80kW Standby / 70kW Prime Power Towable Generator 1.0 General The generator set covered by these specifications shall be a complete, operable and tested towable diesel generator by Caterpillar or an equivalent supplier. The sound attenuated generator shall be of robust quality construction. The generator shall be powered by a Caterpillar brand diesel engine with documented compliance to current EPA Tier emissions standards. The generator shall have well documented warnings and instructions so as to highlight electrical hazard and operation indicators using internationally recognized ISO symbols. 1.1 References and Standards The generator set covered by these specifications shall be designed, tested, rated, assembled and installed in strict accordance with all applicable standards below: (From spec sheet) ISO 8528 G1/G2 IEC60034-1 EN61000-6 NEMA MG-1.22 C22.2 No.100 UL142 NFPA 70, NFPA99 and NFPA 110 1.2 Requirements and Codes The equipment supplied shall meet the applicable requirements of the NEC and all applicable local codes and regulations. The generator set shall be constructed completely of all new components of current production. The supplier of the diesel engine must be the same entity as the generator packager and have a minimum of 25 years of equipment manufacturing experience. The source packaging facility must be certified to ISO9001 standards. 1.3 Substitution Proposed deviations from the specifications shall be treated as follows: 1.3.1 Substitution Time Requirement Requests for substitutions shall be made a minimum of ten (10) days prior to bid date. Manufacturers catalog data shall accompany each request and authorized acceptance shall be addenda only. 1.3.2 Substitution Responsibility The power system has been designed to the specified manufacturer's electrical and physical characteristics. The equipment sizing, spacing, amounts, electrical wiring, and other characteristics have all been sized and designed around CATERPILLAR supplied equipment.
Should any substitutions be made, the bidder shall bear responsibility for the installation, coordination and operation of the system as well as any engineering and redesign costs, which may result from such substitutions. 1.4 Submittals Engine-generator submittals shall include the following information: 1. Factory published specification sheet including total equipment weight, power output at available voltages, oil capacity, fuel capacity, fuel consumption, cooling capacity, airflow, exhaust flow, and generator set noise provided in dba as an 8 point logarithmic average at 23 ft. 2. Manufacturer s catalog cut sheets of all optional equipment. 3. Manufacturer's warranty statement 1.5 Warranty The genset warranty period shall be 12 months with no limitation on the number of available run hours for prime power applications and 24 months and 1000 hours for standby applications. All terms begin after date of delivery to the first user. 1.6 Service The engine-generator supplier shall maintain 24-hour parts and service capability within 100 miles of the buyer s location. The distributor shall stock parts as needed to support the generator set package for this specific project. The supplier must carry sufficient inventory to cover no less than 80% parts service within 24hrs and 95% within 48 hours. The supplier shall provide factory certified electric power service technicians. 1.6.1 Extended Service Coverage The genset supplier shall provide firm quote for an optional extended service coverage contract for 5 years and 2500 hours with no deductible. Extended Service Coverage provides for 100 percent of usual and customary parts and labor costs for failures due to defects in materials and workmanship to the as shipped consist from the factory, excluding certain items such as trailer components and consumables as outlined in the ESC contract document up to 8 hours and 320 miles per incident. 2.0 Product Requirements 2.1 Rating The generator set shall be a Caterpillar Model XQ80 rated for prime power duty and operating at 1800 RPM (60 Hertz) with the minimum power output capabilities: 208/120V 3-phase, 4-wire, prime power: 70kW (87.5kVA) 480/277V 3-phase, 4-wire, prime power: 70kW (87.5kVA)
Generator set shall be sized to operate at the specified load at a maximum ambient of 43C. Prime power output ratings shall be defined per ISO8528 as delivering an average load factor of 70% of the prime power rating with varying load for an unlimited number of hours per year with a permissible 10% overload capability for emergency purposes for 1 in 12 hours. The generator voltages of 480/277V 3-phase and 208/120V 3-phase shall be generated simultaneously via a dual wound generator with 2 separate sets of bus bar connections (3 wires + neutral) on the electrical distribution panel. 2.1.1 Material and Parts All materials and parts comprising the unit shall be new and unused. 2.2 Engine The engine shall be a turbocharged, four-cycle, 4.4 liter displacement diesel engine. It shall be water-cooled and operate with nominal speed not exceeding 1800 RPM. The Brake Mean Effective Pressure (BMEP) shall not exceed 194 psi for operating at the prime power rating. The engine will utilize in-cylinder combustion technology, as required, to meet applicable EPA nonroad mobile regulations for compression ignition engines. Actual engine emissions values must be in compliance with applicable EPA emissions standards per ISO 8178 D2 Emissions Cycle at specified ekw / bhp rating. Utilization of the Transition Program for Equipment Manufacturers (also known as Flex Credits ) to achieve EPA certification is not acceptable. Emissions requirements / certifications of this package: EPA Tier 3 The engine will be equipped with an isochronous electronic governor, compliant with ISO3046 Class A1 providing steady state speed regulation to =/- 0.25%. 2.3 Generator The generator shall be screen protected and drip-proof, permanent magnet, self-regulating, brushless generator with fully interconnected damper windings, IC06 cooling system and sealedfor-life bearings. A 2/3 pitch factor is standard on all stator windings. The generator voltages of 480/277V 3-phase and 208/120V 3-phase shall be generated simultaneously via a dual wound generator. The generator shall be listed by Canadian Standards Association (CSA Approved). (optional) 2.3.1 Insulation System The insulation system shall be Class H with windings impregnated in a triple dip thermo-setting moisture, oil and acid resisting polyester varnish plus a heavy coat of anti-tracking varnish for additional protection against moisture or condensation. 2.3.2 Electrical Characteristics Electrical design in accordance with BS5000 Part 99, IEC60034-1, EN61000-6, NEMA MG- 1.22.
