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Home My WebLink AboutF2004-0101 - MiscPLAN CHECK NO.: ARCHITECT: CONTRACTOR: ENGINEER: PROJECT: f 4-1 a'i Dr Newport Beach Fire Department fC*d6 (Lj - 2X5Q tt Fire Prevention Division 3300 Newport Blvd. Newport Beach, CA 92663 (949) 644-3106 Plan Check Correction Sheet 0614-2004 TAYLOR Sr ASSOCIATES MACARTHY BUILDING SATO, STAN UNDERGROUND PIPING FOR GENERATOR & ADDITIONAL DAY TANK PROJECT LOCATION: 1 HOAG DRIVE DATE: MARCH 16, 2004 Corrections: 1. Indicate size of day tank for new and existing generators. 2. Indicate make and model of new tank and generator, provide manufacturer's cut sheet. 3. Show venting for tank, where does it terminate. Plan Check #: 0614-2004 Subject: Response to Plan Corrections Project: Aboveground Piping for Generator & Additional Day Tank Architect: Taylor & Associates Architects • • • March 24, 2004 Newport Beach Fire Department Fire Prevention Division 3300 Newport Blvd. Newport Beach, California 92663 Re: HOAG MEMORIAL HOSPITAL PRESBYTERIAN Aboveground Piping for Generator & Additional Day Tank. Taylor & Associates Job No. 1350.80 Plan Check No.: 0614-2004 To Newport Beach Fire Department, In response to your Plan Check Correction Sheet, dated 3/16/04, please find the following clarifications regarding the above -mentioned project. Comment 1: Indicate size of day tank for new and existing generators. Response: Complied. Refer to the enclosed Specification Section 16230B-10 for the size of new day tank for the new generator. The existing building, generator system and day tanks were approved by OSHPD and OSHPD Fire and Life Safety. The Building was constructed in 1998. Refer to the enclosed Specification Section 16615-6 for the size of existing day tank for the existing generator. Comment 2: Indicate make and model of new tank and generator, provide manufacturer's cut sheet. Response: Complied. Refer to the enclosed Specification Section 16230A-2 for the new generator's make and model. Also, refer to enclosed Diesel Engine Generator & Day Tank Submittal for the manufacturer's cut sheets for the generator. Refer to the enclosed Diesel Engine Generator & Day Tank Submittal for the new day tank's make and model. Also, refer to enclosed Diesel Engine Generator & Day Tank Submittal for the manufacturer's cut sheets for the day tank. Comment 3: Show venting for tank. Where does it terminate? Response: Complied. Refer to previously submitted Record Drawing Sheet P-4.27, Duplex Fuel Oil System Piping Diagram. The venting for the new day tank connects to existing 1 %" VTR Line above ground. The existing 1 '/i" VTR Line was approved by OSHPD and OSHPD Fire and Life Safety. Letter to Newport Beach Fire Department HOAG MEMORIAL HOSPITAL PRESBYTERIAN East Tower March 24, 2004 Page 2 of 2 The termination for venting of the new tank is at the roof of the existing building, refer to enclosed Record Drawing P-3, Plumbing — Roof Plan, where existing 1 %" VTR is shown. If you have any questions, please contact me at 949.574.1325. Sincerely, TAYLOR & ASSOCIATES ARCHITECTS Joseph Dunn 1350 Aboveground Piping & Day Tank Plan Check Comments.doc • • Specification Section 16230B • • •., • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST ADDITION 1350.10 1.1.3 Installation General: The day tank shall be installed adjacent to the prime mover, on the same grade. Install (as shown on the plan drawings, [as detailed herein]) on a housekeeping pad adjacent to the prime mover. Anchor tank to the pad. B. Day Tank Ratings 1.3.1 Capacity: 100 gallons. 1.3.2 Power requirements: 115V AC, 3-phase, 60 Hertz, 15A dedicated branch circuit. 1.3.3 Day tank construction. 1.3.3.1 All welded steel atmospheric tank of rectangular construction built in accordance with codes and standards noted above for indoor use COMPLIANCE CONFIRMATION with fuel oil. 1.3.3.2 Pipe thread connections shall be provided for: Fuel oil supply from remote pump set, 1.0 inch. Supply to prime mover, 0.75 inch. Return from prime mover, 1.0 inch. Supply to overflow return pump, 0.75 inc. Vent, 2.0 inch. Emergency vent, 4.0 inch. Drain, 0.75 inch, with drain valve. 1.3.3.3 An inspection port in the top shall be provided. 1.3.34 The tank shall be equipped with .a welded steel channel base suitable for bolt attachment to a concrete pad. 1.3.3.5 The tank shall have interior corrosion protection consisting of an epoxy coating. 1.3.3.6 The exterior of the day tank shall receive a heavy duty industrial anti- corrosion coating and be finish painted. 1.3.3.7 All day tank system components shall be protected by a removable steel equipment cover. 1.3.3.8 Day tank shall be factory leak tested at 5PSI. 1.3.3.9 The tank shall be installed and anchored within a UL Listed steel containment dike/basin having a minimum capacity of 150% that of the day tank. The containment shall be equipped with a leak detector that shall activate the "rupture" alarm described below. A DIESEL ENGINE -GENERATOR 03/18/02 16230E -10 HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST ADDITION 1350.10 drain with ball valve is to be supplied. The containment shall be painted inside and out to match the day tank. The day tank system shall be painted to match the diesel generator. C. Fuel Delivery System 1.4.1 The day tank shall be fed from a remote duplex pump set. 1.4.2 Provide the following inlet devices: COMPLIANCE CONFIRMATION Main inlet shutoff valve, 1.0 inch. Inlet strainer, 1.0 inch. Main inlet solenoid valve, 100PSI rated, 0.75 inch brass body, viton or buna-n seal. Day Tank Level Controller. A UL Listed, integrated design level controller package shall be supplied which provides differential level control for activation of remote pumps, tank level indication, system alarms and manual operating controls. Level controller shall be self-contained as a unit within a NEMA1 box mounted on top of the day tank. The controller shall utilize discrete level sensors and circuit paths for level alarms, primary pump control and backup pump control. Failure in one sensor or circuit path shall not necessarily disable the entire controller. All indicators are to be long life light emitting diodes. 1.5.1 The level controller shall provide the following control functions: 1.5.1.1 "Auto -off -manual" pump control mode switch. 1.5.1.2 'Press to test" pump push-button. 1.5.1.3 Pump start -stop automatic level control. 1.5.1.4. Pump overflow control backup Indication Functions 1.5.1.5 Fuel level. 1.5.1.6 Power available. 1.5.1.7 Switch not in auto. 1.5.1.8 Pump running. 1.5.1.9 Low level alarm. 1.5.1.10 High level. 1.5.1.11 Overflow alarm/pump control backup activated. 1.5.1.12 Day Tank leak. Outputs 03/18/02 DIESEL GENERATOR SECTION 16230E-11 • Specification Section 16615 Existing Day Tank • • ,Nd HOAG MEMORAL HOSPITAL PRESBYTERIAN 1020.10 EMERGENCY GENERATOR BUILDING g. Voltage transient at rated kVA (voltage regulation, stability, and response). h. Regulator range test (voltage adjust). Phase sequence. j. Mechanical balance (vibration). k. Inherent voltage regulation. Circulating current. m. Dissipation factor tests. The above tests shall be conducted in accordance with IEEE-115, NEMA MG-1 and MIL -STD 705 standards. Dissipation factor tests shall be performed per IEEE Std 286. The generator shall be provided with a drip -proof and oversized terminal box and shall meet the NEMA MGI.22.40 requirements for temperature rise. The generators shall be Kato Engineering or equal. 2.02 DAY TANK (One for each engine) A. Provide and install one jl)_ 1QO ga1100 packaged floor- standing day tank separated from the diesel engine generator. The fuel pump on the diesel engine shall draw from and return to the day tank. A pump at the main fuel tank shall provide fuel for the day tank. See mechanical specifications. The main tank pump shall be controlled by two sets of float switches in the daytank (for redundancy). The float switch shall control, in addition to the pump, a 120 vac solenoid valve, with filter screen and manual bypass, mounted at the suction inlet on the day tank from the main storage tank. The day tank shall be equipped with a top mounted glass sight gage, test controls, pilot lights, and low fuel alarm contacts. The day tank shall be similar to Sim lex ModelNq,$Fr-140A except as modified herein on the plans. The day tank shall have a rupture basin including alarm contact. Day tank shall be equipped with over flaw/return tank per mechanical documents. 2.03 MUFFLER AND EXHAUST SYSTEM (No. required by engine type) A. Critical type silencers shall be furnished complete with a seamless flexible connector. The silencer shall be a Nelsen 400 series with an inlet diameter matched to the flexible exhaust fitting outlet (161. \The silencer shall have a side inlet and shall be suitable for mounting in a horizontal position. The silencer shall be fitted with a condensate drain on the bottom centerline adjacent to the exhaust �j outlet. The seamless flexible connector between the aiesel-engine exhaust outlet and the silencer inlet shall be stainless steel and shall be provided with an ANSI 125 pound drilled slip flange. A I 4.:" complete piping and installation diagram and performance curve shall be furnished prior to ordering rJ . equipment. The silencer and exhaust piping shall be insulated and painted with the manufacturer's ') recommended paint. High temperature insulation shall be provided in accordance with other Divisions of this specification. B. Engine Coolant. The radiator and the diesel engine cooling system shall be filled with a 30% solution of ethylene glycol and 70% distilled water to prevent freezing and rust formation. • 16615 - 6 DIESEL ENGINE -GENERATOR • Diesel Engine Generator & Day Tank Submittal • • • • CAT ruing Southern California jor Over 75 yjears TABLE OF CONTENTS BILL OF MATERIAL PSA 2. DIMENSIONAL DRAWING 1327-B-1 3. ISOLATOR LAYOUT PLAN 1327-B-1A 4. SPECIFICATION SHEET 1750ekW 5. GEN SET ENGINE PERFORMANCE DM4502-02 6. SYSTEMS DATA 197-9039 7. JACKET WATER HEATERS KIM 8. PRELUBE PUMP 2N7613 9. RADIATOR YOUNG/TOUCHSTONE 10. HP & HEAT REJECTION VERIFICATIONS PSA 11. FUEL COOLER YOUNG 12. FUEL WATER SEPARATOR DAHL 13. ELECTRONIC INSTRUMENT PANEL 3500B 14. PRCM DESCRIPTION GAT 15. ELECTRONIC CONTROL MODULE (GOVERNOR) ADEM II 11). LOAD SHARING MODULE WOODWARD 17. GENERATOR SPEC. SHEET (SR4B) 820 18. GENERATOR DATA GKN401-11 19. DIGITAL VOLTAGE REGULATOR SPEC SHEET D.V.R. 20. FUEL DAYTANK SIMPLX 21. EXHAUST SILENCER NELSON 22. EXHAUST FLEX CONNECTOR DME 23. BATTERY CHARGER (A46) LAMARCHE 24. BATTERIES CAT 25. BATTERY BOX 7418-06 26. VIBRATION SPRING ISOLATORS (GENX) CALDYN 27. CRANKCASE VENT FILTER RACOR 28. PARTS & SERVICE STATEMENT PSA 29. STANDARD WARRANTY LEDX8496 5 YEAR EXTENDED SERVICE COVERAGE ESC LOADBANK LOADTEC 32. 4-20Ma TRANSDUCERS FOR SCADA INTERFACE TX1502 / PXMS • BILL of MATERIAL (1) New Caterpillar Model 3516B DITA Diesel Generator Sets rated 1750 kW standby, 480 Volt, customized to match existing where possible; exceptions and accessories as noted below: 10-second auto start and 100% block loading capability (2) 2500 watt, 120 volt Jacket Water Heaters with 120-140 degrees F thermostats and Oil Pressure disconnect; 120VAC continuous duty pre -tube pump Touchstone Model FR73FX radiator with special fan, skid mounted; note: dual circuit to support EPA/SCAQMD approved gen set — higher air flow and sound than previous units Dahl 300MFV3, triple unit fuel water separator with manifolds and valves; fuel priming pump; flex fuel lines; fuel oil cooler installed and pre -plumbed Lube oil drain valve and extension; initial fill of lube oil Dual starters Caterpillar electronic instrument panel and control module with all gages and protective devices as required to interface with the paralleling switchgear; Programmable Relay Control Module for mounting in the gear ADEM II governor with Woodward Load share module to maintain specified performance Caterpillar SR4B generator, form wound with VPI, 105 degree rise, permanent magnet exciter, single -bearing with certified test reports; new part #, but fully compatible with existing units Caterpillar Digital Voltage Regulator with KVAR/pf controller feature. Simplex Daytank System with features to match existing Nelson 400 series Exhaust silencer with drain fitting; Stainless Steel Flex with slip flange Initial fill of 30% Caterpillar antifreeze, 70% distilled water • LaMarche battery charger with 30 Amp output, low battery voltage and ac failure relays; 24- hour automatic timer for equalize; Batteries for minimum 90 seconds cranking at 25-120 degrees F; Battery Boxes with integral seismic anchoring bracket CalDyn GENXG series vibration spring isolators with 3" deflection springs, integral seismic restraints, sized to comply with seismic zone 4 and OSHPD codes Per Drawing E1.2, oil vapor recovery system (Racor CCV) to match existing is included Testing at PSA's plant including 6 hour load test at 0.8 pf (warmup + 4 hrs at 1750kW Jobsite startup and 4 hour loadtest (NFPA110 testing, if required, to be run concurrent) 5-year warranty Filter replacement following acceptance testing; spare filters for oil and fuel to be supplied (new style do not match existing) No jobsite Fuel is included Operator training & Operation and Maintenance manuals — video taping by others Tech rep assistance for system testing at 4-6 week intervals after acceptance Seismic zone 4 anchoring calculations (submitted separately) Preventive maintenance contract 750 kW radiator mounted loadbank and field modification of existing controller to add required lights/switches Certified Equipment permits and SCAQMD coordination 4-20mA transducers for Water Temperature, Exhaust Temperature and Oil Pressure for interface with SCADA; existing units will have Exhaust Temp transducers added, and water di temp upgraded to match new le Portable Loadbanks for testing and acceptance, duration as specified Coordination with switchgear manufacturer to ensure full compatibility • Specification Section 16230A • • • • conipc Aa"c-E eo.vz/2rnfrr /oA' con-/cE/E % cL-ZvlS 3//0/0 3 PART 1-GENERAL HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 SECTION 16230A (PRE -PURCHASE) DIESEL ENGINE -GENERATORS 1.01 CONDITIONS OF THE CONTRACT A. Work under this section shall conform to applicable requirements of Section 16100. 1.02 SCOPE A. Fumish, start-up and test one (1) diesel engine generators complete with safety devices, day tanks, exhaust mufflers, radiators, govemors, govemor controls, voltage regulator equipments, electric start motors, battery console with battery and charger, piping, load banks, connections and all other accessories and appurtenances to result in a complete and operating plant. Diesel/generator shall be a match and lineup with the existing. PART 2 - MATERIALS 2.01 DIESEL ENGINE GENERATOR A. The diesel engine generator shall be rated for stand-by duty. Stand-by duty rating is the output that the unit shall produce for the duration of a utility power outage without producing injurious levels of heat or mechanical stress in the engine or generator. The duration of any outage can not be anticipated to any specific period of time and may be hours, days or weeks. Upon failure of a normal source of power, the diesel engine generators shall receive a starting signal and shall start and obtain rated voltage and frequency within ten (10) seconds, starting and stopping sequence can be initiated manually or automatically by closing and opening of a contact. The set shall immediately shut down in the event of overspeed, low oil pressure, high water temperature and overcrank. Cause of shutdown shall be. indicated by a light annunciator. System logic shall prevent restart until fault is cleared. There shall be a provision on the engine for an electric shutdown in the event of an emergency. Each generator set shall be capable of paralleling manually and automatically to the system bus. Appropriate monitors and safety devices will be included to provide system protection while paralleling and operating on the system bus. Automatic operation shall include control devices to compare and adjust oncoming units to frequency and phase of system bus, sense matching within acceptable limits, and signal closure of the circuit breaker. Control circuits shall prevent more than one circuit breaker for simultaneously closing onto a dead bus. Load sensing circuits shall compare system requirements with on -bus generator capacity. Generator set will automatically be added and removed from the bus according to system load DEMAND. The engine generator system shall be capable of 100% block loading for emergency healthcare applications. Compliance Confirmation DEVIhTE- EXACT m/tTtµ RIOT AvAicif 17LE: UN iT wrcc 8E rut-Ly comPATI8LE w/T'-j EX/ST/uG ec pLy 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A -1 • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 B. The complete power generation system, including engine, generator, and radiator shall be provided by one manufacturer who has been regularly engaged in the production of complete generating systems for at least twenty (25) years. All components shall have been designed to achieve optimum physical and performance compatibility and prototype tested to prove integrated design capability. The manufacturer must have at least five (5) years product experience after installation, at a minimum of five (5) job sites within Orange or Los Angeles County, with its cataloged, standard production, 1750 KW rating generator sets. Any exceptions or variations must be noted. The responsibility for performance to this specification shall not be divided among individual component manufacturers, but must be assumed solely by the primary manufacturer. This includes generating system design, manufacture, test, and having a local supplier responsible for service, parts, and warranty for the total system. The local engine generator set supplier shall have the single source responsibility. C. The diesel engine shall be as manufactured by Caterpillar. The Caterpillar engine generator set shall be model 351.6,TA jSeries B . The engine shall be a four-cycle design, liquid cooled;) rpm, V-type, Tyr ry exhaust manifolds. It shall have 16 cylinders with minimum displacement of 4,210 cu. in. and be manufactured in the United States. Maximum catalog fuel consumption at full 1750 KW load shall be no more than 117 gaVhr with maximum NOx emissions at 9.0 g/bhp/hr. Compliance Confirmation Cc»'PL. y The design of the basic engine shall provide for maximum structural integrity to extend service life. Materials used in the engine shall incorporate the highest level of proven metallurgical and manufacturing technology. Block shall be of one piece design and cast of high tensile strength iron in the system manufacturer's own foundry. Multiple blocks, multiple crankshafts, and block counterboring for cylinder liners shall not be permitted. Crankshaft shall be a one piece forging with regrindable wear surfaces hardened through heat treat methods. Cylinder wear surfaces shall be induction hardened over their entire length. Main and rod bearings shall consist of aluminum bonded by copper to a steel backing. The wear surface shall be coated with a lead -tin overlay and the bearing covered by a tin flashing. Connecting rods shall be high strength steel with tapered pin bore. Drilled passages to supply oil from rod bearing for piston cooling and lubricating oil will not be permitted. Pistons shall be a lightweight aluminum alloy which is elliptically ground across the skirt and tapered from crown to skirt. Compression rings in steel piston crowns shall seat in hardened steel grooves. Oil jets shall DIESEL ENGINE -GENERATOR 7/30102 SECTION 16230A - 2 Delta 10 Miscellaneous Revisions HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 supply piston cooling and lubricating oil. Valves shall be hard -faced with replaceable inserts. D. , The diesel engine horsepower rating shall be based on operating at synchronous rpm with all necessary operating accessories at 105 degrees F ambient temperature and 2500 feet elevation. The diesel engine manufacturer shall furnish certified curves, prior to ordering of equipment, which certify the diesel engine and generator of model and series to be fumished will produce not less than 1750 kW for standby continuous duty at synchronous rpm at 105 degrees F ambient temperature and 2500 feet elevation. The engine shall be capable of starting cold solely from the heat of compression and shall operate on #2 fuel oil (ASTM D396). Two 120 VAC jacket water heaters (2500 watts each), manufactured by Kim Hotstart Manufacturing Company, shall be fumished and installed in the jacket water bypass and shall be of ample capacity to automatically maintain water temperature on the engine between 120-140 degrees F. Heaters shall be installed using isolation valves. The engine shall be provided with a 120 VAC pre -lubrication pump which shall automatically circulate lubricating oil when the engine is not operating. • E. The diesel engine shall be water cooled and shall be provided with a cooler pump capable of providing full coolant flow to the radiator. The pump shall be an integral part of the engine and shall be driven by an engine shaft power train. The radiator shall be skid mounted on the front of the engine and shall include all required fittings and shrouds. Radiator shall be Young Model MWC-456E with special fans for 55, 534 ACFM with 1.5" water column restriction, 10,000 FPM tip speed for sound ratings as listed in the specification. F. The engine fuel system shall have duplex fuel filters with replaceable element conveniently located in one accessible housing mounted before the fuel injection pumps so that fuel shall be thoroughly filtered before it reaches the pumps. Fitter elements shall be located so that the elements can be easily removed without disturbing fuel line connections, fuel pumps or any other part of the engine. Provide Dahl 300 Fuel -Water separators. The diesel engine shall be equipped with a built-in gear type engine driven fuel transfer pump capable of lifting fuel and a fuel priming pump against a head of 12 feet. Provide radiator mounted fuel cooler complete with flexible fuel line connections. Dual DAHL 300MF manifolded to allow continuous engine operation during changeout and draining. Compliance Confirmation Corn? DEVIATE - moPEt. 