry away from moving parts Before starting work on the generator disconnect battery charger from its AC source then disconnect starting batteries negative cable first This will prevent accidental starting e Make sure that fasteners on the generator are secure Tighten supports and clamps keep guards in position over fans drive belts etc Do not wear loose clothing or je
32. r site at no cost to be available for you the next business day after APC is notified of this requirement If you choose to upgrade the system to include an on site contract APC offers modular service packages to match your needs Each point product incorporated into the system has a separate factory warranty that is applied when sold as a standalone unit When incorporated into an InfraStruXure solution the unit will be covered by the InfraStruXure warranty In cases where one warranty favors the customer over the other the stronger ofthe two warranties will take precedence The InfraStruXure factory warranty covers only those parts appearing on the bill of materials for that solution Megawatt UPS systems are not covered under the InfraStruXure factory warranty Battery functionality is typically impacted by age and environmental conditions and therefore certain requirements must be met by the end user Failure to adhere to these requirements may put the battery warranty at risk APC supplied batteries must always be kept whether stored or installed in a climate controlled environment and should be re charged at a minimum of every three 3 months The battery environment must be free of excessive moisture construction dirt corrosive elements or other contaminants The temperature range must be maintained at 41 to 95 F 5 to 35 C All warranties are null and void unless startup is performed by authorized an APC Global Services service c
33. ree Latin America 1 401 789 5735 USA Europe Middle East Africa 353 91 702000 Ireland Japan 0 35434 2021 Australia New Zealand South Pacific area 61 2 9955 9366 Australia Local country specific centers go to www apc com support contact for contact information Contact the APC representative or other distributor from whom you purchased your APC product for information on how to obtain local customer support 34 InfraStruXure Generator Index A Agency approvals 29 B Batteries charging 26 27 replacing 26 warnings 5 6 Battery charger 7 9 Block heater checking 28 location 8 9 block heater location 7 Companion manuals 1 Compliance 29 Control panel 10 11 Coolant 17 18 location of components for maintenance 7 9 maintenance 18 type and capacity 17 D Digital display 10 E Electric shock warnings 4 Electrical specifications 29 Engine components 7 9 Environmental specifications 29 E stop button 23 24 Exhaust gas warnings 3 F Fault acknowledge reset button 10 Fuel monitoring and runtime 22 problems with 19 21 specifications 21 warnings 2 G Generator controller 7 9 H Home button 10 Indicator lights description of 11 location of 10 L Lamp test button 10 Life support policy 33 M Maintenance factors affecting schedule 13 items checked during 14 Manual run stop switch
34. so Coolant type Use a low silicate antifreeze that meets ASTM4985 test criteria It is recommended that you use an antifreeze with a 50 percent concentration level of ethylene glycol or propylene glycol in most climates The following table provides specifications for the antifreeze protection that you need according to the climate that your generator is operating in Ethylene Glycol Propylene Glycol 40 9 F 23 C 40 6 F 21 C 50 35 F 37 C 50 27 F 33 C 60 65 F 54 C 60 56 F 49 C 68 96 F 71 F 68 81 F 63 C Coolant capacity The coolant capacity for the generator is as follows 80kW 6 5 gallons 24 6 liters 125kW 8 2 gallons 31 0 liters 200kW 6 8 gallons 25 7 liters InfraStruXure Generator 17 Coolant Draining cleaning flushing and refilling the coolant system 18 A Caution Note 0 See also Do not add cold coolant to a hot engine To prevent damage allow the engine to cool to below 120 F 50 C before adding coolant Handling and disposing of used antifreeze is subject to federal state and local regulations Use authorized waste disposal facilities If in doubt contact your local EPA authorities for guidance as to proper handling of used antifreeze For instructions on how to perform maintenance on the generator s cooling system including changing or refilling the generator s coolant refer to t
