Converter Installation Requirements and Recommendations

Required:

 It is required to mount the converter no more than 15 linear feet of 14” diameter piping from the
transition mounted to the engine exhaust flex flange and upstream of an exhaust silencer if so
equipped.

 The converter location must be isolated from engine vibration and external loading due to the
weight of the converter or thermal expansion.

 Sufficient clearance must be allowed from surrounding components to avoid the risk of fire or
explosion, due to the high operating temperatures of the converter.

 Do not lift the converter from the center body area, only lift it from the end pipe flanges.

 Expansion joints need to be used whenever the converter housing is installed between two fixed
points.

 Do not use anchor supports on both sides of the catalytic converter due to thermal growth.

 No external forces can be applied to the converter and piping connected to the converter must be
properly supported to prevent cantilevering loads.

 Install supplied expansion joints between the engine exhaust flange and the converter inlet flange.
This will isolate the converter and other downstream components from engine vibration and
thermal expansion. NOTE: Insulated piping will expand more compared to non-insulating piping.

 Only use supplied fasteners. Do not substitute with unknown grade fasteners. Contact Waukesha
Parts for replacement parts. High temp anti-seize should be used on the fasteners.

 The converter must be structurally supported from beneath the converter center body when
mounted horizontally. This structural support needs to allow for expansion of the housing due to
thermal loads. Do not support the converter by the flanges when mounted horizontally.

 Design the exhaust system so it will not impose torsional forces on the exhaust flexible
connection.

 An exhaust flexible connection has “spring constants” (lateral, axial, radial, and torsional) that
should be considered when engineering the exhaust system. Transmission of forces to the engine
exhaust connection must be zero. NOTE: Any specific load or bending moment limits shown on an
engine installation drawing must not be exceeded.

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ECO155976 6/13 RELEASED REV. NO. 101

TITLE - Catalytic Converter Installation DR. MMR 6/3/13

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Requirements and Recommendations CH. MTR 6/3/13
FORM M-1880 1/09 07232-412
APP. REO 6/3/13
  The exhaust flexible connection should be designed to allow for flexing caused by engine
operation: acceleration, deceleration, starting, and stopping. A Waukesha exhaust flexible
connection (when supplied) will accommodate engine vibrations with a solidly mounted unit, but
cannot tolerate the additional forces/displacement imposed by mounting on spring isolators.

 Utilize a combination of fixed supports, rollers and flexible connections to provide a well-designed
exhaust system. See diagrams in Figure 1-1 for additional concepts.

Support
Support

Figure 1-1

 The minimum requirements for the design of the exhaust system should be to contain explosions
that could be encountered during the operation of the engine. Waukesha requires the use of
carbon steel schedule 20 pipe as a minimum and stainless steel schedule 10 pipe is preferred
because of its greater strength properties at elevated temperatures. Waukesha does not allow
using double walled piping or slip joints on engine exhausts.

 Size piping and silencer so that exhaust system back pressure, as measured at the engine outlet
flange, is less than that indicated in the Waukesha Technical Data Engine Specifications. NOTE:
14” diameter piping is required for the exhaust system.

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ECO155976 6/13 RELEASED REV. NO. 101

TITLE - Catalytic Converter Installation DR. MMR 6/3/13

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Requirements and Recommendations CH. MTR 6/3/13
FORM M-1880 1/09 07232-412
APP. REO 6/3/13
  The exhaust system must remain air tight at all times for proper operation of the converter.
Explosion relief valves, flexible connections, flanges, water traps/drains, and piping may leak over
time and may require repair or replacement to maintain an air tight exhaust system.

 Using a single exhaust system fed by several engines is not allowed by Waukesha because an
engine which is shutdown becomes a path for exhaust gas to leak. This exhaust gas will condense
water in the shutdown engine causing hydraulic lock, valve sticking, ring sticking, rust, and other
engine damage. The exhaust leak path could also cause poisonous exhaust gas to collect in an
engine room.

 NOTE: Exposure to excessive temperatures significantly reduces the catalyst life. At no time shall
the catalyst outlet temperature be permitted to exceed 1350°F. Normal continuous operating
temperature shall not exceed 1300°F for more than 15 minutes during any 24 hour period.
Exposure to temperatures exceeding these values will automatically void the warranty. It is for
this reason that the use of a high temperature alarm set for 1250°F and shutdown system set for
1300°F at the catalyst outlet is required.