03ScLETE. L,�Q(FEQ rzwi,iATog WITH SEPARf,TE AP E 2. co o l.E 2 Ci gat li Rr Qu' RED To mart A-QWI-1) RE(J4LATioas c o vtn 1' . G. The engine lubrication system shall be a pressure system supplying a continuous flow of lubricant under pressure to all moving parts. Circulation shall be by means of a positive displacement gear pump. The lubrication system shall include full flow oil filters and a series connected oil cooler of sufficient size to properly cool all lubricating oil circulated. All lubrication system equipment shall be installed and mounted on the engine complete with piping and automatic lubricating oil temperature control. The filter system shall be equipped with a spring loaded 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 3 I•• HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 bypass valve to prevent stoppage of lubricating oil circulation in the event that the oil filters become clogged. Provide a lube oil drain valve and extend the lube oil drain to the edge of the steel base H. The engine starting system shall consist of dual D.C. electric motors integrally mounted on the engine, equipped with a 24 vdc solenoid, an engine speed controlled motor disconnect, and auxiliary relays. The electric start system shall be capable of starting the engine in 10 seconds. The engine shall be equipped with one or more dry- type air cleaners. J. The engine shall be provided with protective devices to cause automatic shutdown in the event of low lubrication oil pressure, high water temperature, overspeed, and overcrank control panel function. Alarm contacts and transducers shall be provided on the engine for approach to high water temperature, low water temperature, approach to low lubricating oil pressure. All alarm and shutdown devices shall be connected to a terminal strip located in an accessible junction box mounted on the engine. • K. The engine shall be equipped with an instrument panel containing a water temperature gauge, an oil pressure gauge, a fuel pressure gauge, running time in hours and an engine tachometer. L. DIESEL FUEL SYSTEM WITH ELECTRONIC UNIT INJECTION The fuel system shall be integral with the engine. It shall consist of fuel filter, transfer pump, injection pumps, lines, and nozzles. The transfer pump shall deliver fuel under low pressure to individual injection pumps - one for each cylinder. A unit fuel injector shall be mounted in each cylinder head, with extemal feeder lines requiring less than 75 PSI fuel pressure Injection timing and duration shall be electronically controlled by a Caterpillar ADEM It Engine Control, with injection pressure accomplished by a piston pump driven from the engine camshaft. GOVERNOR CONTROL, ADEM II The engine control shall be a Caterpillar Advanced Diesel Engine Management (ADEM II), and shall control engine speed while optimizing both steady state and transient engine performance. The control will monitor all significant engine parameters, and adjust engine performance according to speed, altitude, temperature, after cooler temperature, and engine condition. It shall incorporate revisable control software capable of reconfiguring engine operation to desired performance. The engine control shall be configurated to avoid interruption of power whenever possible. In the event of system faults which do not require Compliance Confirmation Co PLY DIESEL ENGINE -GENERATOR 7130f02 SECTION 16230A-4 Delta 10 Miscellaneous Revisions • ( • M. HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 immediate shutdown, the engine shall be programmed to continue operation at power levels sufficient to remain within performance limits. It shall display real time and historical data to allow user to optimize operation and provide accurate service information in the event of a malfunction. Information shall be accessible through data link for remote monitoring, or through a RS 232 port. A data link failure shall not cause an interruption of engine operation. The control shall be compatible with CA) vn?LY Compliance Confirmation the Woodward digital load share module to allow isochronous load sharing between automatically paralleled generator sets. Engine goveming shall maintain steady state speed regulation of +/-0.25%, and be C ow\ e L V adjustable from a remote location. Speed droop shall be adjustable from 0 (isochronous) to 10% from no load to full rated load and share within 5% when paralleled with similarly equipped engines. Ramping to rated speed during startup shall be delayed until engine oil pressure is assured, with rate of acceleration controlled. During start-up and load changes, smoke shall be controlled electronically to minimum levels. GENERATOR: The generator (by Caterpillar/Kato) shall be a statically regulated, 2/3 pitch, controlled rectifier type and shall be equipped with a brushless exciter. The generator shall be rated 2187.5kVA, 1750kW at OM power factor, 480 volts A.C., 3 phase, 4 wire, 60 hertz, 105°C rise. The generator shall be a salient pole, rotating field design with amortisseur, cross - compensating windings designed for parallel operation. The stator frame shall be fabricated bar and plate steel construction. It is to be machined to tolerance to provide alignment with the rotor. Non -orientated, silicon steel laminations with core plated insulation on both sides shall be used to reduce core loss and temperature rise in the machine and to improve efficiency. The stacked laminations shall be skewed to reduce harmonic distortion caused by the slots, and held under pressure with clamping plates without welding on the laminations. Winding overhang on the stator shall be insulated between phases. Surge ropes shall be used to support the winding overhang. The windings shall be braced to withstand single phase and three phase fault conditions. All insulation materials used in the stator shall have a minimum temperature rating of Class 155 Degrees C (Class F) per IEEE Std 1. The coils shall be of a formed coil construction using a magnet wire meeting NEMA MW36-C specifications and shall not exhibit a temperature rise exceeding 105°C over 40°C ambient. cow,Pl-Y 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 5 ( • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 Tum-to-tum testing shall be performed on all stator windings per IEEE Std AA 522 prior to impregnation. A high -potential test shall be conducted on the stator prior to impregnation per IEEE Std 115. The complete stator shall be processed in a Vacuum Pressure Impregnation (VPI) chamber. Encapsulation of the stator shall be accomplished with a two-part epoxy system. The epoxy resin shall be held within a groundwall tape made of woven glass fabric with mica paper, which has a minimum of 16-25% resin and 450-600 volts/mil of Electrical Strength. The proper stoichiometric balance of the epoxy resin and hardener shall be accomplished during the VPI cycle. To ensure thorough penetration of resin into the windings, the vacuum pressure cycle shall be below 500 microns, and the air pressure cycle shall be greater than 90 psi. The final cured epoxy shall meet a Dissipation Factor of less than 0.1% in accord with ASTM D150, and a Water Absorption Factor of less than 0.05% in accord with ASTM D570. The rotor shall be of the fully laminated, salient pole type. Low resistance amortisseur bars shall be inserted through slots in the field poles and brazed/welded to a continuous shorting ring to complete the damping circuit. Cooling fans shall be an integral part of the rotor assembly. The rotor shall have accessible provisions for bolt -on balancing weights. All insulation material used in the rotor shall have a minimum temperature rating Class 155 Degrees C (Class F) per IEEE Std 1. The poles shall be of a layer would construction using a magnet wire meeting NEMA MW35-C or MW36-C specifications. of A high -potential test shall be conducted on the rotor prior to impregnation per IEEE Std 115. The complete winding and rotor pole assembly shall be processed in a Vacuum Pressure Impregnation (VPI) chamber. DIESEL ENGINE -GENERATOR SECTION 16230A - 6 C0v+'PL7 Compliance Confirmation Cowtpl,y Sow E Z-ERv\S brw PIto ?Ia crkei TO KP(TO. c%TS ?QEmlawn. `r cRW1 (Ail)" " G-EIJEILrTdC ,&ct.uvC r--EnTa.E. r/-t"A'r ptee- futJCT/6444., eoaiUALEtJ 2 7/30/02 Delta 10 Miscellaneous Revisions • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 Encapsulation of this assembly shall be accomplished with a thixotropic, single component epoxy resin. To ensure thorough penetration of resin into the windings, the vacuum pressure cycle shall be below 500 microns, and the air pressure cycle shall be greater than 90 psi. The final cured epoxy shall meet a Dissipation Factor of less than 1.8% in accord with ASTM D150, and a Water Absorption Factor of less than 0.13% in accord with ASTM D570. Compliance Confirmation The exciter shall be a high frequency, direct connected, rotating brushless type, three phase, full wave rectified, surge protected, and shall be matched with the generator rotor and control system. The rotating part of the exciter, including the rectifier assembly, shall rotate together C 0 w' Pt" 7 with the alternator rotor as a complete assembly on one shaft o 12 Orr Ifistt Both the armature and field windings shall be Vacuum Pressure Impregnated (VPI) cOU t1 with Epoxy resin. I The exciter leads shall be terminated at a terminal strip located in a secondary low voltage terminal box. The brushless exciter shall be compatible with the voltage regulator. The automatic voltage regulator shall be supplied with the altemator, with a complete solid state type Diode Failure Detection System to be manufactured by the generator manufacturer to provide system compatibility. Kato Engineering's permanent magnet altemator (PMA) type pilot exciter shall be included to provide power to the voltage regulator. The PMA shall rotate on the same shaft as the brushless exciter and altemator rotor. The stator winding shall be Vacuum Pressure Impregnated (VPI) with epoxy resin. The PMA stator shall electrically connect to the voltage regulator, and shall have the ability to provide a minimum 250% of rated three phase short circuit for ten seconds at the altemator terminals. 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 7 • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 N. The generator shall be provided with a voltage regulator and a paralleling accessory. This equipment shall be provided by the generator manufacturer and shall be shipped by the generator manufacturer to the switchgear manufacturer for installation, connection and testing in the switchgear plant. The voltage regulator and paralleling accessory shall be completely static and shall be correctly matched to the brushless exciter field current, voltage and power requirements. The generator, exciter, regulator and accessory package shall provide a steady state voltage regulation of plus or minus 2% of rated voltage. • • The voltage regulation shall apply to any change in load, from no load to rated load, at rated power factor and is defined as the change in the output voltage after all transients due to the load change have decayed to zero. With the generator initially at rated speed, rated voltage and no load, the sudden application of rated load at rated power factor, shall not cause a transient voltage deviation of more than 20% of rated. In addition, the output voltage shall recover to, and remain within, a band of plus or minus 5% of rated voltage in seven seconds or less. The voltage regulator shall be Kato Type Kc 760 or equal. O. The generator shall be a two bearing machine. The generator bearings shall be of the anti -fiction type selected to give long, trouble -free life. The bearing housing shall be designed to provide ample grease lubrication and to prevent leakage of lubricants. The bearing(s) shall be of a self aligning, regreasable, split, cylindrical roller bearing design. They shall be serviceable without any need to either move the altemator from the base or disconnect the coupling from the engine. P. The generator shaft shall be of ample size and strength to assure conservative torsional and transverse stresses and shall be made from high-grade machine steel or forged steel. The bearing joumals shall be machined to a dose tolerance. The generator shaft shall be connected to the diesel engine through a flexible disc coupling. Q. The generator cast or fabricated metallic parts shall be coated with a rust inhibiting primer as soon as the parts are produced before any rusting has occurred. Generator shaft extensions which are finished bright shall be given a generous coating of rust inhibiting slushing compound The slushing compound shall be removable with common solvents. The generator shall be given two (2) finish coats of paint to match the prime mover. C J.a'� Compliance Confirmation pEV iAct ..50*LE 6, 4wsrl�GJ GorvPi- co pLY DIESEL ENGINE -GENERATOR 7/30/02 SECTION 16230A - 8 Delta 10 Miscellaneous Revisions HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 R. Certified test reports shall be required. The tests shall consist of the following: 1. 1 2. Insulation resistance of all windings. 3. High potential on all windings. 4. Open circuit saturation. 5. Voltage balance on windings. 6. Current balance on windings. 7. Voltage transient at rated kVA (voltage regulation, stability, and response). 8. Regulator range test (voltage adjust). 9. Phase sequence. 10. Mechanical balance (vibration). 11. Inherent voltage regulation. 12. Circulating current. 13. Dissipation factor tests. Resistance of all windi The above tests shall be conducted in accordance with IEEE-115, NEMA MG-1 and MIL -STD 705 standards. Dissipation factor tests shall be performed per IEEE Std 286. The generator shall be provided with a drip -proof and oversized terminal box and shall meet the NEMA MG1 22 40 requirements for temperature rise. The generators shall be Kato Engineering or equal. 2.02 VAR POWER FACTOR CONTROLLERS, BASLER MODEL NO: SCR250G 2.03 DAY TANK A. General gs (cold). c0 vrPL „GAT co. eau lvto- Compliance Confirmation tom12/Y GA-1 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 9 • • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 1.0 General: Provide a packaged design fuel oil day tank for each prime mover. Day tank shall be complete in all respects in order to provide the prime mover with a reliable, local source of fuel. Day tank shall be for use with main tank and fuel delivery system described in order to provide an automatic, self -refilling fuel supply system. 1.1 The day tank shall be designed and supplied as an engineered system by the manufacturer. Each tank shall be of packaged design to include all inlet flow control devices, other valves, level controls, remote pump control, indicators, alarms and all other devices as required to form an integrated, functional system such that field installation is restricted largely to external piping, wiring and such intermediate devices that are required by the prime mover and to provide for external vents as per local codes and UL142, NFPA31 and NFPA37. 1.1.1 The system shall be for use with fuel oil as described by NFPA321, "Basic Classification of Flammable and Combustible Liquids". As defined by this standard, the fuel supply system shall be for use with "combustible liquids", those having a flash point at or above 100°F and future defined as class II or class 111 liquids. In no case shall a liquid defined as "flammable", or as "class I" or as having a flash point less than 100°F be used. In every case, the system shall not be used or applied at a temperature in excess of the flash point of the contents. Electrical equipment used in the system shall be in accordance with NFPA30, section 5-7, wherein it states "For areas where class II or class II liquids only are stored or handled at a temperature below their flash points, the electrical equipment may be installed in accordance with provisions of NFPA70, National Electric Code, for ordinary locations..." 1.1.2 The system shall be designed and installed in accordance with applicable sections of NFPA30, NFPA31, NFPA37, UL80 and UL142. The day tank shall bear the label of Underwriters Laboratories standard 142 and UL508. 1.1.3 Installation General: The day tank shall be installed adjacent to the prime mover, on the same grade. Install (as shown on the plan drawings, [as detailed herein]) on a housekeeping pad adjacent to the prime mover. Anchor tank to the pad. B. Day Tank Ratings 1.3.1 Capacity: 100 gallons. DIESEL ENGINE -GENERATOR SECTION 16230A -10 Delta 10 Miscellaneous Revisions co itYx ?L`( C vnfr C FYCS e xl 5T ING) Compli. nce Confirm. tion 7/30/02 • • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 1.3.2 Power requirements: 115V AC, 3-phase, 60 Hertz, 15A dedicated branch circuit. 1.3.3 Day tank construction. 1.3.3.1 All welded steel atmospheric tank of rectangular construction built in accordance with codes and standards noted above for indoor use with fuel oil. 1.3.3.2 Pipe thread connections shall be provided for. • Fuel oil supply from remote pump set, 1.0 inch. Supply to prime mover, 0.75 inch. Return from prime mover, 1.0 inch. Supply to overflow retum pump, 0.75 inc. Vent, 2.0 inch. Emergency vent, 4.0 inch. Drain, 0.75 inch, with drain valve. 1.3.3.3 An inspection port in the top shall be provided. 1.3.34 The tank shall be equipped with a welded steel channel base suitable for bolt attachment to a concrete pad. 1.3.3.5 The tank shall have interior corrosion protection consisting of an epoxy coating. 1.3.3.6 The exterior of the day tank shall receive a heavy duty industrial anti- corrosion coating and be finish painted. 1.3.3.7 All day tank system components shall be protected by a removable steel equipment cover. 1.3.3.8 Day tank shall be factory leak tested at 5PSI. 1.3.3.9 The tank shall be installed and anchored within a UL Listed steel containment dike/basin having a minimum capacity of 150% that of the day tank. The containment shall be equipped with a leak detector that shall activate the "rupture" alarm described below. A drain with ball valve is to be supplied. The containment shall be painted inside and out to match the day tank. The day tank system shall be painted to match the diesel generator. 7/30/02 Delta 10 Miscellaneous Revisions 11 eOW\?L? mfr-reme5 ExrST/�lr> Comp! :nce Confi =lion DIESEL ENGINE -GENERATOR SECTION 16230A - • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 C. Fuel Delivery System 1.4.1 The day tank shall be fed from a remote duplex pump set. 1.4.2 Provide the following inlet devices: Main inlet shutoff valve, 1.0 inch. • Inlet strainer, 1.0 inch. Main inlet solenoid valve, 100PSI rated, 0.75 inch brass body, viton qr tuna-n seal. Fuel solenoid wit manual pushbutton bypass. D. Day Tank Level Controller. A UL Listed, integrated design level controller package shall be supplied which provides differential level control for activation of remote pumps, tank level indication, system alarms and manual operating controls. Level controller shall be self-contained as a unit within a NEMA1 box mounted on top of the day tank. The controller shall utilize discrete level sensors and circuit paths for level alarms, primary pump control and backup pump control. Failure in one sensor or circuit path shall not necessarily disable the entire controller. All indicators are to be long life light emitting diodes. 1.5.1 The level controller shall provide the following control functions: 1.5.1.1 "Auto -off -manual' pump control mode switch. 1.5.1.2 "Press to test" pump push-button. 1.5.1.3 Pump start -stop automatic level control. 1.5.1.4. Pump overflow control backup Indication Functions 1.5.1.5 Fuel level. 1.5.1.6 Power available. 1.5.1.7 Switch not in auto. 1.5.1.8 Pump running. 1.5.1.9 Low level alarm. 1.5.1.10 High level. 1.5.1.11 Overflow alarm/pump control backup activated. DIESEL ENGINE -GENERATOR SECTION 16230A -12 3Y 01"HEte5 Co v^lL7 cmkrotel EXIST/NG) Com. lance Confi ation 7130/02 Delta 10 Miscellaneous Revisions l • ( • F. pump HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 1.5.1.12 Day Tank leak. Outputs 1.5.1.12 Remote pump lead pump start, lag pump start. 1.5.1.13 Low level alarm (60W) 1.5.1.14 High level alarm (60W) 1.5.1.15 Day Tank leak. CVW' PLy con or, cN.ES ` 1.5.2 The level controller shall have an intrinsic overflow cutout backup control which, upon sensing an overflow, will stop the pump, activate an alarm and cause the controller to revert to an emergency backup level control mode which allows the tank to continue operating automatically but which inhibits overflow. 1.6 Overflow -return pump: Provide a day tank mounted overflow -return with controller. 1.6.1 3/4 HP, 10GPM at 50 PSI at 1725 rpm, when operating with fuel oil having a viscosity of 50SSU. 1.6.2 Direct drive, motor driven pump coupled via flexible coupling. 1.6.3. Motors to be open drip proof construction, 3/4 HP, NEMA type B, continuous duty at 40°C, 1725 RPM, 115V AC, 3-phase, 60hertz, 1.15 service factor. 1.6.4 Pumps to be directly driven, positive displacement, intemal gear type with mechanical shaft seal. Pump shall be a high pressure, hydraulic type consisting of two intermeshing, hardened steel, precision ground gear assemblies enclosed by a high strength, die cast aluminum housing, hardened drive shaft, pressure load mechanical shaft seal. 1.6.5 Provide check valve on pump outlet. 1.6.6 Provide overflow-retum pump controller Arm pump at 70% day tank level. Activate pump at 95% day tank level and pump down to 70% level. Lock -out fill system when overflow -return pump is activated. Provide alarm when overflow-retum pump is activated. Provide test push-button, running and armed indicators. Corr ptiance Confirmation 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 13 • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 G. Provide a manufacturers five year parts, labor preventative maintenance warranty. All costs for parts, labor and preventative maintenance for 5 years shall be included in the bid. H. Day tank testing 1.8.1 The day tank shall be supplied with manufacturers test certificates as below. 1.8.1.1 Tank test: pressure test, leak proof test and structure integrity/appearance test. 1.8.1.2 Level controller, operational test with liquid of level sensors, level indicator, level control, alarms, backup devices. 1.8.1.3 Pump: vacuum test, flow test, pressure test, leak proof test, ampere/voltage test, load test, overload test. Day tank manual 1.9.1 The day tank shall be supplied with an illustrated manufacturers manual which includes the following: 1.9.1.1 Registration certificate. 