35. the required maintenance will be covered by a service contract purchased with your Note InfraStruXure generator For full instructions on how to perform the procedures outlined in this manual refer to the Cummins Engine Operation and Maintenance Manual included with your generator InfraStruXure Generator 13 Maintenance Checkpoints The following maintenance items should be completed during your scheduled maintenance visit Check coolant heater Check coolant level Check oil level Check fuel level Check charge air piping Check air cleaner clean if required Check battery charging system Drain water and sediment from fuel tank Drain exhaust condensate trap Change air cleaner element Check radiator hoses for water and cracks Drain fuel filters Check anti freeze and DCA concentration Check crankcase oil and filter Check drive belt tension Change coolant filter Change fuel filters Clean cooling system Adjust valve lash Check starting batteries InfraStruXure Generator Oil Oil Type Use a high quality 15W 40 multi viscosity lubricating oil Oil capacity The oil capacity of the generator is as follows 80KW and 125kW generators 17 3 quarts 16 4 liters 200kW generators 25 2 quarts 24 liters Engine oil level YA Do not check the oil level at the generator while it is running as it may cause oil to be dispersed and could cause severe burns Warning You can check the generator oil
36. welry in the vicinity of moving parts or while working on electrical equipment Loose clothing and jewelry can become caught in moving parts e If adjustment must be made while the unit is running use extreme caution around hot manifolds moving parts etc Do not operate in flammable and explosive environments Flammable vapor can cause an engine to over speed and become difficult to stop resulting in possible fire explosion severe personal injury and death Do not operate a generator where a flammable vapor environment can be created by fuel spill leak etc unless the generator is equipped with an automatic safety device to block the air intake and stop the engine The owners and operators of the generator are solely responsible for operating the generator safely InfraStruXure Generator 3 Warnings Electric shock can cause severe personal injury or death Remove electric power before removing protective shields or touching electrical equipment Wear rubber boots when working on electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surface to be damp when handling electrical equipment Do not wear jewelry jewelry can short out electrical contacts and cause shock or burns Use extreme caution when working on electrical components High voltage can cause injury or death DO NOT tamper with interlocks Follow all applicable state and local electrical codes Have all electrical installations performe
37. with See also Power Distribution Operation manual This section also provides instructions on how to start the generator locally in the event that it is necessary InfraStruXure Generator Clearing a Shutdown Fault You cannot restart the generator when a shutdown fault lamp is lit even if the fault has been cleared Once you have corrected the fault you must reset the shutdown indicators before the generator can restart To reset the shutdown indicators O Turn the O Manual Auto switch to the position Press the Fault Acknowledge Reset button Fehutdewn Warning Press Fault Acknowledge Reset Panel Lamp Lamp Test Manual Run Stop ee SEE A With the exception of generator EPO and remote EPO shutdown faults most shutdown faults even if cleared will occur again when the Nore generator is restarted For this reason if a shutdown fault occurs call customer service at a phone number listed on the back of this manual for assistance InfraStruXure Generator 25 Batteries RA For more information on charging and replacing the generator s batteries refer to lt A the Battery Charger Operator 8 Manual that came with your generator See also Servicing of batteries must be performed or supervised by a person knowledgeable YA of batteries and the required precautions Keep unauthorized personnel away from Caution the batteries Replacement battery type
38. www apc com InfraStruXure Generator InfraStruXure Power Generation System Reference Manual About This Manual Audience This manual is intended for end users of an InfraStruXure Power Generation System generator It provides important safety warnings and instructions an overview of generator components technical specifications and warranty information Companion manuals For additional information about the generator and the InfraStruXure Power Generation System see the following InfraStruXure Power Generation System manuals ATS with Power Distribution Unpacking Sheet 990 1842 e Electrical Installation Manual 990 1844 ATS with Power Distribution Operation Manual 990 1845 Network Management Interface User s Guide available on the Utility CD 990 1993 Refer also to the following Cummins manuals supplied with your generator for engine specific information and instructions Installation Manual e Operator s Manual e Operation and Maintenance Manual Parts Catalogs e Operator s Manual 12 and 24 Battery Charger e Installation and Service Manual 12 and 24 V Battery Charger How to find updates to this manual You can check for updates to this manual by clicking on the User Manuals link on the Support page ofthe APC Web site www apc com In the list of InfraStruXure Power Generation manuals look for the latest letter revision A B etc of the part number on the
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