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ECO155976 6/13 RELEASED REV. NO. 101

TITLE - Catalytic Converter Installation DR. MMR 6/3/13

S-
Requirements and Recommendations CH. MTR 6/3/13
FORM M-1880 1/09 07232-412
APP. REO 6/3/13
 Recommended:

 Provide water traps/drains to prevent exhaust condensation and/or rain from reaching the
engine. This is especially true on long pipe runs. Use rain caps where applicable. Slope piping
away from engine. Exhaust gas contains 10-20% water in the form of steam. During startup of a
cold system large amounts of water will condense and collect in low spots of the exhaust piping
which can result in corrosion. Many silencer and heat recovery equipment manufacturers provide
traps and drains in their equipment.

 Utilize smooth transition to final pipe size when a transition in size is required. Waukesha
recommends a diverging angle of no more than 15 degrees.

 Provide clearance to permit use of a chain hoist for removal of heavy components, such as the
catalyst elements.

 Sufficient clearance must be allowed for the convert hatch to open and for element replacement.
It is recommended the hatch is facing upward as each element is approximately 54lbs.

 To prevent explosions and personal injury the engine and the exhaust system are purged by
cranking the engine for several seconds before the ignition is turned on and the fuel valves are
opened. The purge volume of the engine is approximately its displacement for every two
revolutions. In case the volume of the exhaust system is such that it will not be purged several
times by the cranking of the engine the customer has to use an alternative means to purge the
exhaust system. The purge cycle can be programmed in ESM using the ESP software.

 A burst disk located in the exhaust piping near the engine can protect exhaust components from a
damaging exhaust explosion. Burst disks must be vented to a safe location to prevent fires or
personal injury. These devices will become damaged or leak after an exhaust explosion occurs
which will require replacement or repair. These devices must be air tight.

 The end of the exhaust line must be designed to keep out rain water, dust and dirt. Vertical
discharge outlets should have a rain cap to prevent moisture, dust and dirt from entering while an
engine is shutdown. Exhaust discharge and flow path must be away from radiators and engine
air intakes. Miter cut exhausts will reduce exit noise.

General Notes:

 Never run hot exhaust pipes near flammable materials or fuel supply lines.

 Consider expected life. Cyclic flexing can lead to premature failure by causing fatigue breakage.

 Radiated heat can raise the air temperature around the engine. This could affect the air inlet for
the engine or generator.

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ECO155976 6/13 RELEASED REV. NO. 101

TITLE - Catalytic Converter Installation DR. MMR 6/3/13

S-
Requirements and Recommendations CH. MTR 6/3/13
FORM M-1880 1/09 07232-412
APP. REO 6/3/13
  Exhaust temperatures are higher when utilizing the “hotter” fuels such as HD-5 Propane. The
converter may need to be installed at the 15ft maximum from the exhaust outlet to avoid these
higher temperatures. On the converse, insulation may be needed if the converter inlet
temperature drops below 850-900F.

 Exhaust system backpressure limits are established for each engine model. Back pressure limits
are available in the Waukesha Technical Data Engine Specifications for the particular model of
interest. Exceeding these back pressure limits can cause horsepower output to decrease, fuel
consumption to increase, and breather backpressure to increase, causing high crankcase
pressure. High crankcase pressure will cause numerous oil leaks and may cause operational
problems. Exhaust system backpressure can be calculated using the procedure described in the
Waukesha installation Chapters, Form 1091.

 Exhaust gas is poisonous and must be discharged to a harmless location. Do not discharge gases
near the engine air intake system, ventilation ducts, windows or buildings. The discharge location
must have sufficient natural ventilation to carry away the exhaust gas preventing an unhealthy
concentration. Observe safety and other applicable codes. The discharge must also be at a safe
distance from flammable waste dump sites and fuel storage areas. Observe local fire codes and
other applicable codes.

Page 5 of 5

ECO155976 6/13 RELEASED REV. NO. 101

TITLE - Catalytic Converter Installation DR. MMR 6/3/13

S-
Requirements and Recommendations CH. MTR 6/3/13
FORM M-1880 1/09 07232-412
APP. REO 6/3/13