1.9.1.2 Glossary. 1.9.1.3 Equipment list. 1.9.1.4 Detailed description of operation. 1.9.1.5 Pump specifications. 1.9.1.6 Installation instructions. 1.9.1.7 Troubleshooting instructions. 1.9.1.8 Maintenance instructions. 1.9.1.9 Piping diagram. 1.9.1.10 Electrical drawings. Cow, PLY Comp ance Confi ation DIESEL ENGINE -GENERATOR 7/30/02 SECTION 16230A - 14 Delta 10 Miscellaneous Revisions HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 1.9.1.11 Exploded view parts drawing/parts list. 1.9.1.12 Dimensional drawing. 1.9.1.13 Warranty card. J. The day tank system, shall be designed and manufactured by a single supplier and be a standard product in serial production. The manufacturer shall have at least 10 years experience in the design and manufacturer of these products. This system shall be a Model SST-100 with the following options: X002 Delete standard pump & motor 015 Auxiliary hand pump, 20 gallons per 100 strokes 025 Manual fuel fill - 2" lockable 060 Fuel strainer on tank inlet 063 Vent cap shipped loose for installation by others 080c Solenoid valve for AC systems 087 or 088 Hand valve (specify size required) 190e Rupture basin 191 Rupture basin level alarm switch 192 Rupture basin hand drain valve 195a Rupture basin screen cover 390 Overflow retum pump & controller 410 10 GPM pump for overflow retum 800 3/4 HP motor, 11 Packaged Design Fuel Oil Day Tank as manufactured by Simplex, Inc., Springfield, Illinois, or approved equal by Pryco. Cuw.rL Cowrel.y CMrtTc(+ES EKL S-r LNG Compliance Confirmation 2.03 MUFFLER AND EXHAUST SYSTEM (No. required by engine type) A. Critical type silencers shall be fumished complete with a seamless flexible CO h^ PL'( connector. The silencer shall be a Nelsen 400 series with an inlet diameter £ m ierc e Cs matched to the flexible exhaust fitting outlet (18"). The silencer shall have EK 1 S T I NG) a side inlet and shall be suitable for mounting in a horizontal position. The silencer shall be fitted with a condensate drain on the bottom centerline 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 15 • • ( • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 adjacent to the exhaust outlet. The seamless flexible connector between the diesel engine exhaust outlet and the silencer inlet shall be stainless steel and shall be provided with an ANSI 125 pound drilled slip flange. A complete piping and installation diagram and performance curve shall be fumished prior to ordering equipment. The silencer and exhaust piping shall be insulated and painted with the manufacturer's recommended paint. High temperature insulation shall be provided in accordance with other Divisions of this specification. B. Engine Coolant. The radiator and the diesel engine cooling system shall be filled with a 30% solution of ethylene glycol and 70% distilled water to prevent freezing and rust formation. C. Battery System. The charger shall be suitable for an input voltage of 120 VAC, 60 hertz, 30 amps output and shall include a d.c. voltmeter, d.c. ammeter, indicator lights for float charge and high rate charge, float potentiometer, high rate potentiometer, a.c. and d.c fuses, a.c. failure alarm relay and a 24-hour automatic timer. The battery shall be 24VDC lead acid, sized for 90 seconds cranking in ambient range of 25-120°F. Batteries shall be mounted in seismic designed racks with necessary interconnecting cables provided. Batteries shall be Caterpillar or equal; charger. La March A46 or equal. Each battery system shall be housed in an enclosed and ventilated system. D. Provide Vibration Spring Isolators, Mason Industries Model SLF, static deflection of 3" when loaded with seismic retraints, quantity as required to meet seismic zone 4 codes and support equipment weight. Verify with certified seismic calcs. Coordinate with structural for final anchor supports. 2.05 MAXIMUM SPL FOR EMERGENCY GENERATOR EQUIPMENT A. Requirements All emergency generator equipment to be delivered to the project shall produce noise levels in compliance with all of the requirements of this specification. B. Applicable Standard DIESEL ENGINE -GENERATOR SECTION 16230A -16 CompL'( — A 2.A 14"- -g or &et.- S. Com1' Y �oyv.c'LY C. I/h f\YC t+ e S r KI s T1AJCa) 1)EVLMTION - 6Qu11/ALEu t3 Y Ar uYN c en A -Cc u-E S EXcsri#i DFVIkT10D — cuRs( NT ?Rpaucr -poE S mJ d r rotA-T zM STEc'D LeVEt,S Compliance Confirmation 7/30/02 Delta 10 Miscellaneous Revisions • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 All measurements shall be made and reported in complete compliance with the Field Method as described in the latest version of ANSI Standard S1.13 - Methods for the Measurements of Sound Pressure Levels, as well as other standards referred to in ANSI S1.13. C. Test Conditions The measurements shall be made with the equipment operating at its maximum design load. if a fan -cooled load bank is used to simulate a load, ensure that noise from the load bank cooling fan(s) does not contaminate the measurements. Mechanical noise (engine) and radiator fan noise must be measured separately from exhaust noise: the components which are not being measured should be isolated by the use of mufflers and/or sound enclosures (test details to be submitted to the Architect as noted in section below). D. Submittal The test results shall be certified by an independent testing agency and submitted to the architect. The test report shall include a complete description of the test conditions, measurement procedures and sample calculations. E. Specification The equipment shall produce octave band and A -weighted sound pressure levels that do not exceed the values given in the schedule below, when tested in accordance with the latest version of ANSI Standard S1.13. (When measuring noise levels, credit may not be taken for mitigation measures that are part of the project design): Maximum Sound Pressure Level (dB re. 2 x 104 Pascals) at distance shown A-wtd avg. Octave Band Center Frequency (Hz) 63 125 250 500 tk 2k 4k 8k Maximum mechanical noise (without radiator) at 3.2 feet 105 100 102 98 99 101 99 95 90 Maximum radiator fan (only) noise at 25 feet 66 78 74 69 63 60 58 52 45 Maximum exhaust noise at 4.9 feet with proposed muffler 72 76 69 70 67 64 65 66 67 7/30/02 Delta 10 Miscellaneous Revisions 17 "TES TIAIV- -0`( ~fees OTtvER.S E v t Al to tJ - St E -DATA 1ai 02l6MJk - cLti3mtT7Rt- A-,u'a A A-ClirD PA -Ai Fat 3Es r h✓MtaC GEl/ELS, DIESEL ENGINE -GENERATOR SECTION 16230A - (11 • • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 F. If equipment is submitted that does not conform to the acoustical specifications listed in the bid documents, the Vendor shall be responsible for all of the following costs for equipment submitted that exceeds the sound limitations listed in the specifications: 1) Additional - re -engineering of the project. (By the project engineers) 2) Additional architectural design changes. (By the project architect) 3) Additional acoustical design changes. (By the project acoustical consultant) 4) Additional modifications of the structure and all acoustical mitigation measures. 5) Additional regulatory agency approvals and fees. PART 3 - EXECUTION 3.01 The manufacturer of the diesel engine generator shall provide all of the equipment specified in this section of the specifications and shall be responsible for the coordination of the equipment to meet the requirements mechanically, thermally and electrically, of the system. The switchgear manufacturer is responsible for all electrical control systems and all interconnection diagrams for operation of the equipment specified herein. 3.02 The diesel engine generator shall be tested as a complete equipment at the manufacturers plant. The Engineer reserves the right to witness testing and requires a minimum of two weeks notice of the scheduled test. Three copies of certified test reports are required for approval before shipment of the diesel engine generator is authorized. The tests shall include testing of safety device actuating points in rpm, temperature, psi, etc., when the machine is tested at those limits. The tests shall include load testing at 25% full load for one hour, 50% full load for one hour, 100% full load for four hours where full load is defined as 1750 kilowatts at 0.8 power factor at synchronous rpm. Equipment parameters shall be recorded at ten minute intervals and shall include rpm, jacket water temperature, fuel consumption rate, oil pressure, volt, amperage, kilowatts and hertz. Compliance Confirmation DtV �kTicN - Eat IPmEA/T W/cc t;E Scj9PL(ED TO 14/ p-Tc h Ex? ST W G- 11-ND h+EE7" caR,er'u7 R6 &w ATl ows , PSR we cc AJOI A-SSU/nE /tpJ y COSTS Fog E/U 6- /N E6t/N G/ pre c r+STE e ru eitL 2E'uJog?: cor,PLY W(T(f EXCEP%/OAl S �S Aiorev !-rE2E/Ai CO1--r-t r "DEv (At lolU 3.03 After installation, the diesel engine generator manufacturer shall furnish all labor, F cL r s Byot44CRS material, equipment, load banks, connecting cables, instrumentation, fuel, and cofLT1ou REc5 accessories necessary to repeat the tests specified in paragraph 3.02. Correctable ge Pk I e• - deficiency or failure during this final test will require repeating the test. Deficient ON (-i rota PETiI DIESEL ENGINE -GENERATOR 7130102 Fq/�uRE... SECTION 16230A -18 Delta 10 Miscellaneous Revisions 5EE ceA)72,4x, 7/obi ON AI R K7 PA 6 3.04 3.05 HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 coMr"%UED fea vet - performance or major failure will constitute grounds for rejection of the G rr- S T P A- 66 installation. If rejected, the installation in its entirety shall be replaced. /00 j2EPLA4c Ent EN . Load banks shall be located for sound reduction per City of Newport Beach requirements. Load test paralleled system to 1750kVA for four hours on -site (To be a witness test). Demonstrate proper load sharing. The diesel generator supplier shall provide the 1750kW (unity power factor) load banks for the entire time necessary for testing of the paralleling switchgear and owner acceptance of proper load sharing. This will be operatedinparallel with site (4) - 750kW load banks. Warranty entire system for five years from jobsite owner's acceptance for all parts and labor. Base bid shall include all required service and parts for manufacturers recommended maintenance for 5 years. Compliance Confirmation CorrlY hS Cct7YEMuIJai ntCArrS LIRKUwN� ckY 2 YEfit were_RkN! Y „csc.Q _o Sygs After final acceptance of the test results, all filters including air, oil and fuel shall be co w p replaced. All strainers shall be cleaned. After testing, the fuel oil storage tank shall be topped off by the contractor with the manufacturer's recommended fuel oil (provide altemate price for topping off with "amber" fuel to fill tank). 3.06 The diesel engine generator manufacturer shall provide three full days of operator training to the owner's personnel at the job site by a factory engineer. Video taping of this training shall also be provided and delivered to the owner with three copies of the operation and maintenance manuals in three-ring binders. 3.07 The battery enclosure and day tank assembly shall be painted to match the prime mover. 3.08 The battery assembly and day tank shall be rated and mounted to meet seismic zone 4 requirements. 3.09 Provide all required transducers or G.E. Fanuc "Genius Blocks" to meet the specified central monitoring system requirements. 3.10 3.11 3.12 Each engine to be equipped with dual water separators and valves. -3'- a -I- H Et S peltkT 10 IV - yv1 5 115 , • -red, i 13 y oti- claS LowInl-Y c-eLy _ luocurriu g 7 o-r lase s �owf1y GO.r, PLYkTc HES EX r STING' Each engine shall be equipped with a fuel cooler for fuel return to day tank. CO w. ? The diesel engine supplier shall supply all #2 diesel, low sulfur (sulfur not to exceed.05% by weight) free of moisture and meeting AQMD requirements for all testing and to top -off all day tanks and main fuel tanks subsequent to owner's acceptance. 7/30/02 DIESEL ENGINE -GENERATOR Delta 10 Miscellaneous Revisions SECTION 16230A - 19 -g `- DT H-as IS HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 3.13 The diesel generator supplier shall provide a technical representative on site every four weeks for six months after owner acceptance of the building (at the time designated by the owner) to assist the owner in his system testing. 3.14 The diesel generator supplier shall provide a complete inventory of spare parts including the following: Spare parts already provided in first phase. 3.15 Provide certification that equipment is braced to comply with seismic zone 4 requirements. 3.16 Manufacturer shall include a complete preventative maintenance, review and repair for all engines for 5 years. 3.17 covn?l-Y Compliance Confirmation Ctw-PL.,- 2ELTS, FILTER; THA-T /tti uiwqu6 WSLC. HAVE SPft2CS vecvivCD. c.aw-pcy covv..(Ly The radiator shall be manufactured by Young and shall be "oversize.' del 7i Ev iAT t oN desi ned to co 1 with the acoustical requirements for the roject Radiator shall have e�emai coo afP ^��raf -- �— co w. FLy 3.18 Each engine shall be equipped with a complete and operational integral 750kW unity power factor radiator mounted load bank. 3.19 SCAQMD RESPONSIBILITY A. It is the responsibility of the engine manufacturer to provide all the technical data required for the South Coast Air Quality management District (SCAQMD) application to construct and operate. This data shall be in the format indicated on application forms 400A & 400-E-13. B. To reduce the owners permit cost and to reduce application review time, engines that have certified equipment permits are preferred and copies of the permits shall accompany the bid. C. The engine generator supplier shall coordinate with the owner and submit all forms and associated support documents to SCAQMD and obtain all required approvals. All permit fees will be paid by the owner. The SCAQMD submission process shall be conducted on a schedule consistent with the project requirements and in coordination with the contractor and owner. 3.20 Manufacturer shall supply a list of previously installed engines and generators (combination as required by base bid) at the 1750kW rating. The list shall include engine model number, location, date of installation and references. -D EN, tPer ' QE[Lvn TTlurf B ( OTIt6(-S co r�7 DIESEL ENGINE -GENERATOR 7/30/02 SECTION 16230A - 20 Delta 10 Miscellaneous Revisions • I • HOAG MEMORIAL HOSPITAL PRESBYTERIAN EAST TOWER 1350.10 3.21 In addition to all required testing the 1750kW load bank shall be provided for (3) days of owner witness testing. If the tests fail the 3 day requirement shall be extended until all tests are successfully completed. 3.22 The diesel engine generator supplier shall coordinate with the "emergency power generator control and distribution switchgear" supplier during the bid process to insure full and complete compatibility of components and operation. 3.23 All coolant hoses shall match the currently installed hose types on the existing diesel generators. - eLy 3.24 After 6 months generator supplier shall retighten and torque all belts, supports, mountings, nuts, etc. - PLY 7/30/02 Delta 10 Miscellaneous Revisions 21 DIESEL ENGINE -GENERATOR SECTION 16230A - YoungTonchstone A Wabtec company POWER GENERATION STANDARD SIZING PROGRAM INPUT DATA Series Face System Core Type Area Type Split Model Number FR 73 F 67 Circuit 1 Motor Fan FPI #Rows #Pass HP Speed 2 4 1 30 H COOLING SYSTEM REQUIREMENTS Heat Rejection (Btu/min) Coolant Type Coolant Flow (gpm) Max Coolant Temp at is Number Inlet Conn. Inlet Diameter (in.) Number Outlet Conn. Outlet Diameter (in.) ( • Elevation (feet) Standard Guards? Additional Fan Static Application Circuit 2 FPI #Rows #Pass Custom 2 3 3 X Core #1 Core #2 39809 30/70 EG/W 400 Inlet Tank 210 2 3 1 5 24283 30/70 EG/W 153 Outlet Tank 150 1 3 1 3 GENERAL INFORMATION- 500 Yes (in. H2O) 1.00 PSA Hoag. Alt. #3 RATED MODEL PERFORMANCE 2/14/2003 9:19:09 AM AIR Max Inlet Temp (°F) = 117.0 Inlet Temp (°F) = 210.0 Outlet Temp (°F) of Core #1 = Core #2 = Static Restrictions (in H20) External 1.00 Frame Core #1 Core #2 Total 0.14 0.37 0.25 1.76 180.6 141.1 Outlet Temp (°F) = 197.3 Pressure Drops (psi) Tanks 0.69 Core 0.61 Total 1.30 COOLANT Core #1 Core #2 170.2 150.0 0.49 4.17 4.67 Limiting core No. 2 variance (°F) 4.9 Fan: Fan RPM: 585 Actual Fan HP: 27 Air Flow (ACFM): Series Description: FR - Fan on Radiator Overall Size Description: H over Tanks x uard verall Size: 126 x 113.61 x 56 62,118 W over Side Frames x D over Fan Shaft and Core • Mar 07 03 01:45p WARNER AIR, LLC NOISE 1 410 655-5970 p.3 NOISE CALCULATION CHART REM # 1 REFERENCE 0 FAN DIAMETER 96 HUB DIAMETER 2 NO. BLADES 6 ACFM 62118 BLADE WIDTH 13 STATIC PRESS 1.760 RPM 585 TIP SPEED 14703 N OCTAVE BANDS OVERALL 1 2 3 4 5 6 7 8 Mast a.no) (1-12) 63 125 250 500 1000 2000 4000 8000 e0v/ERcevo.(Ce) 117.6 SPECTRUM TAsC)+ -8.1 -8.1 -5.6 -9.6 -11.5 -15.5 -19.5 -36.5 POWER CeVtl. srstrRUM PWL (DB) 109.5 109.5 112.0 108.0 106.1 102.1 98.1 81.1 *A•WRWNr CORRRCTION -26 -16 -9 -3 0 1 1 -1 POWER LEVEL SRCInm OR(A) 110.9 83.5 93.5 103.0 105.0 106.1 103.1 99.1 80.1 OM=+ROi4ODCd, a uMr(rT) II 25.0 MUST FILL IN DISTANCE FROM EDGE OF UNIT ]ISTtORR(PRfM ANIS OP MN) 29.5 -27.4 -27.4 -27.4 -27.4 -27.4 -27.4. -27.4 -27.4 sn. mu 25.0 CROMEOGE OF UNIT' (F7) 83.5 56.1 66.1 75.6 77.6 78.7 75.7 71.7 52.7 D0306YT PRINTED 3/712003 • • Power Systems Associates CAT Heat Rejection Verifications Project: HOAG MEMORIAL Date: 3/11/03 Project Engineer: Dave Lewis Heat Rejection: (to jacket water) A -- HP Ht Rejection (BTU/min) 2523 2445.4 2268 C D A B 39809 Y 37022 --D D = C/AxB Y = 37022 +D Y = 38961 BTU/min Heat Rejection: (to aftercooler) A -- HP 2523 2445.4 B 2268 C D A B C-- Ht Rejection (BTU/min) 24283 Y 20928 D = C/A x B Y = 20928 +D Y = 23262 BTU/min --D Conclusions: Radiator sizing was based on Heat rejection figures that assumed a 50 hp fan; the resulting lower data gives a 2-4% additional safety margin PJ1327 note: data from CAT TMI, perfomance curve DM4502-02 use for "Core #1" use for "Core #2" Power Systems Associates CAT° Horsepower and Heat Rejection Verifications Project: HOAG MEMORIAL Date: 3/10/03 Project Engineer: Dave Lewis Horsepower: KW: 1750 Gen efficiency: 97 CAT Radiator HP: 27 Young Engine HP required: kW + Rad. HP .746 X Eff. HP calculation: 2445.4 Heat Rejection: (Engine to Atmosphere) A -- HP 2523 2445.4 B 2268 C D A B C-- Ht Rejection (BTU/min) 7564 Y D 7222 D = C/A x B Y = 7222 +D Y = 7460 BTU/min PJ1327 (was 33) note: data from CAT TMI, perfomance curve DM4502-02 Power Systems Associates CAI Ventilation Requirements (for Radiated Heat Only) or: Air -to -Core Temperature Rise Project: Hoag 3516E 1750 kW w/ FR73FX Radiator V (cfm) H (Btu/min) D (Ib/ft3) x Cp (Btu/deg F) x AT (degreesF) V (ventilating air) 62118 H (Heat Radiation) 10539.6 D (Density of Air at 100deg) 0.07 Cp (Specific Heat of Air) 0.24 AT(Assumed temp. rise) 10 1 alculate T: ¶or given V) T = 10.1 Calculate V: (for assumed T) V = 62736 H engine: 7460 from TMI H gen: 3080 calc from Efficiency H total: 10540 H gen Calc: kw 1750 efficiency 97.0 H gen: 3080 Conclusion: With Ambient spec of 105 and 10.1degree air -to -core rise, radiator needs to be sized for at least 115.1 degrees inlet temp. 117 degree rating gives approx. 2% additional safety margin. (assumes all losses go to heat) • Loadbank / Radiator Compatibility Statement: From: Dave Ballweg [dave@loadtec.com] Sent: Friday, March 07, 2003 4:26 PM To: Dave Lewis Cc: Cristina A. Partridge Subject: RE: LoadTec W0#220178; Hoag Hospital Dave: The submitted unit has the same internal resistor & control design as the original Hoag Hospital project. Since the original units are operating properly, and the new unit has a higher air volume then the original, the reasonable assumption is the this new unit will operate properly when all other variables are equal. If there are any questions or we can be of any assistance, please do not hesitate contacting us. Regards, David Ballweg LOADTEC - Load Technology TEL: 1-800-LOADTEC x24 1-800-562-3832 1-702-643-8750 x24 FAX: 1-702-643-8751 EMAIL: dave@loadtec.com Original Message From: Dave Lewis [mailto:dlewis@catpower.com] Sent: Friday, March 07, 2003 3:49 PM To: Dave Ballweg Cc: Cristina A. Partridge Subject: LoadTec W04220178; Hoag Hospital Dave, Our Radiator airflow has changed! It is still more than the original Hoag units(55600cfm), but need you to evaluate: Radiator -remains FR73 (basically 100" x 100" core area), but airflow is now 62,118 cfm. Please confirm that this will be adequate for the 750kW Loadbank. Thanks in advance, Dave Lewis L WIRES IN CONDUIT WITH 0 Z F J <ow < wQ o o KO m<yiw Q mQ 1- XU M W J6'W KZ O zwz 0 aF UQ� F Q0 o 0WM W Z 0 Wa0 to cc°✓1 K mu co-ao2 d wow dW woo a maw zo WQw m oaa >a Qi0 0 zmo =z DFw a 30Z ND i6z m. aA...Wo 2U NJU (~AO JW 4 FWm U mF oz EwzN ¢z 6 2MMZm- OF Um] QO ff7W J� -IOW W J Y oUl Jm Jwz UZ 0 ec J w O ti N J a O O 0 0 0 0 < 12 p Q 0 > 0 QED' < 0 Q 3 ZU N Z Kw w o ro J Z Za < w O 2 06 N H 0 OQ O ^a M 0 0 a 1 c ri 0 u 03 N CONDUIT CONNECTION POIN MAIN POWER & GROUND a d m J Le 120VAC TO CHARGER ffi J Ce¢¢o Wz 00 =U Fz Na m to o zo a mw <0 J 00 0 O 0 MN MECHANICAL CONNECTIONS: 1" N.P.T. FUEL INLET LINE 1" N.P.T. EXCESS FUEL RTN LINE 18" ASA EXHAUST OUTLET FLANGE O O O O O O O O O O PLAN VIEW 2 N 0 n 0 6rc gp ug Ci El �V r ad t g 3Lva Na5N3N "ON FRONT VIEW N bw= apt tl araw g Nu, o- Q �Citha 0 m N 274.70 0.A.L SIDE VIEW 1- V 0 0 a ni 0 J 0 en 0 F z a 9 0, m 11 O 11 A a- 0 a 0 m m N N N MATERIAL OESCRIP110N 0 z0 di.. as a. Z 0 0 0 S i wz Nro z c Z Q J 0 0 Q J 0 Q —J I H MVO NOISLA3N 'ON PLAN VIEW • CATERPILLAR® • • Image shown may not reflect actual package. FEATURES DIESEL GENERATOR SET STANDBY 1750 ekW 2187 kVA, 60 Hz 1800 rpm 440 Volts Caterpillar is leading the power generation marketplace with Power Solutions engineered to deliver unmatched flexibility, expandability, reliability, and cost-effectiveness. EMISSIONS • EPA and CARB Emissions Certified for non -road mobile applications UL 2200 • UL 2200 Listed configuration available FULL RANGE OF ATTACHMENTS • Wide range of bolt -on system expansion attachments, factory designed and tested ENCLOSURES (optional) • Weather protective and sound attenuated SINGLE -SOURCE SUPPLIER • Fully prototype tested with certified torsional vibration analysis available WORLDWIDE PRODUCT SUPPORT • Caterpillar® dealers provide extensive post sale support including maintenance and repair agreements • • Caterpillar dealers fill 99.7% of parts orders within 24 hours • Caterpillar dealers have over 1,844 dealer branch stores operating in 166 countries • The Cat Scheduled Oil Sampling (S•O•SSM ) program cost effectively detects internal engine component condition, even the presence of unwanted fluids and combustion by-products VAPA WHERE THE WORLD TURNS FOR POWER le CAT 3516E TA DIESEL ENGINE • Reliable, rugged, durable design • Field -proven in thousands of applications worldwide • Four -stroke -cycle diesel engine combines consistent performance and excellent fuel economy with minimum weight • UL 2200 Listed packages are available. Certain restrictions may apply. Consult with your Caterpillar dealer se CAT SR4B GENERATOR • Matched to the performance and output characteristics of Caterpillar engines • Optimum winding pitch for minimum total harmonic distortion and maximum efficiency • Single point access to accessory connections • UL 1446 recognized Class H insulation MICAT CONTROL PANELS • Controls designed to meet individual customer needs: - EMCP II+ offers full -featured power metering and protective relaying • UL 508A Listed ' CATERPILLAR® STANDBY 1750 ekW 2187 kVA 60 Hz 1800 rpm 440 Volts • FACTORY INSTALLED STANDARD & OPTIONAL EQUIPMENT System Standard Optional Air Inlet • Single element canister type air cleaner • Service indicator • Dual element & heavy duty air cleaners • Air inlet adapters & shutoff Cooling- ' Radiator with gvatd (43nt) o-- ty Coolant daairtli enivith valve " • Fan and beltguards " t a �%' Caterplllaec. ended Life42 olanta X ,� i CoolantJep l sensors'Nptylricluded with p re nhout radiators r r s �, - Radiator with 50°Cambient capability n RadlatotfiremdVel- Fteatexchangecand eXpansion tank r *di9to¢'r3uat fiarjge i 'sCodl#antleval„gwt gh gadge • ..aaaket water heatgt = • .