2.3.3 Automatic Voltage Regulator (AVR) The fully sealed automatic voltage regulator shall maintain the voltage within the limits of ± 0.5% at steady state from no load to full load. Nominal adjustment shall be by means of a trimmer incorporated in the AVR. The panel door shall also incorporate an additional voltage adjustment potentiometer. 2.3.4 Permanent Magnet Generator The generator shall be equipped with a permanent magnet for excitation and providing 350% short circuit capabilities, enhanced motor starting and non-linear loading performance. 2.3.5 Waveform Distortion, THF and TIF Factors The total distortion of the voltage waveform with open circuit between phases or phase and neutral shall be in the order of 1.8. On a 3-phase balanced harmonic-free load the total distortion is < 4%. Machines shall be designed to have a THF less than 2% and a TIF less than 50. 2.3.6 Radio Interference Suppression shall be in line with the provisions of EN61000-6. 2.3.7 Anti-condensation heater 120VAC anti-condensation heaters shall be installed in the generator. The heater control circuitry shall automatically shut the heaters off when the genset starts. (optional). 3.0 Component and Systems 3.1 Electrical Distribution Panel A electrical distribution panel shall be collocated with the genset controls behind a single access door with the following connection types: 3.1.1 Bus Studs Two sets of bus studs representing 480/277V and 208/120V three phase power (4 posts for each of 3 phases with neutral plus a common ground connection) shall have non-conducting dividers to prevent contact between phase cables. Bus studs shall be enclosed with hinged transparent cover for easy access. A trip relay shall be installed in the bus door cover such that the primary breaker is tripped if the protective door is opened while the bus is energized for operator safety. A weather protective rubber strip shall be affixed at generator distribution panel door to prevent water ingress and reduce sheet metal contact with distribution cables. 3.1.2 California Twistlock Receptacles Two single-phase California style Twistlock receptacles, code CS6369, rated to provide 50 Amps and 240 Volt single phase power with 4 wires including 2 phase legs + neutral + ground connection. 3.1.3 NEMA Locking Receptacles Two NEMA locking receptacles, NEMA code L21-20R, to provide 20 amps each of 3 phase 208/120V power.