+ 2 . ` , z , ,,x Exhaust • Dry exhaust manifold • Flanged faced outlets • Mufflers (15 dba) • Stainless steel exhaust flex fittings • Elbows, flanges, expanders & Y adapters fuel , - __. '" • Secondary fuel -filters - • Fuel pnming pump - x `t4' I Fle$ablr fuel liftas �, 3. : fuel epplery" NQt inctl-IderTwith paekaws it iuf radiators`'.,* Water separator. Du{il x fuel filter; Generator • Permanent magnet excited • Class H insulation • Class F temperature (1054C prime/130'C standby) • Reactive droop • Digital Voltage Regulator, 3-phase sensing • Bus bar connections • Winding temperature detectors • Anti -condensation space heaters • Digital Voltage Regulator with KVARIPF control • Bearing temperature detectors • Oversize & premium generators • Cable access box • European bus bars • Circuit breakers, UL listed, 3 pole with shunt trip (low & medium voltage only) • Circuit breakers, IEC compliant, 3-pole with shunt trip (low & medium voltage only) Governing- `-ADEM JI`-* '•"Load Share. module Control Panels • EMCP II+(package mounted, rear facing) • Customer Communication Module • Local alarm modules • Remote annunciator modules • Auto starting aid & switch" `Cannot be used with UL LIST Luba �.. Lgbricaling oil and filter i Oil drain line with valves Fume's` disposal - • Gear type ube oil pump �+ -toil level regulator i Deep sump o]L pan -Electric & air pp`reWbe pumps - • Manual prelubewittl sump pump • Duptexoil,:fdterx c .. • .. .. 3' ;'. ?'O,il fe.(ietregulatdK - - Mounting • 330 mm (13 in) structural steel rails • Spring -type, anti -vibration mounts (shipped loose) • Isolator removal Starting/Charging ' •24 voltstartirig,motor(s) • i• 45 amp charging alternator Battene&.with rack and cables -; Battery disconnect switch r , Batt ry chafger4 tinmp:' Oversrze batteiie5 Etherstarting a)ds Heavy duty starting motors 4,Bagnrig device (fiarlual) • Airstarfing motor with control & silencer General • Right-hand service • Paint - Caterpillar Yellow except rails and radiators gloss black • SAE standard rotation • Flywheel and flywheel housing - SAE Na 00 • Enclosures • Front stub shaft • CSA certification • EU Certificate of Conformance "Note _:. .. Standard and optional equipment may vary for tfli' 2200 Listed Packages. UL 2200 Listed packages may have oversized generators with a different .; = s` ' teniperattire riseand motor starting characteristics _ k •- ?-" 2 19 November 2002 4:13 PM CATERPILLAR* vir SPECIFICATIONS CAT GENERATOR SR4B Generator Excitation Permanent Magnet Pitch D.6666 Number of poles 4 Number of bearings Single Bearing Insulation UL 1446 Recognized Class H with tropicalization and antiabrasion IP rating Drip Proof IP22 Alignment Pilot Shaft Overspeed capability - % of rated - 150 Wave form Less than 5% deviation Paralleling kit/Droop transformer Standard Voltage regulator.3 Phase sensing with selectible volts/Hz Voltage regulation Less than +/- 1/2% (steady state) Less than +/- 1% (no load to full load) Telephone Influence Factor Less than 50 Harmonic Distortion Less than 5% STANDBY 1750 ekW 2187 kVA 60 Hz 1800 rpm 440 Volts lei CAT DIESEL ENGINE 3516B TA, V-16, 4-stroke-cycle watercooled diesel Bore - mm 170.00 mm (6.69 in) Stroke - mm 190.00 mm (7.48 in) Displacement - L 69.06 L (4214.04 cu. in) Compression ratio 14.0 TO 1 Aspiration TA Fuel system Direct unit injection oo 0 CAT CONTROL PANELS • EMCP II+ - 24 Volt DC Control • NEMA 12, IP44 enclosure • Electronically dead front • Lockable hinged door • Generator instruments meet ANSI C-39-1 • Generator terminal box mounted • Single location for customer connection - UL508A Listed • Panel illuminating lights • Auto start/stop control • True RMS metering, 3-phase • Digital indications for: - RPM - Operating hours - Oil pressure - Coolant temperature - System DC volts - L-L volts, L-N volts, Phase amps, Hz - ekW, kVA, kVAR, kWhr, %kW, PF • Shutdowns with indicating lights for: - Low oil pressure - High coolant temperature - Low coolant level - Overspeed - Emergency stop - Failure to start (overcrank) • Programmable protective relaying functions: - Under and over voltage - Under and over frequency - Reverse power - Overcurrent (phase and total) • Programmable kW level relay • 3 spare indicator LED's (programmable) • 4 spare alarm/shutdown inputs 3 19 November 2002 4:13 PM • • CATERPILLAR® TMI - GEN SET ENGINE PERFORMANCE DATE: 11/19/02 3516B DITA SCAC DRY MANIFOLD TURBO QTY: 4 PARALLEL ADEM GOV DM4502-02 STANDBY GEN 1810.0 EKW @ 1800 RPM W/O FAN 60 HERTZ A/C TEMP: DEG F 140 CERTIFICATION YEAR 2000 CERT AGENCY EPA - GENERAL PERFORMANCE DATA * * * * * * * * * * * * * * * * * * * GEN PER ENG ENG S FUEL FUEL INTAKE EXHAUST PWR CENT PWR BMEP CONSUM RATE MANF T MANF P AIR FL MANF T STK T GAS FL EKW LOAD BHP P5I LB/BHP-BR GPH DEG F IN-HG CFM DEG F DEG F CFM 1810 100 2523 264 .333 119.9 175 71.8 5725 1094 800 13949 1629 90 2268 237 - .335 108.6 170 65.2 5396 1054 776 12900 1448 80 2014 210 .340 97.8 167 58.7 5061 1019 759 11915 1357 75 1888 197 .342 92.4 165 54.7 4842 1003 755 11375 1267 70 1762 184 .345 86.8 163 50.4 4605 986 752 10806 1086 60 1511 158 .350 75.6 158 41.9 4132 953 745 9634 905 50 1261 132 .357 64.3 154 33.4 3655 917 737 8408 724 40 1016 106 .366 53.1 151 25.2 3185 864 715 7176 543 30 768 80 .380 41.7 148 17.2 2712 794 680 5926 - HEAT REJECTION DATA * * * * * * * * * * * * * * * * * * * * * GEN PER REJ TO REJ TO REJ TO EXH RCOV FROM FROM WORK LHV HHV PWR CENT JW ATMOS EXH TO 350F OIL CLR AFT CLR ENERGY ENERGY ENERGY EKW LOAD BTU/MN BTU/MN BTU/MN BTU/MN BTU/MN BTU/MN BTU/MN BTU/MN BTU/MN 1810 100 39809 7564 95883 47884 12853 24283 106972 257734 274568 1629 90 37022 7222 87068 42596 11658 20928 96167 233167 248351 1448 .80 34236 6938 78594 38217 10521 17630 85419 209167 222816 1357 75 32814 6768 74329 36169 9895 16037 80073 197168 210077 1267 70 31392 6597 70121 34065 9327 14445 74727 185225 197282 1086 60 28378 6313 61704 29970 8132 11374 64092 161397 171918 905 50 25307 6028 53287 25876 6881 8474 53515 137568 146554 724 40 22009 5687 44757 21212 5687 5858 43107 113967 121417 543 30 18483 5346 35885 16208 4493 3469 32586 89854 95712 - SOUND (NOISE) DATA - EXHAUST @ 4.9 FEET * * * * * * * * * GEN PER OVERALL OBCF OBCF OBCF OBCF OBCF OBCF OBCF OBCF PWR CENT SOUND 63HZ 125HZ 250HZ 500HZ 1000HZ 2000HZ 4000HZ 8000HZ EKW LOAD DB(A) DB DB DB DB DB DB DB DB 1810 100 115 106 120 116 108 107 108 108 106 1629 90 114 105 119 115 107 106 107 107 105 1448 80 113 104 118 114 106 105 106 106 104 1357 75 113 103 118 114 106 104 106 105 103 1267 70 112 103 117 113 105 104 105 105 103 1086 60 111 101 116 112 104 103 104 104 102 905 50 110 100 115 111 103 101 103 103 101 724 40 _109 99 114 110 102 100 101 101 99 543 30 107 97, 112_ 108 100 99 100 100 98 PAGE 2 11/19/02 DM4502-02 STANDBY GEN 1810.0 EKW @ 1800 RPM W/O FAN 60 HERTZ - SOUND (NOISE) DATA - EXHAUST @ 22.9 FEET * * * * * * * * * GEN PER OVERALL OBCF OBCF OBCF OBCF OBCF OBCF OBCF OBCF PWR CENT SOUND 63HZ 125HZ 250HZ 500HZ 1000HZ 2000HZ 4000HZ 8000HZ EKW LOAD DB(A) DB DB DB DB DB DB DB - DB 1810 100 102 93 110 104 95 94 95 94 92 1629 90 101 92 109 103 95 93 94 93 91 1498 80 100 91 108 102 99 92 93 92 90 1357 75 99 91 107 102 93 91 92 92 89 1267 70 99 90 107 101 92 91 92 91 89 1086 60 - 98 89 106 100 91 90 90 90 88 905 50 97 88 105 99 90 89 89 89 86 724 40 95 87 103 97 89 87 88 88 85 543 30 94 85 102 96 87 86 86 86 84 - SOUND (NOISE) DATA - MECHANICAL @ 3.2 FEET * * * * * * * * * GEN PER OVERALL OBCF OBCF OBCF OBCF OBCF OBCF OBCF OBCF PWR CENT SOUND 63HZ 125HZ 250HZ 500HZ-1000HZ 2000HZ 4000HZ 8000HZ EKW LOAD DB(A) . DB DB DB DB DB DB DB DB 1810 100 105 92 100 . 101 99 100 101 99 103 1629 90 105 92 100 101 99 100 101 99 103 1448 80 105 92 100 101 99 100 101 99 103 1357 75 105 92 - 100 101 99 100 101 99 103 1267 70 105 92 100 101 99 100 101 99 103 1086 60 105 92 100 101 99 100 101 99 103 905 50 105 92 100 101 99 100 101 99 103 724 40 105 92 100 101 99 100 101 99 103 543 30 105 92 100 101 99 100 101 99 103 - SOUND (NOISE) DATA - MECHANICAL-@ 22.9 FEET * * * * * * * * * GEN PER OVERALL OBCF OBCF OBCF OBCF OBCF OBCF OBCF OBCF PWR CENT SOUND 63HZ 125HZ 250HZ 500HZ 1000HZ 2000HZ 4000HZ 8000HZ EKW LOAD DB(A) DB DB DB DB DB DB DB DB 1810 100 94 81 88 89 87 89 90 87 91 1629 90 94 - 81 88 89 87 89 90 87 91 1448 80 94 81 88 89 87 89 90 87 91 1357 75 94 81 88 89 87 89 90 87 91 1267 70 94 81 88 89 87 89 90 87 91 1086 60 94 81 88 89 87 89 90 87 91 905 50 94 81 88 89 87 89 90 87 91 724 40 94 81 88 89 87 89 90 87 91 543 30 94 81 88 89 87 89 90 87 91 • • PAGE 3 11/19/02 DM4502-02 STANDBY GEN 1810.0 EKW @ 1800 RPM W/O FAN 60 HERTZ - EMISSIONS DATA * * REFERENCE NOTES * * EMISSIONS DATA MEASUREMENT IS CONSISTENT WITH THOSE DESCRIBED IN EPA CFR 40 PART 89 SUBPART D & E AND ISO 8178-1 FOR MEASURING HC, CO, PM AND NOX. THIS ENGINE'S EXHAUST EMISSIONS ARE IN COMPLIANCE WITH THE FOLLOWING US EPA AND CALIFORNIA NONROAD REGULATIONS EXHAUST EMISSIONS LIMITS G/HP-HR HC CO NOX 1.0 8.5 6.9 PM .40 - EMISSIONS DATA * * * * * RATED SPEED * * * * STANDARD TIMING "NOMINAL DATA" 02 (DRY) GEN ENG NOX TOTAL PART IN EXH SMOKE BOSCH PWR % PWR (AS NO2) CO HC MATTER (VOL) OPAC SMOKE EKW LOAD BKW * *- * * * * * * G/HP-HR * * * * * * * % % NO. 1810.0 100 1881.5 7.59 .10 .13 .063 11.20 1.4 1.28 1357.5 75 1408.2 5.56 .15 .17 .084 12.10 1.8 1.28 905.0 50 940.7 4.98 .28 .20 .107 12.80 2.5 1.28 452.5 25 478.8 5.24 .58 .28 .140 14.20 2.0 1.28 AT RATED: WET EXHAUST MASS 26015 LB/HR WET EXHAUST FLOW ( 800 DEG F STACK TEMP ) 13956 CFM WET EXHAUST FLOW RATE ( 32 DEG F AND 29.98 IN HG )5446 STD CFM DRY EXHAUST FLOW RATE ( 32 DEG F AND 29.98 IN HG )5018 STD CFM FUEL FLOW RATE 119.4 GAL/HR - ALTITUDE CAPABILITY DATA * * * * * * * * * * * * * * * * * * AMBIENT OPERATING TEMPERATURE DEG F => 50 68 86 104 122 NORMAL ALTITUDE --FT * * * * MAXIMUM SET GROSS ENGINE POWER - BHP * * * * 0 2535 2535 2535 2535 2535 2535 984 2535 2535 2535 2535 2535 2535 1640 2535 2535 2535 2535 2535 2535 3281 2535 2535 2535 2535 2535 2535 4921 2535 2535 2535 2535 2535 2535 6562 2535 2535 2535 2474 2398 2535 8202 2535 2484 2402 2325 2253 2535 9843 2414 2332 2256 2183 2115 2406 10499 2353 2273 2198 2128 2062 2358 • CAIERPILLAR® • SYSTEMS DATA SALES MODEL: 3516B DITA SCAC DATE: 11/19/02 EFFECTIVE SERIAL NO PREFIX: 1HZ ENGINE ARRANGEMENT NUMBER: 197-9039 AIR INTAKE LINE# 010 MAX 020 MAX SYSTEM ALLOW INTAKE RESTR W/CLEAN ELEMENT ALLOW INTAKE RESTR W/DIRTY ELEMENT COOLING SYSTEM LINE# 010 ENGINE ONLY COOLANT CAPACITY JW/AC 012 TOTAL.SYS COOLANT CAP W/ FR73 RAD: JW/AC 020 MAX ALLOW ENGINE COOLANT OUTLET TEMP 030 REGULATOR START -TO -OPEN TEMP 040 REGULATOR FULL OPENING TEMPERATURE 050 REGULATOR LOCATION ENGINE SPEC, SYSTEM ' LINE# 050 CYLINDER ARRANGEMENT 060 NUMBER OF CYLINDERS 075 CYLINDER BORE DIAMETER 095 PISTON STROKE 115 TOTAL CYLINDER DISPLACEMENT 130 COMPRESSION RATIO (TO ONE) 140 CRANKSHAFT ROTATION (FROM FLYWHEEL END) 160 CYLINDER FIRING ORDER 170 CYLINDER FIRING ORDER - CONTINUED 200 NUMBER 1 CYLINDER LOCATION EXHAUST SYSTEM LINE# 010 MAX ALLOWABLE SYSTEM BACK PRESSURE 012 MANIFOLD TYPE 020 MAX ALLOW STATIC WT ON EXHAUST CONN 030 MAX ALLOW STATIC BEND MOMENT ON EXH CONN FUEL SYSTEM LINE# 010 MAX FUEL FLOW TO TRANSFER PUMP (TO ENG) 020 MAX ALLOW FUEL SUPPLY LINE RESTRICTION 025 MAX ALLOW FUEL TEMP AT TRANSFER PUMP IN 027 MAX FUEL FLOW TO RETURN LINE (FROM ENG) 030 MAX ALLOW FUEL RETURN LINE RESTR 040 NORMAL FUEL PRESSURE -CLEAN SYSTEM 050 FUEL SYSTEM TYPE 061 MAX TER PUMP PRMG LIFT W/O PRMG PUMP 10 IN WTR 25 IN WTR 54 / 7.4 GAL 142 / 94 GAL 210 DEG F 180 DEG F 198 DEG F OUTLET VEE 16 CYL 6.69 IN 7.48 IN 4214 CU IN 14.0 TO 1 STD - 1-2-5-6-3-4-9-10-15- 16-11-12-13-14-7-8 R FRONT 27 IN WTR DRY 62 LB 31 FT LB 332.9 GPH 8.9 IN HG 151 DEG F 322.3 GPH 8.0 IN HG 60.2 PSI EUI 12.1 FT FUEL PAGE 2 SYSTEMS DATA 197-9039 LURE SYSTEM LINE# 025 RECOMMENDED OIL TYPE - API CF-4 090 OIL FILTER TYPE FULL FLOW 100 LURE SYSTEM OIL COOLER TYPE BUNDLE 150 MAXIMUM ALLOWABLE OIL TEMP - NAV 160 NOM OIL PRESS W/SAE 10W30 OIL @ 99 DEG C. 65.0 PSI 170 MIN LI OP W/SAE 10W30 OIL @ 99 DEG C 55.0 PSI 500 CAPACITY W/ FILTER CHANGE 106 GAL MOUNTING SYSTEM LINE# 031 C/G LOC - X DIMEN - FRM REAR FACE OF BLK 47.2441 IN 040 CENTER OF GRAVITY LOCATION Y DIMENSION 7.9528 IN 050 CENTER OF GRAVITY LOCATION Z DIMENSION .1969 IN 090 FLYWHEEL HOUSING SIZE -SAE NUMBER 00 130 MASS MOMENT OF INERTIA - X AXIS - 10620.888 LB IN SEC2 140 MASS MOMENT OF INERTIA - Y AXIS 123910.360 LB IN SEC2 150 MASS MOMENT OF INERTIA - Z AXIS 132761.100 LB IN SEC2 ° STARTING SYSTEM', LINE# 010 MIN CRANKING SPD REQUIRED FOR START -RPM 020 LOWEST AMBIENT START TEMP W/O AIDS 060 REC BAT CAP 24V 10W30 ABOVE 0 DEG C 120 RPM 50 DEG F 1300 CCA New Part Number Old Part Number Volts Phase Watts Amps Fig. No. CD 1101 XX-000 CD1102XX-000 CB1151XX-000 CB1158XX-000 CB1152XX-000 CB1157XX-000 WE1154XX-000 ASP 110/KSP_ ASP220/KSP_ LBSP110/KSP_ LBSP208/KSP_ LBSP220/KSP_ LBSP277/KSP_ LBSP440/KSP_ 120 240 120 208 240 277 480 1 1 1000 1000 1500 1500 1500 1500 1500 8.4 4.2 12.5 7.2 6.3 5.4 3.2 2 2 2 2 4 CB1201XX-000 CB1208XX-000 CB1202XX-000 WE1204XX-000 CB1251XX-000 CB1258XX-000 CB1252XX-000 CB1257XX-000 WE1254XX-000 MBSP110/KSP_ MBSP208/KSP_ MBSP220/KSP_ MBSP440/KSP_ BCSP110/KS.P_ BCSP208/KSP_ BCSP220/KSP_ BCSP277/KSP_ BCSP440/KSP_ 120 208 240 480 120 208 240 277 480 1 1 1 1 1 1 1 1 1 2000 2000 2000 2000 2500 2500 2500 2500 2500 16.7 9.6 8.3 4.2 20.8 12.0 10.4 9.0 5.2 2 2 2 4 2 2 2 2 4 FIGURE 1 u.10 a.n-� '-FIGURE 3 CE1301XX-000 CE1308XX-000 CE1302XX-000 CE1307XX-000 W E1304XX-000 DSP110/KSP_ DSP208/KSP DSP220/KSP_ DSP277/KSP_ DSP440/KSP_ 120 208 240 277 480 3000 3000 3000 3000 3000 25.0 14.4 12.5 10.8 6.3 3 3 3 3 4 CE1408XX-000 CE1402XX-000 CE1407XX-000 WE1404XX-000 ESP208/KSP_ ESP220/KSP_ ESP277/KSP_ ESP440/KSP_ 208 240 277 480 4000 4000 4000 4000 19.2 16.7 14.4 8.3 3 3 3 4 W E1508XX-000 WE1502XX-000 WE1507XX-000 WE1504XX-000 1PSP50208/KSP_ 1 PSP50/KSP_ 1 PSP50277/KSP_ 1 PSP5044/KSP_ 208 240 277 480 1 1 1 1 5000 5000 5000 5000 24.0 20.8 18.1 10.4 4 4 4 4 4.90 571 NOTE: ALL MODELS ARE WEATHEBTIGHT 1 NOTE: QUANTITY = 2 I THERMOSTAT RANGE To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temperature Range 100° - 120° Catalog Number: Model CB1151XX-000 Order as: Model CB115110-000 TEMPERATURE RANGE NUMERICAL ON OFF CODE 60F 8OF y 100F 120F 8OF 100F 120F 140F 06 08 10 12 140F 160F 14 Page 9 Kim Hotstart Mfg. Co., Inc. P.O. Box 11245 Spokane, WA 99211-0245 (509) 534-6171 LUBRICATION SYSTEM 35 Q W u a a = or�< SSyy O II I II i dm ^f8?�B�madd cr jmagi %lira �1 L rrn 00 0 tY 1 E ord un. 4 4 4 4 4 4 2 4 4 4 5 0 N • m CY 0 0 4 0 4 2 m m O m 1, 6 0 01 00 6 0. 0 0 4 • CO CI 0 0 4. m 0 m 0 0 0 m 0 • 0 0 0 0 0 0 • a r. io au 0 r m 0: 00 00 oQ nm l0.69 l9'6S 19'44 l9'9Z ONN NoN 0 N0 (0 N0 01 CO CC 0 N 00'L 00 L9'tt 99.9t — L9'OZ 0S' Z9 O m 0- •do 00 oQ L SZ'Zl l '^m L9'49 Ym1N411 ma O f9'flt l9.96 /--Of'l 00' tn 4 Y, W Qy • 2 N O < LA• 0 a Z CZ 0. m O J a m m w w w 0 0 Z ^ N b 1 r 2 rc W 2 .4 0 40 Customer: Project name: Engine: Radiator: Max air temp @ fan: Air flow: Fan power: External static: Fan Sound level: Jacket water Heat load: Flow: Inlet Temp Press. Drop: Young Touchstone Company Radiator Data Sheet Power Systems Associates Hoag Hospital Cat 3516B rated 1750KW Young Touchstone model FR73FX 241 40S 243 120 degrees 70,850 ACFM 33 HP at 530 RPM 0.75 IWC 82.7 dB(a) at 25 feet Hz: 63 125 250 500 1000 2000 4000 8000 dBa: 55 65 75 77 77 75 71 52 39,809 BTU/Min 400 GPM , 210 degree 1.1 PSI Aftercooler Heat load: 24,283 BTU/Min Flow: 153 GPM Return Temp: 150 degrees Press. Drop: 3.7 PSI Based on 2500' elevation, 30% EG-water coolant mix Standard features: • "Flat -Round" premium solderless cores Optional features included: • MOC-6M fuel oil cooler 1 Power Systems Associates CAT Horsepower and Heat Rejection Verifications Project: HOAG MEMORIAL Date: 11/19/2002 Project Engineer: Dave Lewis Horsepower: KW: 1750 Gen efficiency: 97 CAT Radiator HP: 33 Young Engine HP required: kW +Rad. HP .746 X Eff. HP calculation: 2451.4 Heat Rejection: (to jacket water) A -- HP Ht Rejection (BTU/min) 2523 2452 2268 C _ D A B C-- 39809 Y 37022 --D D = C/AxB Y = 37022 +D Y = 39033 BTU/min PJ1327 note: data from CAT TMI, perfomance curve DM4502-02 Conclusion: Safety Margin for Hp required vs available, and Radiator sizing, is approx. 3% so' RADIATOR COMPANY FUEL COOLERS For SUPER MWC Radiators • Mounted in radiator plenum between fan and core • Fuel connections easily accessible • Two sizes, MOC-6M and MOC-8M • Heavy duty brazed steel tube -to -header construction • 2- pass for effective heat transfer • 4 week leadtime for SUPER MWC with mounted fuel cooler HEAT TRANSFER AND PRESSURE DROP Based on No. 2 diesel fuel entering at 150 F, and air entering at 120 F , , Model GPM 2 4 6 8 10 12 Moe-6M Btu/min* 290 350 400 440 470 490 A P(psi) 0.6 1.3 2.7 4.1 6.2 8.3 MOC-8M Btu/min* 380 490 550 600 645 680 A P(psi) 0.5 0.9 1.8 2.8 4.3 5.5 * For MWC- XQ models, reduce Btu min by 10%. YOUNG RADIATOR COMPANY 2825 FOUR MILE ROAD RACINE, WI 53404 Form No. 3831 TELEPHONE: 414-639-1010 FAX: 414-639-1013 Diesel Fuel Filter/Water Separators Proven performers with operating flow rates from .5 to 1800 G.P.H. •per filter. Designed for trucking, marine, automotive, agriculture, mining, construction, and railroad applications. • re MODEL 100 Flow Rate: 40 G.P.H. (la complete speciltcallons —see page el APPLICATIONS: • Small diesel engines up to approximately 200 H.P. (except Cummins and Detroit) • Automobiles and Pick -Ups • Small pleasure crafts and sailboats • Caterpillar engines through 3300 Series • Small generators and farm tractors • Refrigeration units dtrilb MODEL 200 Flow Rate: 120 G.P.H. liarcompiele specifications— see page a) APPLICATIONS: • All Cummins and Detroit engines up to 8 cyl. • Caterpillar engines up to approximately 1000 H.P. (including 399) • All other medium size diesel engines up to approximately 1000 H.P. • Trucks, buses, construction and agricultural equipment • Smaller commercial boats • Medium size generators a MODEL 300 Flow Rate: 180 G.P.H. par complete specifications —see page 8) APPLICATIONS: • Cummins and Detroit engines . 12 & 16 cyl. • EMD & ALCO engines up to 2000 H.P. • Locomotives • Large stationary engines. boats and generators • Any applications with 812 fuel line (.610' LD.) Manifold Units DAHL's manifold units are designed for larger capacity diesel engines requiring more than one unit. For conditions requiring continuous operation, dual units with manifold and valves are also available. MODEL 200MFV (2 units wlmanifold & valves for continuous operation) Max. Flow Rate: 240 G.P.H. (120 G.P.H. per unit) Port Size: a/=" NPT (pipe threads) ODEL 300MFV3: (NOT SHOWN) 40007/1\3 FILTERS WITH VALVES ALLOWS FOR CONTINUOUS 360GPH FLOW WITH TWO OF THREE UNITS ON LINE MODEL 300MF (2 units wlmanifold) Max. Flow Rate: 360 G.P.H. (180 G.P.H. per unit) (Port Size: 1" NPT (pipe threads) e lc MODEL 300MFV (2 units wlmanifold & valves for continuous operation) Max. Flow Rate: 360 G.P.H. (180 G.P.H. per unit) (Port Size: 1" NPT (pipe threads) • Systems Operation 3500B Electronic Instrument Panel '00000 00000 10 032142 11 trN 14 ' 15 16 35008 Electronic Instrument Panel (1) Electronic instrument panel. (2) Main display module. (31 Gauge cluster module. (6) "Scroll' switch. - (7) "Mode/cleat' switch. (8)"114(LH" switch. (10) Emergency stop push button. (11) Alarm. (12) Alarm silence switch. (14) Customer connector "D". (15) Customer connector "C" (16) Engine control switch. For EPG packages with switchgear conversion and all other engine applications, the 35008 Electronic Instrument Panel is the control and information center for the engine system. The electronic instrument panel houses the 35008 instrument modules, the engine control switch, emergency stop switch, instrument module control switches, alarm, alarm silence switch, various circuit breakers and wiring, and the customer interface connectors. 3500E Electronic Instrument Panel 4 Systems Operation • • Instrumentation There are a minimum of two standard configurations for the 3500B instrument modules. The standby EPG package with switchgear conversion will have two modules as standard, while the other EPG packages with switchgear conversion and all other engine applications will have three modules as standard with the option to add a fourth module and a pyrometer (4). The two modules included with every instrument box are the main display module (2) and gauge cluster module (3). The main display module (2) controls all the instruments and gauge cluster module (3) displays: • engine oil pressure • engine coolant temperature • system voltage • engine fuel pressure Applications other than standby EPG have a gauge cluster module (9) which displays: • right hand and left hand air inlet restriction • right hand and left hand exhaust temperature • fuel filter differential pressure • oil filter differential pressure STAfi'�87 EPG WI LC.. stow A3ovc VA CUCs%, [ N TN-E ID S pL A Y q- 2 G pr o F- 11÷ rnhiM DtSPLitt/ vies c D od-E Main Display Module Display 1 •c b. MI RN Met i1V11 SFMI in El 8 ELBA Pr D26919 Main Display Module Display (1) Alert indicators. (2) Display area. Engine Control Switch The engine control switch (ECS) (16) has four positions and is used to control the engine. 1. The "OFF/RESET" position removes power from the engine. 2. The "AUTO" position powers up the engine control module (ECM) and allows the ECM to monitor the status of the remote start/stop switch. When the ECS (16) is in the "AUTO" position a remote switch can be used to place the engine in three different states. The remote "OFF" position leaves the ECM powered up. • The ECM is in a power conserving mode where there is reduced power usage. The remote "COOLDOWN/STOP" position places the engine in cooldown mode (if programmed to cooldown) and then stops the engine. The remote "START/RUN" position places the engine in the cycle crank sequence and allows the engine to continue to run once it is, started. 3: The "MANUAL/START" position starts the engine cycle crank sequence and allows the engine to continue to run once it is started. 4. The "STOP" position places fhe engine in cooldown mode (if programmed to cooldown) and then shuts off the engine. NOTE: The customer remote start/stop switch, if equipped, is a switch that can be wired into the system through the customer connector "C" (15) to provide a method to remotely start and stop the engine. Emergency Stop Push Button The emergency stop push button (10) is used to bring the engine to a quick stop during emergency situations. The emergency stop push button (10) removes power from the ECM. NOTE: The customer remote shutdown switch, if equipped, is a switch that can be wired into the system through customer connector "C" (15). This switch will disable fuel injection. 3500E Electronic Instrument Panel 5 Systems Operation Description of the PRCM The Programmable Relay Control Module (PRCM) provides control of seven relays, six alarms, and two fault LED's for customer use. In addition, the PRCM can be programmed to control up to two Relay Driver Modules (RDM). Each RDM provides an additional nine relay outputs for a total of twenty-five relays. The PRCM receives information via a CAT data Zink from the Engine Control Module (ECM) and from eight switched inputs on the PRCM to control the outputs. Control of each relay (up to twenty-five) is programmable through a keypad and displayed on the PRCM. The PRCM always outputs the present state of the selected input, if available. If the communications between the PRCM and Engine Control Module (ECM) are disrupted, the PRCM can either output the last data received or reset the data. The data hold/reset option is selectable from the setpoint menu. The Caterpillar part number is located on the rear housing (as shown in the illustration). Programmable Relay Control Module (Front View) J 1 Programmable Relay Control Module (Rear View) (1) Location of part number. (2) 40-pin connector. (3) Relay module. Specifications Environmental • Ambient operating temperature range: -40 to +70°C (-40 to +158°F) • Storage temperature range: -40 to +85°C 7(-40 to +185°F). • Humidity: 0 to 100 percent relative humidity. • Resistant to salt spray, fuel, oil and oil additives, coolant, spray cleaning (steam, trisodium phosphate 10 percent solution), chlorinated solvents, hydrogen sulfide, methane gas and dust. Electrical • The operating voltage range is from 15 to 45 VDC. The RDM is designed to only operate when powered by 24 or 32 VDC battery systems. • The PRCM case is electrically isolated from its internal circuitry. • The PRCM is protected against reverse battery polarity. • All inputs and outputs are protected against shorts to + or - Battery. Exceptions to this are terminals 2, 13, and 14 on the relay module which are NOT fused and therefore are NOT protected from short circuits to + or - Battery. • The PRCM is capable of operating with or without an earth ground. • The PRCM must share common ground with the optional RDM modules and relay boards. Note: PRCM provides interface with Paralleling Switchgear for Generator Set Control and Alarm Monitoring. It ships loose and is installed in the Emergency Paralleling Switchgear by Russelectric. Programmable Relay Control Module • FEATURES RELIABLE, DURABLE All ADEM 1! controllers are designed to survive the harshest environments. • Environmentally sealed, die-cast aluminum housing isolates and protects electronic components from moisture and dirt contamination. • Rigorous vibration testing ensures product reliability and durability. • Accuracy maintained from -40° C to 120° C • Electrical noise immunity to 100 volts/meter • Internal circuits are designed to withstand shorts to +battery and -battery. SIMPLE SERVICING Each ADEM !l system works in combination with the Caterpillar ET service tool software to keep the engine operating at peak performance. • Displays measured parameters • Retrieves active and logged diagnostic codes • Retrieves logged event codes documenting abnormal system operation • Performs calibrations and diagnostic tests • Supports flash programming of new software into the ADEM II ECM 3500B GENERATOR SET ADEM II ECM The Advanced Diesel Engine Management (ADEM) control is the main Electronic Control Module (ECM) used on diesel engines. The ADEM control is designed to control/ interface Electronic Unit Injector (EUI) equipped engines. A 3500B ADEM engine system is composed of the ADEM ECM, control software, sensors, actuators, fuel injectors, and interface to the generator system. The prime benefit of a 3500E ADEM engine system is to better control and maintain the particulate emissions, both steady state and transient, while improving engine performance over the Mechanical Unit Injector (MUI) engines. SELF DIAGNOSTICS Each ADEM 11 ECM has a full compliment of self diagnostics. The ECM can detect faults in the electrical system and report those faults to the service technician for quick repair. • Self -diagnostic capability pinpoints operational problems in need of attention. ADVANCED FEATURES • Isochronous or droop speed control • Enhanced performance from fuel injection timing and limiting • Adjustable monitoring of vital engine parameters • Idle/rated speed setting • Programmable speed acceleration ramp rate • Adjustable cooldown duration • Data link interfaces OPTIONAL FEATURES • Starter motor control • Integrated ether control system • Integrated prelube control system • Air shutoff control • Remote monitoring and control http://www.CAT.com ( ADEM II• ENGINE CONTRO MODULE CATERPILLAR® • • DESCRIPTION The ADEM ECM is housed in an environmentally sealed casting. All wiring connections to the ADEM ECM are made at the two sealed forty -pin connectors. ENGINE SPEED GOVERNING Desired engine speed is calculated by the ADEM and held within +/-0.2 Hz for isochronous and droop mode. The ADEM accounts for droop that is requested. The proper amount of fuel is sent to the injectors due to these calculations. The ADEM also employs cooldown/shutdown strategies, acceleration delays on startup, acceleration ramp times, and a low/high idle switch is also available via the CCM. Load share option is available. FUEL LIMITING Warm and cold fuel -air ratio control limits are controlled by the ADEM. Electronic monitoring system derates, torque limit, cranking limit, programmable torque scaling, and cold cylinder cutout mode are standard features. FUEL INJECTION TIMING Master timing for injection is controlled by the ADEM control. Temperature dependencies are accounted for in the fuel injection calculations. ELECTRONIC MONITORING Electronic monitoring of vital engine parameters can be programmed. Warning, derate, and shutdown event conditions may be customized by the user. INFORMATION MANAGEMENT The ADEM control stores information to assist with electronic troubleshooting. Active and logged diagnostic codes, logged events, fuel consumption, engine hours, and instantaneous totals aid service technicians when diagnosing electronic faults and scheduling preventive maintenance. CALIBRATIONS Engine performance is optimized through injection timing and auto/manual sensor calibrations are standard features. ON -BOARD SYSTEM TESTS System tests are available to assist in electronic troubleshooting. These tests include: injector activation, injector cutout, and override of control outputs. CAT DATA LINK INTERFACES The ADEM control can communicate with other electronic modules over the Cat Data Link. These modules include: Caterpillar Monitoring System, Electronic Modular Control Panels (EMCP II and EMCP 11+), Programmable Relay Control Module (PRCM), electronic service tools, and Customer Communication Module (CCM). ELECTRONIC SENSORS The following sensing is available on the ADEM control: oil pressure, fuel pressure, atmospheric pressure, air inlet pressure, turbo outlet pressure, engine coolant temperature, engine speed, throttle speed, droop position, exhaust temperature, engine control switch position, remote start/stop switch position, oil filter pressure differential, fuel filter pressure differential, air filter pressure differential, crankcase pressure, and remote e-stop switch position. ELECTRONIC ACTUATORS Electronic Unit Injectors are driven by the ADEM control. Actuators to control ether, prelube, starting motors, air shutoffs, and shutdown notification are optional. ADEM II ENGINE CONTROL MODU[. CATERPILLAR® SPECIFICATIONS Humidity 0 to 100% relative humidity Impervious to: salt spray, fuel, oil and oil additives, coolant, spray cleaners, chlorinated solvents, hydrogen sulfide and methane gas, and dust Input and output protection all inputs and outputs are protected against short circuits to +battery and -battery Input voltage range (24 VDC nominal) 18to32VDC Mounting engine mounted Reverse polarity protected Shock, withstands 20 g Temperature range Operating: -40° C to 120° C (-40° F to 248° F) Storage: -55° C to 105° C (-67° F to 221° F) Vibration withstands 2.0 g @ 18 to 500 Hz 1 ENGINE CONTROLS Load Sharing Module Pulse Width Modulated Output The Woodward Digital Load Sharing Module is made for use with Caterpillar engines equipped with Caterpillar Digital Speed Controls. (Diesels with Electronic Fuel Injection and spark ignited gas engines with Caterpillar Digital Electronic Controls.) This control allows use of Woodward power generation accessories and allows load sharing between the new engine and engines controlled with Woodward 2301, 2301A, 700, or 1000 type controls. The Digital Load Sharing Module is designed and manufactured by the Woodward Governor Company, Engine and Turbine Controls Division, P.O. Box 1519, Fort Collins, Colorado, 80522. Telephone (303) 482-5811. DESCRIPTION The Digital Load Sharing Module provides isochronous and droop load -sharing capability for engines equipped with Caterpillar Digital Controls in generator set applications. Additional equipment in the control system can include the Woodward SPM-A Synchronizer, Paralleling Phase Switch, Import/Export Control, Precision Frequency Control, Generator Loading Control, and Automatic Power Transfer and Loading Control. ti CA&TERPILLAR • Shown with optional equipment CATERPILLAR® SR4B GENERATOR SR4B Generators 820 Standby 50 Hz 1000-2250 kV•A 1500 rpm 60 Hz 1000-2250 kW 1800 rpm Type Brushless, revolving field, solid-state automatic voltage regulator Construction Single bearing, two bearing three phase, wye connected Insulation Class H Enclosure Drip proof IP 22, guarded Alignment Caterpillar pilot shaft Overspeed capability 150% Waveform less than 5% deviation STANDARD FEATURES Paralleling capability... Standard with adjustable voltage droop Voltage regulator 3-phase sensing with Volts -per -Hertz response Voltage regulation Less than ±1% Voltage gain Adjustable to compensate for engine speed droop and line loss TIF Less than 50 THD Less than 5% Number of leads 6 General Class H insulation (rotor, stator, and leads) Improved efficiency Motor starting capability in excess of 1.9 SkVA per continuous kW Improved wire & terminal identification ensuring reliable connections New compact size — reduction in length Performance and design matched to Caterpillar engines Radio frequency noise suppression better than industry standards Six leads standard for differential protection Standards: meets or exceeds the requirements of IEC 34-1, NEMA MG 1-22, BS4999, BS5000, VDE0530, UTE5100, CSA22.2, IS08528-3 Superior construction and testing Mechanical Full cage construction Six -hole power bus bars for convenient customer load connection Terminal box with DIN rail mounted terminal blocks Wet, layer wound rotors individually tested to 125% of rated speed; prototypes to 150% @ 170° C for two hours Stator Anticondensation heaters standard Optimum winding pitch for minimum total harmonic distortion Standard voltages: 380V, 480V, & 600V @ 60 Hz; 380V, 400V, 415V, & 500V @ 50 Hz Vacuum impregnation insulation system Windings coated with a fungus resistant resin Excitation System Adjustable voltage droop and paralleling capability Improved transient response with a standard V/Hz regulator Self excited 'DVFjautomatic voltage regulator with three phase sensing Permanent Magnet Exciter provides 300% amps for 10 sec under fault conditions; power isolation for voltage regulator CATERPILLAR' SR4B GENERATORS — 820 STANDBY • OPTIONAL FEATURES 2/3 stator winding pitch Bearing temperature detectors — 10052 Pt or 104 Cu Custom voltages Manual voltage control Oversized, generator mounted circuit breaker box (1009 H x 685 W x 406 D mm) Paralleling kit with sensing and power isolation transformers RFI filter — 82/499/EEC, VDE 875/10.84 A2 Level N, BS800 standards, and MIL-STD-461B (conducted, radiated, and susceptibility) ROTOR CONSTRUCTION The main rotor uses a precision "wet" layer wound process, with epoxy painted on the bare rotor and on each layer. This ensures bonding of all the wire layers together, bonding of the coils to the rotor laminations, and a sealed insulation system. The rotor epoxy is then oven - cured. The exciter rotor is Machine wound and receives two dips and bakes of a fungus -resisting resin. Numerically controlled turning and grinding machines produce rotor shafts with close repeatable tolerances. Grade-8 bolts are used wherever joints are subject to induced stresses. A complete coating of red sealer is applied to protect the rotors and shaft from moisture corrosion. All rotor designs are prototype tested to 150% of rated speed at 170° C for two hours without any movement of material. Every production rotor is dynamically balanced in two planes to within 0.025 mm peak -to -peak amplitude and run at 125% of rated speed before assembly into the stator. MAIN STATOR CONSTRUCTION New square lamination stator design Stator coil pitch, coil distribution, and skew are designed to produce optimum waveform and minimum total harmonic content. Stator slots are insulated by slot liners and coil separators. Slot liners, coil separators, and top sticks provide a minimum of 25 mm (1 in) distance from the coil to ground. The thickness of liners, separators, and phase sheets provides superior protection between phases and ground. Low voltage stator windings are given a 3000 volt "high pot" test (150% of the NEMA and IEC requirements for 480 volt generators) before the insulation is applied. The stators are then given a vacuum impregnation treatment of polyester material followed by an application of epoxy resin. This sealed stator is then given a final 2000 volt "high pot" test. Stator temperature detectors — Type J (iron- constantan) thermocouples Terminal box extension with: separate compartment for control devices modular design allowing RH or LH mount optimized for use with or without circuit breakers dimensions are 1009 H x 685 W x 304 D mm VR3F for enhanced transient response and block loading C&TERPI LLAR® GKN401-11 TMI GENERATOR PERFORMANCE DATA 11/19/02 3516 60 HZ STANDBY 1750 KW 480 V .80 PF 144-1820 STAR CONNECTION TYPE FRAME POLES SYNC SPEED NO OF BRG SAE FLYWHEEL HOUSING SR4B 824 4 1800 RPM 1 NO. 521 NO. 00 NUMBER OF LEADS WIRES PER LEAD GENERATOR PITCH EXCITATION 6 8 0.6666 PERMANENT MAGNET GENERATOR EFFICIENCY AT .80 POWER FACTOR * * * * LOAD PER UNIT KILOWATTS EFFICIENCY -PERCENT .25 437.5 94.9 .50 875.0 - 96.6 .75 1312.5 97.0 1.00 1750.0 97.0 1.25 2187.5 96.8 RESISTANCES AT 25 DEG C * * * * STATOR = 0.00050 OHMS FIELD = 0.93120 OHMS REACTANCES * * * * PER UNIT OHMS SUBTRANSIENT - DIRECT AXIS X " D 0.2232 0.0235 SUBTRANSIENT - QUADRATURE AXIS X " Q 0.2071 0.0218 TRANSIENT - SATURATED X'D 0.3121 0.0328 SYNCHRONOUS - DIRECT AXIS XD 4.0205 0.4234 SYNCHRONOUS - QUADRATURE AXIS XQ 1.9028 0.2004 NEGATIVE SEQUENCE x2 0.2151 0.0226 ZERO SEQUENCE XO 0.0048 0.0005 SHORT CIRCUIT RATIO 0,2891 GENERATOR TIME CONSTANTS * * * * SECONDS OPEN CIRCUIT TRANSIENT - DIRECT AXIS T'DO 6.1366 SHORT CIRCUIT TRANSIENT - DIRECT AXIS T'D 0.4764 OPEN CIRCUIT SUBTRANSIENT - DIRECT AXIS T " DO 0.0166 SHORT CIRCUIT SUBTRANSIENT - DIRECT AXIS T " D 0.0022 OPEN CIRCUIT SUBTRANSIENT - QUADRATURE AXIS T " QO 0.0126 SHORT CIRCUIT SUBTRANSIENT - QUADRATURE AXIS T " Q 0.0000 ARMATURE SHORT CIRCUIT TA 0.0749 EXCITATION * * * * EXCITATION VOLTAGE : NO LOAD = 5.27 V EXCITATION CURRENT : NO LOAD = 1.38 A • RATINGS * * * * LINE - LINE VOLTAGE : 480 KVA RATING = 2187.5 AT RATED LOAD .80 PF = 24.41 V AT RATED LOAD .80 PF = 6.39 A * LINE - NEUT VOLTAGE : 277 * RATED RMS CURRENT 3 PHASE = 2631.15 • • 1 • PAGE 2 GKN401-11 TMI GENERATOR PERFORMANCE DATA 11/19/02 3516 60 HZ STANDBY 1750 KW 480 V .80 PF 144-1820 STAR CONNECTION VOLTAGE REG AND ACCURACY * * * * VOLTAGE LEVEL ADJUSTMENT = +/- 5.00 PERCENT OF RATED REGULATION WITH CONSTANT SPEED (ISOCHRONOUS) GOVERNOR = +/- 1.00 PERCENT WITH 3 PERCENT SPEED CHANGE = +/- 2.00 PERCENT WAVEFORM DEVIATION LINE -LINE NO LOAD = LESS THAN 5.00 PERCENT TELEPHONE INFLUENCE FACTOR = LESS THAN 50 TEMPERATURE / COOLING DATA * * * * STATOR RISE = 105.0 DEG C * ROTOR RISE = 105.0 DEG C HEAT DISSIPATED = 53.99 KW (3071 BTU/MIN) GENERATOR MOTOR STARTING CAPABILITY * * * * PERCENT VOLTAGE DIP ACROSS THE LINE STARTING SKVA 2.5 195 5.0 401 7.5 618 10.0 848 12.5 1090 15.0 1347 17.5 1619 20.0 1908 22.5 2216 25.0 2544 27.5 2895 30.0 3271 32.5 3675 35.0 4110 37.5 4580 40'.0 5089 GENERATOR CURRENT DECREMENT DATA (3 PHASE FAULT) ELAPSED TIME (CYCLES) 0.0 1.0 2.0 3.0 4.0 5.0 7.5 10.0 12.5 15.0 20.0 25.0 30.0 35.0 40.0 45.0 CURRENT DECREMENT (AMPS) 11787 BASE VOLTAGE : 480 11382 10991 10613 10248 9896 9067 8308 7893 7893 7893 7893 7893 7893 7893 7893 > 300% CURRENT IS SUSTAINED FOR 10 SECONDS NOTE: MAX SHORT CIRCUIT AMPS IS FOR LINE TO NEUTRAL/GROUND FAULT: 17815 AMPS ; C&TERPILLAR • FEATURES Shown with Optional Equipment eragr rnmabi operating charactensticsr' U�ftpnapKVARIPFrontr'olier i OPtuznat t-ewer>3e power relays T r Overexpitatiort 5rnfection "µ faciltillitiatiOrkrersing �x Di ifaLdis la Allows system parameter monnn noong ette.comrnunicafign capability E1d11-isfab4avervoltage protection 73drustable frndervolfage protection' True RMS 3 phase voltage mbnrtonng Etatatmg diode monitor Undefrequaney protection t $oiid sta%Yciitage bu I Jup tmprovedperformance + r IritegratesacceSaones rh aoneconvenier)t ■ Interchangeable W�th'p No replaceable fuses OPTIONAL FEATURES 41e1C.rNCtd.IDE1.-) KVAR/PFcontroller -can be operated in either mode. Provides KVAR or power factor control when generator is paralleled with utility. Reverse Power Relay Activation Point — monitors generator output power and initiates a shutdown of the unit if a reverse power condition is detected. Remote Communication Capability—D.V.R. RS422 port allows display and modification of parameters via link to a personal computer. Includes software. Q ENGINE D FACILITIES, ISO: 9005 CEfTIFIEG Digital Voltage D.V.R. Regulator SPECIFICATIONS Regulation: ±0.25% no load to full load Regulator temperature drift Less than 0.5% for any 40° C change over the operating temperature range Programmable Volts/Hz characteristic Two slope ranges adjustable from 1 to 10 V/Hz (See Fig. 1, page 2) Regulator response time: Maximum of 10 milliseconds Regulator sensing True RMS 3-phase sensing is standard. Single phase sensing is available. Variable sense range 90 to 600 volts Regulator stability Regulator responds to the fundamental component of the sensed voltage and remains stable for total harmonic distortion of the generator output voltage waveform up to 20% Regulator filtering Telephone Influence Factor (TIF) less than 50 Complies with MIL STD 461B Part 9, EN 50081-2, and EN 50082-2 Fine voltage adjust range -10% to 10% of regulator sensing voltage Regulator voltage gain (IR compensation) Adjustable 0-10% Fault detection and identification Diagnostics identify operation outside of programmed limits, and specific fault information is available even after the unit has been powered down Regulator start-up voltage Meets ISO8325-3 class G2 specifications Harmonic tolerance The D.V.R. will maintain precise control of the generator output with up to 20% harmonic distortion in the generator output voltage Reactive droop adjustment: Adjustable 0-10% Overexcitation protection Shuts off generator output when excitation current exceeds normal operating currents for 15 seconds or instantaneous shutoff if output is shorted Ambient operating temperature: -40° C to +70° C Storage temperature range: -40° C to +85° C Power dissipation: Quiescent -5W; 55W max. Shock: Withstands up to 20 g's Vibration: Withstands 4.5 g's at frequencies between 18 and 2000 Hz in three mutually perpendicular planes Salt spray: Meets MIL-STD-810C, method 509.1 Sealing: Withstands up to 35 kPA (5.08 psi) Weight: 5.0 kg 24V DC, 0.5A power supply required • DIGITAL VOLTAGE REGULATO SUMMARY OF OPERATING PARAMETERS CATERPILLAR® Power Input Output Rating Sensing Reactive Droop Input Exciter Field Resistance Voltage Rating Type V Freq Hz VA MaxVA Continuous Forcing in V Max Burden per (� Max Voltage Max Burden Min Ohms Max Ohms V A V A 120 volt PM 70-120 30 50-240 1500 44 11 60 15 79/124 1 5 1 3 10 240 volt PM 70-120 30 50-240 1500 44 11 60 15 125/249 1 5 1 3 10 480 volt PM 70-120 30 50-240 1500 44 11 60 15 250/600 1 5 1 3 10 REGULATION CHARACTERISTIC — Figure 1 % OF NOMINAL VOLTAGE 125 — 100 75 50 25 UNDERFREQUENCY POINT / GENERATOR OUTPUT VOLTAGE IG DECREASING SLOPE 1 (1-10 V/HZ) DECREASING SLOPE 2 (1-10 V/HZ) 5 HZ (FIXED) MINIMUM VOLTAGE SETPOINT KNEE FREQUENCY 0 20 40 60 80 100 % OF NOMINAL FREQUENCY PROGRAMMABLE VARIABLES AND RANGE OF ADJUSTMENT • Voltage vs frequency characteristic Two slope ranges adjustable for 1-10 V/Hz for optimum performance • Fine voltage level 1+10% to -10%) • Droop adjustment (up to 10% @ 0.8 pf) • Overvoltage setpoint (105% to 140% of nominal) with adjustable trip time • Undervoltage setpoint (60% to 95% of nominal) with adjustable trip time • Gain (0-10% of nominal) • Single-phase or three-phase sensing • Underfrequency point (20 to 40 Hz) • Knee frequency (45 to 65 Hz) 120 PROTECTIVE FUNCTIONS • Overvoltage protection • Undervoltage protection • Loss of sensing • Rotating diode monitor — monitors the status of the rotating diodes and operates the alarm relay in the event of failure of one or more of the diodes. • Overexcitation protection • Loss of excitation — monitors excitation and will initiate a shutdown of the unit if excitation is lost • Underfrequency protection to avoid overheating of rotor • Instantaneous field overcurrent trip to protect the digital voltage regulator in the event of output short circuit or improper connections N h n n 0 0 w J 0 0 W U N 0 2 2 Z N z 0 a 0 0 ce a 111 W z 01 J 111111 MO 1 I1111 Ill 1IIII Isill IIIII 1111 I1111 WI ll 11 IIIII 111 um till 1111 IIIII iiii 11 1 l 11 ir 1 11 is IIIII 11 11 Hill fill 11 1 11 11• 11 II II •11i II 1 111 III 11111 IIIII 0 = (� LaI O p W W j I I 1• a i • 9. • 1 z Y ( 0 m O 0 0 4. 