3.1.4 Circuit Breakers Two 3-pole molded case circuit breakers (MCCB) with solid neutral (4 Wire) shall be provided. They shall be UL/CSA listed with shunt trip and an integral trip unit for thermal and magnetic overload protection on the MCCB. Individual sub-circuit breakers for protection of individual receptacles shall also be provided. 3.1.5 Duplex Receptacles Two GFCI Duplex receptacles rated for 20 Amps and 120V single phase shall be provided. 3.1.6 Stop / Start Connections One two-wire set of remote start connection terminals shall be provided. 3.1.7 Shore Power Connection One 30A, 125V single phase NEMA locking inlet receptacle shall be provided to provide an external power source for generator internal loads. 3.2 Control Panel Supplier shall provide a set mounted auto start digital control panel in a vibration isolated NEMA 1 sheet steel enclosure with a hinged lockable door and viewing window for monitoring when the door is closed. The panel shall be collocated behind a common door with the distribution panel. The control panel shall include the following: Run/Stop/Auto control pushbuttons with LED light status indicators LED status light indicators for both warning and shutdown events with an alarm silencer pushbutton Panel light ON/OFF switch Lamp Test Key A High/Low voltage toggle switch to easily change metering display between 480/277 and 208/120 3-phase voltages English and Spanish text capability The control panel shall have the following metering capabilities: Volts 3-phase and 1-phase (both line-to-line and line-to-neutral) Amperage (per phase & average) Generator Frequency Battery Voltage Engine hours run Engine Jacket Water Temperature (in C or F) Lube oil pressure (in psi, kpa or bar); Engine speed (rpm) The control panel shall include the following protective functions:
Fail to Start Shutdown Low oil pressure shutdown High engine temperature Low/High battery voltage Battery charger failure Underspeed / Overspeed Loss of engine speed detection 20 event fault log 3.3 Fuel System The fuel system shall be a dual wall (167.5 gallon) UL142 Listed fuel tank design. The complete fuel tank shall be integral with the genset base frame allowing the genset to be removed from the optional trailer while still providing the specified run time without need for external fuel tanks. The fuel system shall have the capacity to run for a minimum of 34 hours on a single fuel fill at 75% of prime power load (28 hours when operated at 100% of the prime power load). The fuel system shall include 3-way fuel valves which allow the user to select between on-board and external fuel supplies. In addition to a Racor fuel filter, there shall also be installed a primary fuel filter/water separator in the fuel inlet line to the engine. All fuel piping shall be black iron or flexible fuel hose rated for this service. No galvanized piping shall be permitted. A lockable fuel fill shall be provided. A low fuel level alarm contact, and fuel tank rupture alarm contact for optional dual wall tank shall be provided. A manual fuel priming pump integrated into the fuel filter shall be provided for ease of starting. 3.4 Lube System The lube system shall come complete with spin-on lube oil filters, lube oil cooler, crankcase breather with collection assembly, and lube oil. The oil drain lines shall be routed to the base of the unit and include valves to simplify the oil change process. 3.5 Exhaust System An internally mounted critical silencer with flexible connector with vertical exhaust discharge shall be provided. No site installation of exhaust components shall be required. Heat guards shall be provided to protect personnel from exhaust heat per OSHA standards. 3.6 Starting System The starting system shall consist of a 12 volt system with 65A battery charging alternator, and starter motor on engine. The engine shall include glow plugs fitted on the engine to improve startability in cold climates. A 12V Cat brand heavy duty maintenance free battery, battery rack, and cables on the generator set baseframe shall be provided. A UL and CSA Listed 3 Amp 120 VAC battery charger shall be mounted on control panel. (optional). 3.7 Cooling System
The generator set shall come with a vertical discharge, cooling system. The package mounted, cooling system shall be complete with radiator, blower fan, fan drive, drive guard, belt guards and shall ship from the factory with 50% coolant antifreeze with corrosion inhibitor. The cooling system shall also include a coolant level reservoir/sight gauge and coolant drain line routed to the exterior of the package with shutoff valve. 3.7.1 Jacket Water Heater A 120 VAC, thermostatically controlled coolant heater shall be provided to ensure specified engine start capability under cold environmental conditions. The coolant heater shall be protected by a fuse in the control panel and the AC supply shall be disconnected automatically upon engine start. The coolant heater shall be compatible with all approved engine coolant additives (optional). 3.8 Sound Attenuated Enclosure The fully weatherproof and sound attenuated enclosure shall provide sound attenuation of 67.5dBA at 23ft. The enclosure shall be painted white with a black base and lifting arch. Enclosure construction shall incorporate the following features: 12 gauge sheet steel components pretreated with zinc phosphate prior to polyester powder coating at 200 C (392 F) Black stainless steel padlockable latches Zinc die cast hinges/grab handles Rooftop maintenance access doors for fluids access Side doors for genset compartment access Front panel for air discharge box access Lube oil and cooling water drains piped to exterior of the enclosure Safety glass control panel viewing window in a lockable access door Cooling fan and battery charging alternator fully guarded Fuel fill and battery reachable only through lockable access doors Tested and certified single point lifting eye Lifting points on baseframe 3.9 Trailer The generator set shall be mounted on a double axle towing style trailer. The trailer shall comply with Federal DOTs Federal Motor Vehicle Safety Standards. It shall be equipped with a 3 eyepintle hitch (2-5/16 ball coupler hitch optional). The trailer shall be equipped with a hydraulically actuated surge brakes (electrically operated brakes optional). Tires shall be rated as ST225/75R15 - load range C. Electrical connection shall be via a 6-prong plug. The trailer construction shall be of ASTM A36 Grade structural steel channels. Fenders shall be of 12 gauge galvanized steel, roll-formed and bolt-on. The trailer shall be coated with an epoxy ester high solid enamel primer, then finish painted with polyurethane, two component, high solid enamel in gloss black. 3.10 Operation and Maintenance Manuals
The generator set shall be provided with two (2) sets of operation and maintenance manuals.