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UNIT MUST GE GROUNDED FOR OPERATORS SAFETY. a 2 O H 0 0 W 2 �0 JC 0 N g 0 t O ❑ d Y LI W W 16 J° {{ge y o .Q ro ;LG o 2 00 , , W VI W 1- 04 Otm/ZW 0 R{a �z i s 1[/R1[R/��--110 2 g k❑� aWWLL g 1 i V . rck, •ooz m003�@y 0OOOOu 5 0 iY S❑iY�m WZ 2 ❑ a0 `D1-�j I = 16zy�=. 8'wp��o 1 1 002 I-3 o Z--1w89yjW D m u `Wg` m W I oY-a JN`W 1-3 Jwgl°80 xF i N1- a$p O0J 0 {ReZ8 dm}j W pZ 0.0 m..W 00 = 6 =5W . ..1 i i F.- O8 LL4O aas20 e4 MI Y' N 1 DUPLEX' PUMP SYSTEM FOR SST SERIES ADVANCED UNE DAYTANKS 0. m' OW W N a� Tj❑ 2 oo go tax 11 20 06 in Tt Ci DESCRIPTION OF OPERATION OPTIONS LIST a {f taiD Yy4 W =F Z 70ire d W YR O , 3 ;Wg 9 m z zo bhp`❑' 2 P..d NU te a 0 7 g fop y' d 6 1.71 82 Vt1U� Yn ❑ Of 1/1a xZ 6 p ari' i mRa < 2 s W 6Y 0OpZ •' �I 6 0j J a2f 2 C i 6 2i0 a W 6 a a zig < p O S F r{t- 0 a ! 3 `` ❑ > y>1 5 OF0 ❑ ❑ O O {{J N 1 1 1 1 I 1 N J V yj5 a K� m`z Si5 4.p{¢ 8 IDS :41: I nce �ia-A�NN_ :.4oi W�tt0+=I 3_2, govy; a6iq a:M'4 00 14,30w ;�F W6zj44N ,6J0 3ZO2 a<y ja0� na00 OpFO\ _9 2u 2S iila 1�. i dr00 4 JOOW 0Wa iiNp2 40°2 N3J40 aaz&K zZi Wx iW ❑a N O �O yy2 Z i0 2F rL i�b{�. [� 8o W 0F^�W t; m `�W{ '� 6U13 0W�� gdo`d6 a-s6 iNgEo�W -RR OWN a tag G 5*5 Oaf N ' t w� i 3%na � Z N o~~0Ja i�JYO 0 W°Wpa TW5O�nKz OJ 04— �a tOd iaR G aoo tg ow ow ow an 9tz NWZ aogisim €06 ".AD s D ON 626 Zo i G 2 0 W N> WN 0 &N� GJ WW 82 44 65 im wto FOR WIRING DIAGRAM • NELSON ® Special "400" Level Exhaust Silencers Typical Attenuation Curve dB(A)* (ACTUAL ATTENUATION MAY VARY ACCORDING TO APPUCATION) 45 40 Typical Attenuation dB(A)* 35 NMI 30 25 ! A.■■■■ ,.■.■U. AIOM•U■ 31.5 63 125 256 500 1K 2K 4K 8K Octave Band Cen er F equency (Hz) *Estimated 20 15 10 Application: These silencers are recommended where ambient noise is low and a high degree of silencing is necessary. Construction: Aluminized'Steel: Nelson Silencers through 26° O.D. are fabricated of aluminized steel as standard materials. This material has a maximum operating temperature of 1250°F. Mild Steel/Aluminized Steel: Nelson Silencers 30" O.D. and larger are fabricated of mild steel and aluminized steel. All silencers 30" O.D. and larger have aluminized steel bodies with all other components fabricated from mild steel. Silicone Aluminum Paint: Nelson Silencers through 26" O.D. are given a coat of high heat resistant silicone aluminum paint. Primer/Silicone Aluminum Paint Nelson Silencers 30" O.D. and larger are given a coat of high heat, rust inhibiting primer and then a topcoat of high heat resistant silicone aluminum paint. Physical properties are maintained up to 900°F* on aluminized steel and 1100°F* on mild steel. "F" Mounting Flange: Standard in sizes 4" to 14°. Drilling matches 125/150# ASA standard. Companion flanges available for 4" to 22". Construction Features: Double wrapped body is standard on all "400" Level Special Silencers. Pressure Drop 24 22 18 16 14 12 10 8 6 4 2 a) o ▪ 20 01 2 3 4 5 6 7 8 9 10 11 12 13 14 Exhaust Gas Velocity in Thousands (Ft/Min) Note: When figuring pressure drop for side inlet or middle side inlet add 3" H2O to back pressure shown on above curve. *Estimated Sample Specification: The silencer is to be a Nelson Hospital "400" Level Silencer constructed of aluminized steel (26" body diameter and smaller) or mild steel/aluminized steel (larger than 26" body diameter) with all welded construction and suitable for mounting in any position. The silencer shall be complete with the following Nelson accessories: w J U cn 0 w J aim 1 g y } Z ti 0 CD lace— 0 § I I=-1 0 O F q2 a. a 0 x ,INSTRUCTIONS w o 4Q W J "J C 1- W41 CI 6y J s CO cI, • ¢ s W J G S mt. GI J w = O m � J - ~ N S 1- J 0 Q 0 S 1N- S La _ X W ir N W X 02 J Z u IL:Z ¢ la CI. S W- N vi - nit p N O N H W W W � ^ t • Ill J G p W -� N O 0. H 120 1-- . WM = N N 1-� 10 47 N ti X J — .y J N 40 G ¢ M M'Nu. ti C = WJ I- ¢ i O ▪ N Y Xi -1 N 00 el t ▪ J a0 Lt. ¢ S 1- 111111111 t O O N 8 • P -A O D U C. YOr °I.a Marche A46 Generator Set Float =:': attery Charger tOMITAVOIMOOLT to The La Marche A46 is designed specially for maintaining and recharging starting batteries of engine sets. The La Marche A46 float battery charger is designed specifically for maintaining and recharging the' starting batteries of engine generator sets. It provides the high reliability necessary for the continued operation of emergency standby equipment and eliminates most starting problems by maintaining batteries at full charge, ensuring optimum battery performance and maximum life.* The A46 features the proven dependability, and long life of Mag Amp transformer technology along with transistorized control circuitry. Sensing battery and load conditions, the A46 can determine when the batteries are low and will automatically provide the correct charge. The A46 also assures continued operation of emergency standby equipment and eliminates most starting problems by maintaining the batteries at full charge. Ca11 La Marche today for more details. *The A46 is not recommended for use on sealed valve regulated batteries. the powerful advantage'" LanaRCHE DESIGN FEATURES Proven Mag Amp Technology AC Line Compensation Automatic Operation — output Is regulated by automatic sensing of battery voltage Separate Float and Equalize Voltage Ranges Current Limited -- self protecting under all load conditions DC Ammeter Indicates Output Charge Rate DC Voltmeter Shows Battery Voltage AC Power Failure Will Not Cause Battery Discharge Complete Isolation of AC Input from the DC Cutput — eliminates blown fuses from grounded equipment AC Power Failure Alarm Contacts Heavy Duty Case 5Year Limited Warranty Made In The USA P25•DSA48-1 12872-4/99 •ellitEithe,:.'A46'Hattiebr. Chicr�e6 'clinical Data Standard Features Ammeter and Voltmeter Fused AC Inputs and DC Output Terminals for AC and DC Connections Front Mounted Float/Equalize Switch Finish Base Material Pretreated with Grey Primer ANSI 61 Grey Baked Enamel Finish Coat Schematic SCE `P1z0-PL.CT Optional Accessories tcIL-Le TI A) 1.6 E 16E-Combined Accessary Package Includes: Digital Combination Meter, Multi -mode Equalize Timm and the Following Alarms and Indications — Low DC Volts 1, Low DC Volts 2, High DC Volts, High DC Voltage Shutdown, Low DC Current, Summary/Rectifier Failure, AC "ON", Equalize Lights. Note: All Alarms have LED and two form "C" contacts, except Summary/Rectifier Failure (two form "C" contacts only). Individual Accessories 03A-DC Cranking Disconnect Relay 080-Drip Shield NOTE::1f more than two of the following accessories are required, use the 16E-Combined Accessory Package. • 04J-Electronlc Timer with Float and Equalize Lights 03M-Low/High.DC Voltage Alarm Relay with Lights 055-Float Light (with F/E Switch) 056-Equalize tight (with F/E Switch) 060-AC Pilot Light - DC OUTPUT AC INPUT PT POWER TRANSFORMER SR SATURABLE REACTOR ACF AC FUSE DCF DC FUSE SD SIUCON DIODE SP SURGE PROTECTOR T TRANSISTOR ' ZD ZENER DIODE RZ ZENER RESISTOR Ordering Information RV VOLTAGE DIVIDER RESISTOR PF POWER FAILURE RELAY RC COLLECTOR RESISTOR FES FLOAT EQUALIZE SWITCH A AMMETER V VOLTMETER C CAPACITOR R RESISTOR Model Number DC Output Amps System Voltage Width (inches) Depth Height Weight Case (inches) (inches) (approx.) Size A46-6-12V _iA46-10-12V jA46-20-12V A46-30-12V A46-6-24V A46-10.24V hiltA46-20-24V 46-30-24V 46-40-24V A46-6-32V 46-10-32V A46-20-32V A46-30-32V •6 12 103/8 71/a ' 161/4 30 1 10 12 103/8 71/a 161/4 34 1 20 12 1213/16 10 1714 54 2 30 12 1213hs 10 171/8 68 2 6 24 103/a 71/e 161/4 40 1 10 24 1213he 10 171/a ' 60 2 20 24 1213/16 10 1714 75 2 (30) 24 141/4 101/4 197/a 92 7 40 24 141/4 166/a 197/e 96 7 6 32 1213ha 10 171/e 60 2 10 32 1273hs 10 171/a 64 2 20 32 1213/is 10 171/a 74 2 30 32 141/4 105/a 197/a 96 7 When Ordering Please Specify the Following II La Marche model number A46 • AC input voltage (120, 208 0r240 volts; 50/60 Hz; and, single phase) ■ Number and type of battery cells • Ampere hour capacity of battery ■ Desired recharge time ■ Options required Model Number Format A46-10-12V Product No. DCAmps DC Volts Special Frequency (when required) Frequency Code 50/60 Hz Standard the powerful advantage &MARCHE ( ) Al—( ) LI Factory Assigned Accessory Code AC Phase Code AC Voltage Code AC Voltage AC Phase Code A-120 1-Single Phase 8-240 D-208 106 Bradrock Drive, Des Plaines, IL 60018 USA Tel: (847) 299-1188. Fax: (847) 299-3061 http://www.lamarche-power.com Product Bulletin Option 16E • Series 16E Accessory Package The Ultimate Accessory for your La Marche Battery Charger or Power Supply • Combined Accessory Package for Model Al2B and A46 Series Chargers: The La Marche Informer Series 16E Combination Alarm Package is the ultimate protection for your La Marche charger. Series 16E features a microprocessor —based design that incorporates the most popular alarms in one factory installed package. Completely user-friendly, all settings can be adjusted and calibrated in the field without need of special tools or equipment.. Best of all, adjustments can be made when the battery is on-line without affecting the load. With its uncomplicated interface, operating the 16E is easy. Simply place the charger in Calibration Mode and set the front panel calibration switch to match your alarm setting specification. Series 16E incorporates a field ••••��ar�tt programmable, multi -mode digital equalize timer with equalize settings adjustable from 0ne to 144 hours in all modes. Equalize LED and Equalize Time Remaining features are standard. The timer features five different equalize modes allowing you to select the right mode for the application. All Alarm settings are stored in memory, so the last setting becomes the new default setting...even if an extended power failure occurs. All LED's are instantaneously alarmed, all relays are time delayed. Specifications are subject to change without notice. Please contact La Marche for current specifications.. LMC P/N: P25-DS16E-1 &aifAR HE Series 16E Accessory Package The La . Marche Series 16E Accessory Package includes the following standard features: • LED Display is selectable for DC Voltage, DC Amps, Timer Mode and Equalize Time Remaining (Hours) • Equalize LED • AC Pilot Light • AC Power Failure Relay with two form "C" contacts • Low DC Current Alarm LED and two form "C" contacts • High DC Voltage Alarm LED and two form "C" contacts • Low DC Voltage Alarm LED and two form "C" contacts • Critical (second) Low DC Voltage LED and two form "C° contacts • High DC Voltage Shutdown Alarm LED and form "C" contact • Summary Alarm Relay (includes Low Voltage, Low Voltage 2, High Voltage, High Voltage Shutdown, and Low Current') with two form "C" contacts • * Low Current can be removed from Summary Alarm by dipswitch �• Multi -Mode Digital Equalize Timer, Adjustable from one to 144 hours with five selectable modes: Standard, 7-Day, 14-Day, 30-Day and Equalize after Low DC Voltage Condition Note: All alarm contacts are rated: 0.5 A @ 120 VAC Res. , 2 A @ 30 VDC Res. La Marche Manufacturing Company 106 Bradrock Drive, Des Plaines, IL 60018-1967 Tel: 847-299-1188 Toll Free Fax: 847-299-3061 http://www.lamarchemfg.com e-mail: salesrahlamarchemfa.com it Rugged plates, connectors, and element anchoiing resist the industry's most abusive vibration tests ■ Through -partition connectors shorten the electrical path and maximize starting power in Extra -heavy grids increase life and power in extreme cold and heat • Extra corrosion resistance and built-in overcharge protection reduce maintenance ■ Durable plates with optimum acid/paste combination provide excellent charge acceptance after deep discharge PREMIUM HIGH OUTPUT PERFORMANCE Cat® Premium High Output Batteries Cat Premium High Output Batteries are designed to survive the toughest abuse and built to perform in the harshest environments: They offer reliable starting power and long life in all climates. Their high cold cranking amps and reserve capacities have earned them the maximum performance rating in the battery industry. • Microporous polyethylene separator protects against "shorts"'and vibration damage - ■ 40-degree tilt capacity eliminates damaging spills • Impact -resistant cases provide extra strength, especially in sub -zero temperatures • Flame arrestor safety vents reduce the possibility of explosion from external sparks. BC! Group Size Part No. Volts Cold Cranking Amps' Reserve Capacity Minutest Amp Hr. Capacity @ 20 Hrs. Canshvdion' Add Water Maadenanm Check/Hrs. Max. Overall Dimensions Normal Weight Nominal Acid to Fill liter (qt) Length mm (in) Width mm fin) Height mm (in) Wet kg (Ib) Dry kg (Ib) 4D 9X-9730 12 1300 400 190 LAC/P 1000 528120.8) 21818.6) 25019.8) 541119) 37181) 14114.81 4D 9X-9720 12 1000 275 140 LAC/P 1000 528120.8) 218(8.6) 25019.8) 461101) 27159) 15115.9) 29H 90-4233 12 625 160 80 L"L 250 333{13.0) 17416.8) 23219.1) 29 164) 22(491 6 (6.6) ' For30 seconds at 1rC(0°F 2 Minimum of 25 amp output at 27° C (80° F) ' LA = Low Antimony design LAC = Low Antimony Calcium design P = Polypropylene case fl = Hard Rubber case Batteries have taper post design and are shipped dry. NOTE: Quantity = 4 Connected Series — Parallel 24 VDC, 380 Amp Hrs. to J L1J 0 Gi I— O Z O O (I)4 Z X HO w in — CO 0 o } W < CC K Z �.0 Q J m U o W OPENING FOR BATTERY CABLES MATERIAL DESCRIPTION 0 zw CC ow Z N H 65 a6 z cc z z 0 0 ui w *0 0 o oz xwo mom Wl re 1111 0 0 m 0 0 0 0 0, w 0 a co 0 o n m ce tn Lam 1-W <V) m01 NU <Z CC JL 00 WO COO wa m� 0 0 0 31Y0 NOSL138 'ON 1 eA-�NA MUyF,�O�R�N��A YCS eORPORATION 5572 ALHAMBRA AVE. LOS ANGELES, CA. 90032 (213) 223 - 3882 CALL US - TO SET THINGS RIGHT FAX (213) 223 - 7941 JCIB: HO<F G m6n1 c h/4-e- EfosP i r» 1- CUST: �s EGEC i /L' e - u.v/T - '`S ENG'R: Er even. L TAG R V/ 3 Z 7 Isolator Selection & Loc. C I L) 6- LI 2. 1?ER. 7t RAIN f AJG— I327-13-( •*--Iw Oper. Height @ Limit Stop Rubber Grommet Cushions • ATTACHING AND LOAD TRANSFER STYLES Style T External 4' Min. 1 J_ Not available In 3' or 4' Deflections 1 Inch Deflection GENX Product Ratings W x L w - 1 * Oper. Height E424, E572, E746 E976 E1272, E1660 E2000, E2532, E3204, E3735 E45816E5697, E7209 10 /12 x 12 9 - 10 4 -1/2 4.3/4 5 5 -1/2 5 - 3/4 3 Inch Deflection GENX Product Ratings W x L w - 1 •Heigh. Height G426, G604 G853, G1223 10-1/2 x 12 8 -1/4 9 - 3/4 61706, 62446 9 t0 10 G3412 10-1/2 x 14 10 G4892 9 - 12 10 -1/2 Anchor Hole Style V Internal MIri. rTF TYPE GENX SPRING ISOLATOR HIGH PROTECTION SEISMIC DESIGN FILE 534 8/31/95 DEF'L: DATE: Vet + Laterally Stable - Steel Springs Remaveabla Spacers L RP 1/4 Rubber Pad + The ratio of spring diameter to Its height at rated deflection Is not under . 8 and extra deflection Is not less than 50 %. @ Limit Stops provide protection for drainage, wind and seismic that may be adequate dependent on equipment and requirement . Contact CaiDyn for assistance . * Oper. Height is ± 10 % of operating height. Contact CalDyn It closer accuracy is needed. 2 Inch Deflection GENX Product Ratings W x L w - 1 * Oper. Height F328, F480, F620 F780, F944 F1392, F1988 F2360, F2704, F3300, F3672 F4125, F4590 10 1/9 x i02 6 -1/4 6 -1/2 7 -1/4 7.1/2 8 4 Inch Deflection GENX Product Ratings W x L w - 1 * Oper. Height H624 10-1/2 x 12 9 10 9 11 /2 H884 11-1/2 H1248, H1768, H2496 14 x 18 11-1/2 H3536, H4420 12 - 16 12 l� C/ALFORMA DYNMACs eo8POAATIoN 5572 ALHAMBRA AVE LOS ANGELES, CA. 90032 (213) 223 - 3882 CALL US - TO SET THINGS RIGHT FAX (213) 223 - 7941 BOLT FOR EXTERNAL LOAD TRANSFER & LEVELING EQUIPMENT LOCKING NUT RI +- 181 1t1 0 TYPE GENX SPRING ISOLATOR RESTRAINT INSTALLATION INSTRUCTIONS FILE 98 9/18/9: NUT FOR INTERNAL LOAD TRANSFER & LEVELING / EQUIPMENT jr e 1�1 ,i 11 j — r lua s�=e, aniti ozoratTiTra eirie O//ITI//l/G®rlL In, FIRST - Read and understand instructions. "s' 0 0 (Not provided) (Not provided) GENX's cannot compensate for sloping or wavy surfaces. The lower surface of each GENX must be level. The lower surfaces of all GENX's teaming to support an equipment Item must • be within 1/8' of a common horizontal plane. If not, shims or grout may be needed. A. Locate GENX's to mate with the equipment when placed In the intended location. Check using intended equipment if necessary. B. Mark anchor hole 1Q. locations, set GENX's aside. C. Drill for and install expansion anchors 02 D. Return GENX's (and shims if needed). Start anchor bolts 03 through GENX's anchor holes 0 to engage expansion anchors 02 Run stabilizer nuts ® up. E. Place equipment on the GENX's. If external bolt 05 load transfer style, insert bolts (with nuts ® run up) through holes in equipment and thread through the Top Plates to contact the spring pressure plates 70 If internal nut ® load transfer style, align the upwardly projecting central studs through the holes in the equipment. F. Stepwise, adjust load transfer bolts ) (or nuts 80) compressing the springs of each GENX until the equipment is supported by the springs. Further adjustment lifts the equipment until clearance R = 3/16' is achieved in each GENX. A low end or corner may need more adjustment to level. G. Run stabilizer Nuts ® down to S = 1/16". Tighten anchor bolts 30. Tighten nuts © against equipment to complete installation. TOP PLATE or Racor Crankcase Ventilation Filter • Systems — the clean, complete solution • By trapping crankcase blow -by and recycling engine emissions through high performance filters, Racor Crankcase Ventilation Filter Systems offer an effective solution to reduce contaminated crankcase emissions. Racor systems provide protection for engines and the environment — eliminating the hazardous oily film that used to coat engine compartments and equipment. • Keeps engine compartments and components clean. • Prevents clogging of engine intakes, turbochargers and intercoolers. • Improves reliability and maintainability of diesel engines. •.Superior efficiency and performance. • Reduces environmental pollution from crankcase emissions. • Replacement filter is crushable and burnable. • Reduces smoke and odor in the immediate environment. • Installed as original equipment by major manufacturers worldwide. Racor Crankcase ventilation Filter Systems provide a highly effective solution which is easy to install, maintain and provides superior protection against contaminated crankcase blow -by. With the Racor system, crankcase pressure is regulated and oil mist is removed from blow -by gas prior to recirculation to the air compressor, aftercooler and the combustion process. The only routine maintenance required for the Racor Crankcase Ventilation Filter System is filter replacement. Typical service life of the high performance filter in diesel applications is 750 hours. Some variations in service life occur depending on load profile, engine wear condition, flow and aerosol mass concentration of crankcase emissions, and soot concentration. Closed System Applications CCV8000 40 CFM Closed System Applications CCV6000 20 CFM Closed System, Applications CCV4500 - 10 CFM Open System Applications and Specific Closed System Applications CV1000 15 CFM Open System Applications and Specific Closed System Applications CV820 10 CFM CCV Systems — Specifications • 1 Calculating Flow Rates CCV units are designed to handle crankcase flow rates of up to 40 CFM. Traditionally, the crankcase flow rate can be calculated as follows: Rated horsepower a 40 = cubic feet per minute (CFM). This formula can only he used as a guide since recent improvements in piston design have produced engines with higher horsepower and lower blow -by flow rates. The blow -by flow rate of a worn engine, at time of overhaul, is generally double the flow rate when the engine is new. The flow rate of a worn engine should be considered when specifying the correct crankvent Liter system 3516B 1750kW Hp: 2451 Crankcase Blowby = 2451 / 40 = 61.3 cfm Selection: (2) CCV8000 Model No. CCV4500 CCV6000 CCV8000 Height 9.25" (235.0 mm) 12.00" (304.8 mm) 13.88" (352.6 mm) MadmumOpenhgWidth (rd.clamps &bracket) 7.50" (190.5 mm) 11.25" (286.8 mm) 13.25"(336.6mm) Depth 5.60" (142.2 mm) 7.30" (185.4 mm) 9.30° (236.2 mm) Weight 3.26 lbs. (1.48 kg) 5.01 lbs. (2.28 kg) 8.72 lbs. (3.96 kg) Alter Removal Clearance 2.25° (57.2 mm) 4.00° (101.6 ram) 5.00" (127.0 mm) Replacement ElemenWedla Density/Medium Part # 55248-06 Part # 55274-06 Part # 55222-06 Replacement Dement/Media Density/High Part* 55248-08 - Part # 55274-08 Part # 55222-08 Housing Material Die cast head, glass -filled nylon . j components and black powder epoxy coating. Die cast head, glass -filled nylon components and black powder epoV reefing. Die cast head, glass -filled nylon components and black powder epoxy coating. Inlet & outlet Thread Size 1 3/16' -12 STOR 1 5/8" -12 STOR 1 7/8" -12 STOR Max. Cubic Feet per Minute 10 CFM/283 LPM (see note above) 20 CFM/5661PM (see note above) 40 CFM/11321PM (see note above) Crankcase Pressure Regulator Integral Integral Integral Bypass/Change Indicator Integral or Remote Integral or Remote Integral or Remote Engine Block Check Valve Rehm Atting 1/4" NPT 1/4" NPT 3/8" NPT Swivel 'Fitting (0ty.) # 6 JIC (2pcs) - # 6 JIC (2pcs.) # 8 JIC (2pcs.) Hose I.D. (Oty.) - .375" (3 ft) .375" (3 ft) .5" (3 ft) ADDRIONAL DETAILS ARE AVAILABLE IN TECHNICAL MANUAL #55021. Power Systems Associates 011 Serving Southern California For Over 75 Years PARTS AND SERVICE STATEMENT POWER SYSTEMS Associates, LLC, has existed as the only authorized Caterpillar Engine Distributor, in Los Angeles and Orange Counties since 1972. It is the successor to the Industrial Division of Shepherd Machinery Company. We are Caterpillar's parts, service and sales representative. POWER SYSTEMS Associates, LLC, offers genuineCaterpillar parts and factory -trained mechanics. These are available on a 24-hour basis through our main office: 3500 Shepherd Street Whittier, California, 90601 (562) 463-6000 PS2002 (DURev11/02) Tt .wen.gin.es._and EPG PRODUCTS I LIMITED WARRANTY ESC /NCLuDED FaR Ye%e S 3 rnct S Ext.en.d.ed.. C.ov.era.ge...Available For engine protection that extends service coverage beyond the initial warranty period, Extended Service Coverage (ESC) plans provide added security and added value. Contact your Cat Dealer for more information about ESC plans and other Caterpillar products and services that protect your investment. .. W e've.. G ot. You...0 overed Caterpillar provides separate warranty coverage for engines sold for use in on -highway vehicle applications and marine applications, engines in machines manufactured by or for Caterpillar, or 3500 and 3600 Fancily engines used in locomotive applications. And Caterpillar's extensive dealer network provides the products and services that protect your investment and keep your business running. • Cat ..rp _ia.r If you experience a problem due to a defect in material or workmanship of your Cat product during the warranty period, Caterpillar • Provide new. remanufacrured or Caterpillar approved repaired parts or assembled components needed to correct the defect. • Replace lubricating oil, filters, antifreeze and other service items contaminated by the defect. ' • Provide reasonable or customary labor needed to correct the defect, including labor to disconnect the product from and reconnect the product to its attached equipment, mounting and support systems, if required. For 3054, 3056, 3114, 3116 and 3126 engines and Electric Power Generation products (including any other manufacturer's products packaged and sold by Caterpillar), Caterpillar • Provide travel labor (up to four hours round trip) if, in the opinion of Caterpillar, the product cannot reasonably be transported to an official Caterpillar dealer or other source approved by Caterpillar. Travel labor in excess of four hours round trip and any meals, mileage, lodging, etc. are the owner's responsibility. For all other products, Caterpillar will... • Provide reasonable travel expenses for authorized mechanics, including meals, mileage and lodging, when Caterpillar chooses to make the repair on -site. © 1998 Caterpillar • Items replaced under this warranty become the property of Caterpillar. • All warranty services will be provided during normal business hours by a Cat Dealer or other source approved by Caterpillar. • Caterpillar will determine whether new, remanufactured or Caterpillar approved repaired parts ar assembled components will be used in all warranty service. • Improper use or installation is determined by Caterpillar. • Warranty applies to first -owner sales made on or after January 1, 1987. For more information about Cat products and services, contact your local Cat Dealer or visit our Website at www.Cat-Engines.com. LEDX8496 CATERPILLAR® © 1996 Caterpillar Inc. Printed in U.S.A. The Power To Do Business Better. How long is the coverage? Coverage is available for five years (10 years for EPc standby and EPC load mnnatemeet.)Various hour increments are available for most applications and models. What is covered? Full service coverage covers 100% parts and labor for engine failures due to defects in materials and workmanship on covered components. It also covers a Caterpillar generator or Caterpillar marine gear if applicable. What products qualify for ESC? ESC is available for new commercial engines used in industrial, electric power generation (EPO), petroleum and marine applications for use within the continental boundaries of the United States, Alaska, Hawaii, and Canada. ESC is available for most diesel and gas engine models including our 3000, 3100, 3176, 3200, 3300, 3400, and 3500 series (N/A for 3500 gas). Consult your Caterpillar dealer for more specific information. ESC is also available for new Caterpillar generators, switchgear, power modules, and marine gears sold in conjunction with a new Caterpillar engine. The engine must be purchased at the same time the engine ESC is purchased. • L LOAD TECHNOLOGY, INC_ f• • R TEC 4225•Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 Load Technology : WORK ORDER SPECIFICATION Work Order # : 220178 Date : 11/04/02 Model : ODL4-0750.1-480v33-0600-(5)50 Rating : 750KW. Voltage : 480V, 30, 3W, 60 Hz. Power Factor : 1.0 Customer : Power Systems Associates P.O.# : 55706 Reference : Hoag Hospital Project • L 1 HDTIEC LOAD TECHNOLOGY, INC_ 4225 Production Court Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 TECHNICAL DESCRIPTION Radiator/Duct Mounted Type Hoag Hospital Project LTI No. 02-0586 5/14/02 Page: 1 of 1 MODEL: 00L4-0750.1-480V33-0600-(5)50 LOAD RATING: 750 KW @ 480 V, 30, 3W, 60 Hz, 1.0 P.F. GEN. RATING: 2000 KW RESOLUTION: 50 KW, (5)Steps of: (1)50,(1)100,(3)200KW TOLERANCE: ± 5% overall tolerance, t 2% phase -to -phase balance CONFIGURATION: LOAD BANK with INTEGRAL POWER & SEPARATE PILOT CONTROLS - The Load Bank consists of two (2) separate items: 1)The load enclosure contains the load resistors for mounting in the radiator exhaust and required power control devices and 2)the control enclosure contains all the required pilot. ENCLOSURE: Load: Nema 3R Control: Nema 12 Wall mounted OPERATION: MANUAL CONTROL with AUTOMATIC LOAD DUMP on LOSS of UTILITY POWER The Load Bank is a complete system with all necessary controls and devices to manually load a generator set. Circuitry provisions are provided to disconnect the unit on loss of utility power. PHYSICAL: Load Enclosure: the following are approximates(actual depends on radiator size) • Height: Core Depth + 6" Width: Core Width + 15" Left side & 4" Right side Depth: 18"(nominal) based on % of Load Bank rating to Generator rating Weight: 800 LBS Control Enclosure: 14"H x 12"W x 8"D, 50 LBS PAINT: Preparation: SSPC Surface Preparation Standards # SP1 Primer. Polyvinyl -butyl resin based etching type Finish: Catalyzed type polyurethane enamel AMBIENT: Temperature: -20 F./-30 C. to +130 F./+55 C. Humidity: up to 100 % Altitude: 4000 Ft / 1200 M LOAD RESISTOR: The Loadtec RESISTAR is designed specifically for high density applications. The resistor is continuously supported to eliminate possible shorting contact with surrounding resistors. The RESISTAR has an industry exclusive 3 year limited warranty. COOLING: Forced air cooled by the radiator fan. CONTROL POWER: 120 VAC, derived from the generator by a control power transformer PILOT CONTROLS: • Control Selector Switch: MAN -OFF -AUTO • Load Step Switches: OFF -ON • Load Step Switches: OFF -ON • Cooling Failure Indicator: Red • Loss of Utility Power Interface Circuitry PROTECTIVE SYSTEM: Cooling: A temperature switch monitors the cooling and disconnects the unit on failure. Fuses: Fuse protection is provided for each individual load section and control circuit. POWER CONTROL: Resistive rated contactors SPACE HEATER: A space heater is supplied in the control section of the load enclosure for condensation control. MANUALS: (2) As built drawing manuals are provided at time of shipment. NOTE: The load bank circuit breaker is not included in this proposal. The load bank circuit breaker must be installed at the generator switchgear or generator junction box to protect both the load bank and 'cabling. A circuit breaker in the load bank will not meet code requirements for connection cable protection. L • FIEITEC LOAD TECHNOLOGY, INC. 4225 Production Court Las Vegas, NV 89115 Tel: 702/643-8750 o Fax: 702/643-8751 OPERATION Radiator/Duct Mounted Type No: OP_DCT1 3/20/98 Pg. #1 of .1 BASIC: MANUAL CONTROL with AUTOMATIC LOAD DUMP on LOSS of UTILITY POWER The Load Bank is a complete system with all necessary controls and devices to manually load a generator set. Circuitry provisions are supplied in the Load Bank to interface to the automatic transfer switch or other logic circuitry for proper system operation. If utility power is lost or the generator is supplying power to the system load, the Load Bank will be automatically disconnected. AUTOMATIC: With the Control Mode Switch(CMS) in the AUTO position, the Load Bank is enable for automatic operation. Automatic operation will disconnect the Load Bank when there is a utility power failure as indicated by the Interface with the Automatic Transfer Switch. With the CMS in the AUTO position and utility power available, manually starting of the generator enables the Load Bank With generator voltage available, placing any of the Individual Load Step Switches(LS) in the ON position will connect its respective load to the generator. MANUAL - With the CMS in the MAN position the Load Bank is enable for manual operation. Manual operation is the same as Automatic except the Load Bank will not be disconnected when utility power failures as indicated by the interface with the Automatic Transfer Switch. OFF ,- With the CMS in. the OFF position, all operations are disabled & locked -out. •L i. • FIIITEC LOAD TECHNOLOGY, INC- 4225 Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 INSTALLATION RECOMMENDATIONS & REQUIREMENTS RADIATOR MOUNTED TYPE #IN_DCT1 2/12198 Pg. 1 of 2 GENERAL • The Load Bank is designed for installations to utilize the generators radiator fan for cooling. • The Load Bank imposes approximately a static pressure load of 0.075-0.100" W.C. on the radiator's fan: • The installed ambient must not exceed the stated values specified in the Technical Description Sheet. PHYSICAL INSTALLATION • RADIATOR MOUNTING (OPEN GENERATOR) • The Load Bank is designed to match the radiator. The radiator's dimensional information provided at the time of order entry is used to design the unit to match the physical dimensions and attachment methods to the radiator. • When the radiator is equipped with an attachment flange that is perpendicular to the face of the radiator, the Load Bank enclosure is provided with a matching perpendicular flange that slides over the flange on the radiator. The flange on the Load Bank is then fastened to the radiator flange through the holes provided on the Load Bank flange. • When the radiator is equipped with a face surface hole pattern or a drillable surface area, the Load Bank enclosure is provided with a flange frame that attaches to the radiator. This flange frame creates a perpendicular flange on the radiator. The Load Banks matching perpendicular flange then slides ever the flange frame on the radiator. The flange on the Load Bank is then fastened to the radiator flange frame • with the provided hardware: • Depending on the weight of the Load Bank and the structural capability of the radiator mounting surface, the Load Bank may need additional support. The Load Bank enclosure is provided with base support provisions as detailed on the Elevation drawing. These structural threaded inserts can be used to attach bracketing that would provided additional support from the radiator mounting structure or the grade surface. • The Load Bank enclosure is also equipped with a perpendicular attachment flange on the exhaust side. This flange is provides as an attachment surface for the duct work to exhaust the heated air from the radiator and Load Bank exterior of the generator room. • The. exhaust flange on the Load Bank must be used to seal the transition from the Load Bank to the exterior duct work. The hot exhaust air must not be allowed to re -circulate back through the radiator cooling fan. The generator's cooling fan creates a negative pressure in the installed area, any opening in the exhaust ductwork will provide a forced re -circulation emphasized by the positive pressure of the exhaust duct work. • GENERATOR ENCLOSURE MOUNTING (EXTERIOR SURFACE) • The Load Bank is designed with a weatherproof enclosure to mounted to the radiator exhaust opening of the generator enclosure. The radiator's dimensional information provided at the time of order entry was used to design the unit to match the physical dimensions and attachment methods of the enclosure. • • The radiator exhaust opening provided in the enclosure should be the same size as the radiator core size. Enlargement of the opening will cause low air flows at the perimeter and lower air velocities over the entire Load Bank area. This will seriously affect the cooling performance of the Load Bank and could' cause overheating failure. • The radiator mounted inside of the enclosure must also be have sealed exhaust duct work to the enclosure exterior to eliminate re -circulation around the radiator. Re -circulation around the radiator will reduce the cooling air flow through the Load Bank. • The generator enclosure should be provided a face surface hole pattern or a drillable surface area for attachment of the Load Bank. The Load Bank enclosure is provided with a flange frame that attaches to the enclosure surface. This flange frame creates a perpendicular flange on the enclosure. The Load Banks matching perpendicular flange then slides over the flange frame on the enclosure. The flange on the Load Bank is then fastened to the radiator flange frame with the provided hardware. • Depending on the weight of the Load Bank and the structural capability of the enclosure's mounting surface, the Load Bank may need additional support. The Load Bank enclosure is provided with base support provisions as detailed on the Elevation drawing. These structural threaded inserts can be used to attach bracketing that would provided additional support from the enclosure base or the grade surface. • L FIEITEC LOAD TECHNOLOGY, INC. 4225 Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 INSTALLATION RECOMMENDATIONS & REQUIREMENTS RADIATOR MOUNTED TYPE #IN2DCT1 2/12/98 Pg. 2 of 2 • GENERATOR ENCLOSURE MOUNTING (INTERIOR) • Installation of the Load Bank inside of a compact modular generator enclosure is similar to installation previously described in the "RADIATOR MOUNTING (OPEN GENERATOR)" section with a few additional considerations. • • Follow the instruction for the installation of the Load Bank enclosure to the radiator detailed in the previous "RADIATOR MOUNTING (OPEN GENERATOR)" section. • The exhaust flange on the Load Bank must be used to seal the exhaust of the Load Bank to the exterior of the enclosure. The hot exhaust air must not be allowed to re -circulate back through the radiator cooling fan. The generator's cooling fan creates a negative pressure inside of the enclosure and any opening in the exhaust ductwork will provide a forced re -circulation emphasized by the positive pressure of the exhaust duct work. • These compact style enclosures provided minimal interior clearances, but minimum clearances must be maintain to assure proper Load Bank operation. • The ambient air in the front corners of the generator enclosure may be stagnant causing the radiant heat of the radiator and the Load Bank to elevate the temperatures above acceptable maximum ambient. Air intake louvers in the generator enclosure should be considered for installation in the area of the Load Bank's power connection and access area. This will provided fresh ambient air when the generator and Load Bank is operating. • If the generator enclosure dan not be provided with fresh are louvers and the interior ambient will exceed the specified maximum, consideration should be given to the installation of an optional ductable control section cooling fan. • It is recommended that the generator enclosure is equipped with a hinged access to the power connection and access side of the Load Bank enclosure. ELECTRICAL CONNECTION • The Load Bank electrical connection requirements are detailed by the drawing manual provided. • The Load Bank will require power connection to the generator power output and, if provided with a remote panel, the control panel will have to be installed and wired to the load enclosure. • Connect the required power conductors from the generator to the Load Bank's Main Bus connection points: as detailed by the supplied drawings for the specific unit. All connections must take in consideration National Electrical Code and any local code requirements concerning, but not limited to, cable sizing, wiring methods, and over current protection. • Particular attention must be made in properly grounding the Load Bank per National Electrical Code and any local codes. I1ARNItif�", FOR OPERATOR SAFETY The Load Bank MUST BE ELECTRICALLY GROUNDED in accordance with the National Electrical Code & any local codes. • Control panel connection points as detailed by the supplied drawings for the specific unit. All connections must be made in accordance with the National Electrical Code and any local code requirements concerning, but not limited to, cable sizing, wiring methods, and over correct protection. • Depending on the control functions provide, certain wiring to extemal monitoring or control points may be • required. If required, these connection should be made as detailed by the supplied drawings for the specific unit. All connections must be made in accordance with the National Electrical Code and any local codes. 10 1 L RDTEC LOAD TECHNOLOGY. INC. 4225 Production Court, Las Vegas, NV 89115 Tel 702/643-8750 a Fax: 702/643-8751 No Device 1 **L 2 **L 3 C01-08 4 CF01-03 5 CFL05 6 CFRO5 7 CMS05 8 CPT 9 CTS 10 ENCL_LB 11 ENCL_LB 12 ENCL LB 13 ENCL_LB 14 ENCL LB 15 ENCL 16 ENCL 17 F01-48 18 FBLK 19 LR01-270 20 LS51-55 21 LUGS_GND BILL of MATERIALS WO#: 220178 as of 11/04/02, Page # 1 Qty Description***************************************************** LTI# Manufacturer Part Number**************** 6 LIGHT: BASE, SQUARE, OILTIGHT, MINITURE BAYONET BASE 120016 IDEC UPOW-199 6 BULB: 120V, MINIATURE BAYONET BASE 020001 IDEC L-120-L 8 CONTACTOR: 85A @ 600 VAC, 3P, 120VAC COIL, 10/30HP 030121 SPRECHER+SCHUH CA7-43-10-U-120-NO 2 FUSE: 5 AMP, 600 VAC 060001 'BUSSMANN KTKS 5 LENSE: RED, SQUARE, TRANSPARENT 120017 IDEC 1 RELAY: 3PDT, 10A @ 28VDC/120VAC, 180084. IDEC APQW1BL-R 120VAC COIL, BACK MOUNTED RR3B-US-AC120V 1 TOGGLE SWITCH: DPDT, 3 POS, 10A @ 250 VAC, 1/4" TAB TERM. 190002 CARLING, 2GM51-73 1 TRANSFORMER: 350 VA, 480/240:120 200060 ACME 1 THERMOSTAT SWITCH: SPST, N.O., 190089 DAYTON 1 POWER PANEL: DUCT LB, 18"(NOM.) 050241 LOADTEC TA-2-81214 ADJ. 140-180 F. 4E117 WIDE, 8XL/8OD/10DY 050241 3 MAIN BUS:- DUCT LB, 18"(NOM,) WIDE, 8XL/80D/10DY 020034 LOADTEC 020034 1 LUG BUS: "A"PH, DUCT LB, 020029 LOADTEC 18"(NOM.) WIDE, XL/OD/DY 020029 1 LUG BUS: "B"PH, DUCT LB, 18"(NOM. 020030 LOADTEC 1 LUG BUS: "C"PH, DUCT LB, 18"(NOM. 020031 LOADTEC WIDE, XL/OD/DY 020030 WIDE, XL/OD/DY 020031 1 LOAD BANK ENCL: DUCT MTD W/O CNTRL, NEMA 3R, 100.00"H x 100.00"W 050204 LOADTEC ODLD 3 DOOR LATCH: SELF ADJUSTING, 080033 SOUTHCO 45 FUSE: 100 AMP, CLASS "T" 060019 BUSSMANN SLOTTED FLUSH HEAD, .750-1.125 GRIP, 44-10-21-0 1 FUSE BLOCK: 30 AMP, 3 POLE, CLASS "M" 060010 BUSSMANN 270 LOAD RESISTOR: 2778W @ 160V 180199 LOADTEC JJN100 BM6033SQ LR2778/160/064/8.78-51.5 5 TOGGLE SWITCH: DPDT, 2 POS, 10A @ 250 VAC, 1/4" TAB TERM. • 190036 CARLING 2GL51-73 2 MECHANICAL LUG: (2) 350MCM-#6AWG 120035 ILSCO AU-350 HEITEC LOAD TECHNOLOGY. INC. 4225 Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 4 Fax: 702/643-8751 BILL of MATERIALS WO#: 220178: as of 11/04/02, Page # 2 No Device Qty Description LTI# Manufacturer************** Part Numb 22 LUGS_PB 3 MECHANICAL LUG: (4) 600MCM-#2AWG 120049 ILSCO • PB4-600 23 NP_CMS05 1 NAMEPLATE: 3.0" x 9.38" BWL, LOAD BANK CONTROL-(6)PT W/LIGHT 140204 LOADTEC NP014 D 24 SL51-55 5 LENSE: BLUE, SQUARE, TRANSPARENT 120020 IDEC APQW1BL-S 12 TERMINAL BLOCK SECTION: 30 AMP, 600 V, TUBULAR CLAMP TYPE 200014 BUCHANAN 715 25 TB09 26 TB09 27 TB10 28 TB10 29-TS 1 TERMINAL BLOCK END BARRIER: 30 AMP BLOCK 200015. BUCHANAN 730 12 TERMINAL BLOCK SECTION: 30 AMP, 600 V, TUBULAR CLAMP TYPE 200014 BUCHANAN 715 1 TERMINAL BLOCK END BARRIER: 30 AMP BLOCK 200015 BUCHANAN 730 1 TEMPERATURE SW: SPST, N.O., SET AT 350 F., MANGE MOUNT 1D2B2-A(350F)' i'90024 VULCAN • END OF REPORT: 2-PAGES •L • FIEITEC LOAD TECHNOLOGY, INC. 4225 Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 AFL .... Air Flow Failure Light AFR .... Air Flow Relay AFS .... Air Flow Switch ALL .... Auxiliary Unit Light ALR .... Automatic Load Relay ALS .... Auxiliary Unit Control Sw. AM .... Ammeter AML .... Automatic Mode Light AMS .... Ammeter Phase Sw. AOL .... Automatic Operation Light ARS .... Ammeter Range Sw. ASR .... Alarm Silence Relay ASS .... Alarm Silence Switch BLDL .... Bypassed Load Dump Light C .... Load Contactor C_T ... Contactor Timer CABLE .... Cable Ref CEL .... Control Enabled Light CF .... Control Circuit Fuse CFL .... Cooling Failure Light CFR .... Cooling Failure Relay CLR .... Control Location Relay CLS .... Control Location Switch CMS .... Control Mode Switch CNTL .... Control Panel_Ref CPB .... Control Power Circuit Breaker CPC .... Control Power Contactor CPL - .... Control Power Light CPR .... Control Power Relay CPS .... Control Power Switch CPT .... Control Power Transformer CPU .... PLC Processor Unit CR .... Current Relay CSR ..,. Control Pwr Source/Rotation Sw CSS .... Control Power Source Switch CT .... Current Transformer CVS .... Control Voltage Sw. CXR .... Contactor Pilot Relay CXT .... Current Transducer D .... Diode DIS .... Door Interlock Sw. DPB .... Disable Pushbutton EFL .... Exercise Failure Light EFR .... Exercise Failure Relay EFT .... Exercise Failure Timer ENCL .... Enclosure_Ref ENR .... Enable Relay EPB .... Enable Pushbutton ER .... Emergency Relay EXDC .... Exerdse Day Counter EXL .... Exercise Light EXR .... Exercise Relay • EXT .... Exercise Timer EXTR .... Exercise Timer Pilot Realy F .... Load Fuse FAN .... Fan Blade FBLK .... Fuse Block FFS .... Fan Start / Failure Reset Sw FL .... Common Failure Light FM .... Frequency Meter FNR .... Fan Relay FR .... Failure Relay FRL .... Fan Running Light FRS .... Fan Rotation Switch FSR .... Frequency Sensing Relay FT .... Frequency Transducer GFL .... Ground Fault Light GFR .... Ground Fault Relay DRAWING LEGEND GFS .... Ground Fault Sensor GND .... Ground GSL .... Generator Starting Light HRN .... Hom HSS .... Hom Silence Switch HVC .... High Voltage Contactor HZFR .... Freq. (Hertz) Failure Relay HZFT .... Freq. (Hertz) Falure Timer HZR .... Frequency (Hertz) Relay INSUL .... Stand -Off Insulator KVM .... Kilovar Meter KVT .... Kilovar Transducer KWM .... Kilowatt Meter KWMS .... Kilowatt Meter Switch KWT .... Kilowatt Transducer L .... Line LBOL .... Load Bank Operating Light LCF .... Load Conned Failure LCL .... Local Control Light LOL .... Load Dump Light LDMS .... Load Dump Mode Sw. LDR, .... Load Dump Relay LI .... Load Inductor LR .... Load Resistor LRS .... Local / Remote Control Switch LS • .... Load Step Switch LST .... Load Sequence Timer LTC .... Loaded To Capacity LUG .... Terminal Lug.,Ref LVC .... Low Voltage Contactor LVR .... Low Voltage Relay LVS .... Load Voltage Switch MBM .... Metering Base Module MC .... Motor Contactor MCB .... Main Circuit Breaker MCH .... Motor Contactor -Hi Voltage MCHT .... Motor Contactor -High V. Timer MCL .... Motor Contactor -Low Voltage MCLT .... Motor Contactor -Low V. Timer MOM .... Metering Display Module MDS .... Main Disconnect Switch MLL .... Master Load Light MLR .... Master Load Relay MLS .... Master Load Switch MML .... Manual Mode Light MMR .... Metering Mode Relay MMS .... Metering Mode Switch MOD .... PLC I/O Module MOL .... Manual Operation Light - MOR .... Manual Override Relay MOT .... Fan Motor MOV .... Metal Oxide Varistor MPT .... Metering Potential Transformer MR .... Metering Relay NAL .... Not In Auto Light NAR .... Not In Auto Relay NEU .... Neutral NOL .... Normal Operation Light NOR .... Normal Operation Relay NP .... Nameplate NPR .... Normal Power Relay NPT .... Normal Power Timer NR .... Normal Relay OFP .... Load OFF Pushbutton OIP .... Operator Interface Panel OLL .... Over Load Light OLR .... Overload Relay ONP .... Load ON Pushbutton OTL .... Over Temperature Light . OVL .... Over Voltage Light OVR .... Over Voltage Relay OVS .... Over Voltage Sensor PB .... Pushbutton Switch PBF .... Pushbutton OFF PBN .... Pushbutton ON PC .... Pilot Contactor PCL .... Power Connected Indicator PFM .... Power Factor Meter PFMS .... Power Factor Meter Switch PFR .... PLC Failure Relay • PFT .... Power Factor Transducer PLC .... Programmable Logic Controller PLG .... Plug PT .... Potential Transformer R .... Resistor RAC .... Rotation ABC Contactor RAT .... Rotation ABC Timer RB .... Rectifier Bridge RBC .... Rotation BAC Contactor RBT .... Rotation BAC Timer RCL .... Remote Control Light RCP .... Receptade , ROL .... Remote Disconnect Light RHS .... Metering Read/Hold Switch RLDL .... Remote Load Dump Light RLY .... Relay RPR .... Reverse Power Relay RSR .... Reset Relay RSS .... Reset Switch RSTS .... Reset Switch RTD .... Resistance Temperature Device RTM .... Running Time Meter SEL .... Section Enable Light SH .... Space Heater SHC .... Space Heater Contactor SHD .... Space Heater Disconnect SL .... Load Step Light •SNT .... Shunt SR .... Step Relay SSR .... Solid State Relay ST .... Shunt Trip T .... Load Connection TB .... Terminal Block TCS .... Test Control $witch TDEC .... Time Delay Engine Cooldown TDF .... Time Delay Failure TDI .... Time Delay Initial TDLC .... Time Delay Load Bank Cooldown TDS .... Time Delay Sequence THS .... Thermostat Switch TS .... Temperature Switch TSL .... Test Source Light TSP .... Test Start Pushbutton TSR Temperature Sw. Relay TSS .... Test Source Selector TTL .... Transformer Over Temp. Light UFS .... Under Frequency Switch UVS .... Under Voltage Sensor VAR .... Voltage Adjust Rheostat VHL .... Voltage / Hertz Failure Light VLS .... Venter Load Switch VM .... Voltmeter VMS .... Voltmeter Phase Switch VPI .... Vernier Position Indicator VRC .... Variable Auto Transformer VT .... Voltage Transducer DvcLgnd980064 • OD CO • in ;; ;[ r et $ k § § ■ 1 • 0 • y < I W6IO ff aka) 8 3&. 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C01-I 2l lil. lie 1 QQ IFC01-2 3iy� COS-3 l� i IL2 C01-3V IF li9 112 las CM -I Ile lit li4 'r C04-2 i3 lie QQQQ lie '13 0--� C04-3 d 'Z• 219 Ty r 2F-2 218 211 2: 213 219 2l4 2i3 CO2-3 211 ®0-2 214 2ir 2i3 222 tie C®-3 n 111 Ile 113 'Y F29 113 IF IF i tits F-A 7 113 b Zjl F3fi 2i�•y021 211 1 �13 F34 21,3 219 F41.�z . 715 223 241 FI2 27 2l1 V 20 F40 2, ala O 0 O 0 O 0 O 0 O 0 O 0 215 Ill tie 7F47 211 F23 _ Il2 2i4 it 2r IF l3 i IF 21! l lie F46 211 22 F22 7 Ill 213 2F • L FIEITEC LOAD TECHNOLOGY, INC. 4225 Production Court, Las Vegas, NV 89115 Tel: 702/643-8750 Fax: 702/643-8751 LIMITED WARRANTY TERMS LOADTEC, Load Technology Inc. warrants thats its products are free from defects in material and/or workmanship under normal use and service. Its liability under this warranty shall be limited to twelve (12) months from date of shipment for all products and/or components except those associated with the "RESISTAR" Load Resistor assemblies which are limited to thirty six (36) months from date of shipment. The "RESISTAR" Load Resistor assemblies extended warranty is limited to the failure of the Alloy wire, its termination, and workmanship of the assembly. The warranty liability is limited to repair or replacement, at its option, at the factory orauthorized service station with products and/or components returned with transportation costs prepaid. Returned products and/or components that are determined defective and within the warranty period will be repaired or replaced, and returned F.O.B. factory or repair station, freight charges collect. This warranty does not cover incidental and consequential damages, nor does this warranty cover defects caused by misuse, improper installation, modifications, shipping damage, accident, or labor charges, service charges, or any liability except repair or replacement of the products and/or components. This warranty is in lieu of any other warranties, expressed or implied. FRM_W NTY_94243 6 Isolated 4 to 20 mA Transmitters For Demanding Applications Thermocouples, RTD or Ohms, Millivolts, Milliamps, Volts • ExNFtksr r 1/47—ite,eri w,a-rcg 100 TErnt rizA- rciRr S 115i1 200,0 ✓ Isolated to 1500 V rms ✓ Two -Wire 4 to 20 mA Operation ✓ 9-50 V Compliance ✓ Turndown Ratio to 10:1 ✓ NMV Protection to 120 Vac ✓ -40 to +85°C (-40 to 185°F) Operation ✓ Shock Resistance to 55 g ✓ NEMA-4X Metal Case ✓ Field -Scalable Unmatched Electrical Performance Two -wire Operation Power is obtained directly from the 4 to 20 mA loop, with no need for separate power input. This simplifies field wiring and eliminates the possibility of noise pickup from power lines. Custom Scaling Available. Specify input signals corresponding to 4 and 20 mA Isolation to 1500 V rms (2100 Vp) This exceptionally high CMV rating from the input to the case or output eliminates the possibility of electrical ground loops between the signal source and the receiver. It also provides a high degree of protection for the receiver against electrical hazards, such as accidental contact between the signal source and an -AC power line. 9 to 50 V Compliance The loop voltage driving the transmitters can be from 9 to 50 V without loss of accuracy. The exceptionally low 9 V limit allows the transmitters to be used with low loop supply voltages, and it maximizes the voltage drop allowed in the current loop for intrinsic safety N-17 barriers and load resistance. For example, at the full 20 mA output of the transmitter, a 750 ohm load can be used with a 24 Vde source and a 150 ohm load can be used with a 12 Vdc source. In either case, there will still be enough voltage left to power the transmitter, namely 9 Vdc. 10:1 Turndown Ratio Turndown ratio is defined as zero suppression divided by span. The exceptionally high 10:1 turndown ratio possible with the TX1500 Series indicates that wide zero offset can be combined with narrow signal span for closed loop control at high gain. The signal span can also be wide for control of batch operations, where a wide range of signal levels may be encountered over the entire batch cycle. C s icalApplication of The kat)9 ttt&a tipllfies,a jo,M Thetivblfj e deteaf4 ,In the regeivfn�pulp ent. APE p ssibili of'gro nd ioo$ beb 10High Overvoltage rotection Overvoltage of 120 Vac may be applied across the input or output leads for 1 minute in case of all models with voltage or thermocouple input. Reverse polarity of 400 Vp may be applied across the output leads indefinitely. These exceptionally high NMV overvoltage ratings provide further protection against possible electrical faults and wiring errors. Designed for Harsh Environments Extreme Operating Temperatures The operating temperature can be from -40°C to +85°C (-40°F to +185°F) while meeting published performance specifications. This allows the TX1500 Series to be used near furnaces or outdoors in the winter. The exceptionally wide operating temperature range is made possible by a proprietary electrical circuit and by extensive use of computer -graded and computer -matched electrical components. Resistant to Shock and Vibration he shock rating is 55 g, which ncludes a 6-foot drop onto concrete. This is made possible by a compact die-cast metal case, Electromagnetic interference (EMI) which is only 74 mm (2.9") in diameter, and by rugged mounting of the electronics. The circuit board assembly is in the shape of a rigid box and is firmly soldered to the top of the transmitter case. Waterproof Case The case is made of die-cast zinc alloy. It is waterproof to 35 kPa (5 PSI) and meets NEMA-4X standards. The top of the case is sealed against the bottom with a fluorosilicone gasket, and the openings in the top of the case for the zero and span adjustment are sealed with fluorosilicone plugs. Explosion -proof Housing Options Three external NEMA-7 explosion -proof and NEMA-4 waterproof enclosures are available as options for use in hazardous locations in Class I, Groups B, C, D; and Class II, Groups E, F, G. Option EPH1 is a single -height, all -metal housing for a single 500-Series transmitter. FM and CENELEC EEx d II C certification is standard. Option EPW2 is a double -height metal enclosure with a glass window for a TX1500-Series transmitter on the bottom and a N-18 TX83A loop -powered indicator on top. FM and CENELEC EEx d II C certification is standard. The TX83A augments the transmitter with an LCD digital readout scaled in engineering units and only adds a modest 2.5 V drop to the current loop. Option EPW3 is a single -height enclosure for one TX83A loop -powered indicator. FM and • CENELEC EEx d II C certification is standard. Easy to Calibrate and Install There is no need to specify different models for different ranges of the same signal type. Zero and span are each set by push -on jumpers for coarse range selection and by a 15-turn precision potentiometer for fine adjustment. The two potentiometers are accessible from outside of the case through openings which are normally sealed by fluorosilicone plugs. To assist in calibration, two test terminals provide a 10 mV/mA output (200 mV full-scale). The scaling procedure is documented in a comprehensive user's manual, which is shipped with every unit. Quick Selection Guide by Input Type yaa1FS 7 ) p c tt Effrii in.L R ' " Jh' Yl ! �i R jfea®ut., "ti; :AT -� �' 1 £ 100 to 1050°C 180 to 1890°F 35 to 400 0 1. •4"3 'P7� 13 , Wp%t N/A TX1 RTD Pt 100 Ohms 200 to 750°C -328 to 1382°1 0 to 365 SZ 850°C 562°F 400 i2 TX1502 J Type J T/C Iron-Constantan 50 to 660°C -58 to1220°F 760°C 1400°F 100 to 810°C 180 to' 1458°F 5 MO(E1kµhu.W TX7502A-K Type K T/C Chromel-Alumei -50 to 1272°C -58 to 2322°F 1372°C 2502°F 100 to1422°C 180 to 2560°F 5 Mfg TX1 T Type T T/C Copper-Constantan -50 to 350°C -58 to 662°F 400°C 752°F 50 to 450°C 90 to 810°F 5 Mfg TX1502 -E CLO A i EfL) Type E T/C Chromel-Constantan -50 to 900°C -58 to1652°F 1000°C 1832°F 100 to 1050°C 180 to 1890°F 5 MO TX1504 Millivolts -30 to 60 mV 160 mV 5 to 100 mV 100 MO TX1505 Milliamps -30 to 60 mA 160 mA 5 to 100 mA 1 11 TX1506-1 Low Volts -3.5 to 6.0 V 11 V 0.5 to 5 V 1 MCI TX1506-2 High Volts -35 to 60 V 110 V 5 to 50 V 1 Mf2 Common Specifications, All Models Signal Output Connection: 2-wire Linear Range: 4 to 20 mA Maximum Output: 35 mA Voltage Compliance: 9 to 50 Vdc Power Supply Rejection: 0.01 % of spanNolt Input/Output Protection CMV, Input to Case or Output: 2100 Vp per HV test, 354 Vp per IEC spacing CMR, Input to Case or Output: 120 dB, DC to 60 Hz NMV Across Output Leads: 120 Vac for 1 min Reverse Polarity Across Output Leads: 400 Vp Accuracy: -40°C to +85°C Hysteresis & Repeatability: ±0.1%of span 6-month Stability Error: ±0.2% of zero suppression Error Due to 50°C Change in Transmitter Temperature: Zero Error. ±0.2% of zero suppression Span Error ±0.2% of span Environmental Operating temperature: -40 to 85°C (-40 to 185°F) Storage Temperature: -55 to 125°C (-67 to 257°F) Relative Humidity: 0 to 100% (sealed case) Watertight Proof Pressure: 35 kPa (5 PSI) Shock: 55 g, half sine, 9 to 13 ms duration Vibration: 1.52 mm (0.06") double amplitude, 10 to 80 Hz cycled . N-19 Mechanical Case Material: Zamak• zinc alloy Gasket Material: Fluorosilicone Diameter: 74 mm (2.9") Height, Including Barriers: 53mm(2.1") Weight: 380 g (13 oz) Electrical Connection: #6 screws with wire damps Terminal Protection: Standard: Screw terminal barriers plus barrier strip cover - CPB1 (Optional): Plastic cover for case top (protects TIC screw terminals from air currents) y-2anA CAu$Rkfqu ?ate C°F) Ito -13co° o -; co ° 1/Non-Common Specifications RTD Input Model TX1501 Signal Source: Pt 100 RTD Span for 4-20 mA Output: 100 to 1050°C (180 to 1890°F) Zero, Suppression: -200 to 750°C (-328 to 1382°F) Source Connection: 2- or 3-wire Excitation Current: 200 pA Lead Resistance, Max: 100 0 Bandwidth: DC-60 Hz Ohms Input Model TX1501 Signal Source: 0-400 52 Span for 4-20 mA Output: 35to400S2 Zero Suppression: 0 to 365 Source Connection: 2- or 3-wire Excitation Current: 200 pA Lead Resistance, Max: 100 S2 Bandwidth: DC-60 Hz AodpITX15bS ;i ,IX} 2U{nAloop isolator,: The TX1505'can he used as a A 20 mA ourrerit loop isolator, The mput"and output Ioops`a?e? each powered by their'own supply: w l Thermocouple Input Model TX1502A Span and Zero Suppression: See input table Input Resistance (Open T/C Detector Resistance): 5 M52 , Bias Current, Max: 50 nA NMV Across Input Leads: 120 Vac for 1 min NMR Across Input Leads: 40 dB, 50/60 Hz, 100 mV input Thermocouple Lead Resistance: For specified performance: 100 52 Maximum: 10 kO2 Step Response, Type: 400 ms Millivolt Input Model TX1504 Span for 4-20 mA Output: 5 to 100 mV Zero Suppression: -30 to 60 mV Input Resistance: 100 Mil Bias Current, Max: 50 nA NMV Across Input Leads: 120 Vac for 1 min NMR Across Input Leads: 40 dB, 50/60 Hz, 100 mV input Step Response, Type: 400 ms N-20 34.4 (2.93I Milliamp Input Model TX1505 Span for 4-20 mA Output: 5 to 100 mA Zero Suppression: -30 to 60 mA Input Resistance: 1 12 Step Response, Type: 400 ms Volt Input Model TX1506 Span for 4-20 mA Output: 0.5 to 5 V (TX506-1); 5 to 50 V (TX506-2) Zero Suppression: -3.5 to 6.0 V (TX506-1); -35 to 60 V (TX506-2) Input Resistance: 1 M52 Bias Current, Max: 1 nA NMV Across Input Leads: 120 Vac for 1 min NMR Across Input Leads: 40 dB, 50/60 Hz, 100 mV input Step Response, Type: 400 ms Dimensions: mm (in) 5 .8 [2.041-1 63.5 [2. IS • Pressure Transmitters and Pressure Transducers PXMS and PXDGS Series Description The PiCMS Series pressure transmitter and the PXDGS Series pressure transducer are state-of- the-art instruments providing 4 to 20 mA (PXMS) or 1-5 VDC (PXDGS) outputs. They feature a precision micro -machined silicon diaphragm with fully welded stainless steel pressure port for greater accuracy, stability and a wide range of compatibility. Silicon technology is used to provide a miniature micro -machined diaphragm which is' electrostatically bonded to a glass substrate and is then stitch -bonded within a glass to metal seal assembly to provide exceptional thermal and stress isolation. This technology assures you of high accuracy and stability over a wide range of operating conditions. The enclosure is made of 316 stainless steel and all wetted parts are 316L stainless steel. Applications The PXMS and PXDGS• models can be used in applications such as Compressors, Engines, Process Control, Liquid Level and Pumps. Specifications Accuracy (Full Scale, Best Straight Line): ±0.25% including non -linearity, hysteresis and repeatability. Long term stability better than 0.25% FS over twelve (12) months. Overpressure/Proof Pressure: 400% for up to 500 psi (3.45 MPa) [34 Bar]. 200% for higher ranges. EyG/.v6 0/1._ ssRe la 0.25% Accuracy m 4-20 mA or 1-5 VDC Output Signal m Precision Etched Silicon Sensor la Field Adjustable Corrosion Resistant Construction m High Stability Burst Pressure: Lower of 4000 psi (27.58 MPa) [275 Bar] or 600% for ranges 5 2,000 psi (13.79 MPa) [137 Bar]; 20,000 psi (137.90 MPa) [1379 Bar] for ranges>2,000 psi ' (13.79 MPa) [137 Bar]. Response Time: Frequency response better than 2 kHz. Temperature: Storage: -65 to 200°F (-54 to 93°C). Operating: -40 to 180°F (-40 to 82°C). Compensated: -20 to 160°F (-29 to 71 °C). Total Thermal Effects Over Compensated Range: t2% FS TEB except ±4% FS TEB for +30 in. H2O range. Environmental Effect: Humidity: No effect. Mounting: Position/orientation has negligible effect. Shock/Vibration: Negligible effect unless severe. Physical: Enclosure: Weather Resistant (IP65). Body: 316 stainless steel. Meets NACE MR01-75. Wetted Parts: 316L stainless steel. Process Connection: 1/4 APT female. Electrical Cable: Integral; 36 in. (914 ram); vented. PXMS Power Requirements: Typically 24 VDC is required. Using the Loop Resistance Graph, 9-30 VDC. PXDGS Power Requirements: 6-30 VDC, 2 mA typical. PXMS Series Transmitter Output: 4-20 mA, 2-wire. PXDGS Series Transducer Output: 1-5 VDC, 3-wire. - Insulation: Greater than 10 Maim® 500 VDC. RFI Protection: included. Voltage Surge/Spike: Protected against a 600 V spike to IEC 60-2. Reverse polarity protected. Zero Offset and Span Setting: ±0.5%FS. Field adjustable 15.0°% FS via potentiometer. Sealed or Vented: Vented for ranges <=1000 psi (6.89 MPa) [68 Bar]. Sealed at one atmosphere at sea level for ranges> 1000 psi (6.89 MPa) [68 Bar]. *Laboratory Approvals: UL/cUL Class I, Div. I, Groups A, B, C, D. Class 11, Division 1, Groups E, F, G; when installed with approved barrier per drawings 05-08-0006 for PXMS models or 05-08-0747 PXDGS models (units through 6000 psi [34.48 MPa] [344 bar] only). Shipping Weigh: 0.90 Ib. (408 g). Shipping Dimensions: 5 x 5 x 5 inches (127 x 127 x 127 mm). Warranty A one-year limited warranty on materials and workmanship is given with this Murphy product. Details are available on:request and are packed with each unit. Dimensions PXMS and PXDGS Dimensions 1/4 NPTF 7/8 Hex Stainless Steel 2-23/32 in. (69 mm) 316 Stainless Steel Housing 1-13/64 in. 1(31 ram) t 1,' 36 in. (915 mm) long cable-std. Order These Options Separately SSA-XM Stainless Steel Pressure Adapter (86031205) 1/4 NPTM NOTE Maximum working pre sure: 5,0 0 psi (34 48 MPa) (344 Bar]. 1/2 NPT Conduit Connector (05004538) 2-7/18In. 1 (62 ram) 1-1/2 Hex Loop Resistance Graph Oupply voltage for the PXMS must be within range of 9-30 VDC. The Graph below • hms the minimum supply voltage (VDC) required for a given load resistance (RL). 1500 500 10 14w4? 20 30 40 250 ohm Power Supply Voltage (VDC) *NOTE Cable resistance effect included in RL. inurphq FWMurphy P.O.Elm 470248 Tulsa, Oklahoma 74147 USA (9181627-3550 fax (9187664.6146 e-motl sales@fwmurphy.mm www.fwmurphy.com 50 CONTROL SYSTEMS 6, SERVICES DIVISION P.D. Box 1019; Rosenberg, Texas 77471; MA 1180 342-0297 lax 12811341-6006 e-mail wles4Rfwmmphyxom MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Raha Cordem 300, Harden del Aguaie Sen Luis Palosi, S.LP.; Mexico 78384 +52-48.206264 fax +5248-206336 e-mail ventasmex@rourphymex.mm cox How to Order To order, please use the part number designation below. Part number example: PXMS-5000 Model PXMS=hczme hansmiticr(4-1OsnAo ur. PXIIGn= rtssure eter dVDC mimes). Pressure Ranger: Specify Far this range 30V30WC -30 to+30" H2O (-76 to +76cm 1120) 30V30 -30" Hg to+30 psig (-76 cm Hg 1o207 kPa) [2.07 Bar] 30V100 -30" Hg to+100 psig (-76 cm Hg to 689 kPa) [6.89 Bar] 5 0-5 psi Is 0-15 psi 30 0-30 psi 60 0.60psi 100 0-100 psi 200 0-200 psi (34 kPa) [0.34 Bar] (103 kPa) [1.03 Bar] (207 kPa) [2.07 Bar] (414 kPa) [4.14 Bar] (689 kPa) [6.89 Bar] (1.38 MPa) (13.80 Bar] 300 400 600 1000 2000 3000 5000 6000 7500 10000 0-300 psi 0-400 psi 0-600 psi 0-1,000 psi 0-2,000 psi 0-3,000 psi 0-5,000 psi 0.6,000 psi 0-7,500 psi 0-10,000 psi (2.07 MPa) (2.75 MPa) (4.14 MPa) (6.89 MPa) (13.79 MPa) (20.69 MPa) (34.48 MPa) (41.37 MPa) (51.71 MPa) (68.95 MPa) tNOTEConversions are approximate. [20.70 Bar] [27.50 Bar] [41 Bar] [68 Bar] [137 Bar] [206 Bar] [344 Bar] [413 Bar] [517 Bar] [689 Bar] Replacement Parts —Order Separately 05052626= stainless steel adapter bushing I NPSM x (2) 1/4 NPTF 05050459 = carbon steel adapter bushing 1 NPSM x (2) 1/4 NPTF FRANK W. MURPHY, LTD. Church Rd; laverstock, Salisbury SPI 107; U.K +441722:410055 lax +441722 410088 e-mail sales@fwmurphy/o.uk www.lwmurphy.co.uk Far Service in French: Pour service en franmin +441722410697 lax +44 1722 410088 e-mail lmnce@lwmarphyxa.uk wmv.lwmurphy.m.uk/franmh.Mm MURPHY SWITCH OF CALIFORNIA 41343 121h Street West Palmdale, California 93551-1442; USA (661)2724700 fax e-mail sales@murphyswsnh.wm www.murphyswilchcom MACOUARRIE CORPORATION 1620 Hume Highway; Cnmphellfield, Vic 3061; Australia +61 3 9358.5555 fax +6139358-5558 e-ma8 murphy4Dmocquorrie.mm.au In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. P,mi.d It U.S • Existing Plumbing Plan For venting location • • •' 16 ( 4 • . . Or 'WS 14.4 • , CAPS Ara sr- it • (TUN OE 4 IN 6 LOCXDONS), 1 ol• to 0 :Voipirra,on.otk;: 'TURD PAL. M. eine, rat - - Nt. EITEL nth's% Ongechc vnuw ILL11.141 04. • . • . . ., • Mi ' • . . . .. . • .. '.. , . . - - . . . . , .. .. • - . . . . # 0 PROVIDE AHD DASTALL At nit 14414 tour 0' wit opL sum". LAE MOE 1TIE DX.* ATI bowsaw AFPROWD NW- ', ..SINCEI VALVE 2' sq. VALLE SMALL RE Of mar CCOSTRUCIOT WIN DASH ?DT PER WADIES CDEPAION AND - • • ' FRAIL BE FREFIDTTED UTTUDE3 WEIDEAMITIRIC cORP... TYPE A. OR APPROLED EQUAL. ..• y. . • alt • • CURLERS CET • A IPTUSE.ITIEFIDC PAD. ROOM FlpOITPLAN VADVAL VALVES MD. Eti WAIL . fliPPOITt YROTT DEL: DEARS TAYLOR at ASSOCIATES 714474431S PAX 714.374.133S %iitikreenArg Me mat* DIXIQH , • M-15271 12/31/9,9