Kohler 6.5RMY Operation Manual
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Kohler 6.5RMY Operation Manual

Kohler 6.5RMY Operation Manual

Industrial generator sets
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Operation Manual
Industrial Generator Sets
Models:
6.5RMY
10-18RY/RZ
Controllers:
Decision-Makert 3, 5-Light
Relay
TP-5631 7/96

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Summary of Contents for Kohler 6.5RMY

  • Page 1 Operation Manual Industrial Generator Sets Models: 6.5RMY 10-18RY/RZ Controllers: Decision-Makert 3, 5-Light Relay TP-5631 7/96...
  • Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions ..Controller Resetting Procedure (following fault shutdown) ....2-13 Introduction .

  • Page 4: Safety Precautions And Instructions

    Safety Precautions and Instructions A generator set, like any other electromechanical device, can pose potential dangers to life and limb if CAUTION improperly maintained or operated. The best way to prevent accidents is to be aware of potential dangers Caution indicates the presence of a hazard that will or and act safely.
  • Page 5 Accidental Starting Disabling generator set. Accidental starting can cause severe injury or death. Turn generator set master switch to OFF position, disconnect power to WARNING battery charger, and remove battery cables (remove negative lead first and reconnect it last) to disable generator set before working on the generator set or connected equipment.
  • Page 6 Battery Battery acid. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat WARNING holes in clothing. Always wear splash-proof safety goggles when working near the battery. If battery acid is splashed in the eyes or on skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
  • Page 7 Engine Backfire/Flash Fire Servicing fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flame or spark to occur near carburetor, fuel line, fuel filter, fuel WARNING pump, or other potential sources of spilled fuel or fuel vapors.
  • Page 8 Exhaust System Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas which is present in WARNING exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision...
  • Page 9 Fuel System Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an WARNING explosion. Store only diesel fuel in tanks. Draining fuel system. Explosive fuel vapors can cause severe injury or death.
  • Page 10 Hazardous Noise CAUTION Hazardous noise. Can cause loss of hearing. Never operate generator set without a muffler or with a faulty exhaust system. TP-5631 7/96 Safety Precautions and Instructions VII...
  • Page 11 Hazardous Voltage/ Installing battery charger. Hazardous voltage can cause severe injury or death. Electrical shock may Electrical Shock occur if battery charger is not electrically grounded. Connect battery charger enclosure to ground of a permanent wiring system. As an alternative, install an WARNING equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on...
  • Page 12 Heavy Equipment WARNING Unbalanced weight. Improper lift can cause severe injury or death and/or equipment damage. Do not use lifting eyes. Lift generator set using lifting bars inserted through skid lifting holes. TP-5631 7/96 Safety Precautions and Instructions IX...
  • Page 13 Hot Parts Servicing generator. Hot parts can cause severe injury or death. Avoid touching generator set field or exciter armature. Generator set field and exciter WARNING armature when shorted become hot enough to cause severe burns. Checking coolant level. Hot coolant can cause severe injury or death.
  • Page 14 Moving Parts Tightening hardware. Flying projectiles can cause severe injury or death. Retorque all crankshaft and rotor hardware after servicing. Do not loosen crankshaft WARNING hardware or rotor thrubolt when making adjustments or servicing generator set. Rotate crankshaft manually in a clockwise direction only.
  • Page 15 Notice NOTICE Hardware damage! Engine and generator set may use NOTICE both American Standard and metric hardware. Use the correct size tools to prevent rounding of bolt heads and nuts. This generator set has been rewired from its nameplate voltage to: NOTICE When replacing hardware, do not substitute with inferior grade hardware.

  • Page 16: Introduction

    Introduction California Emission All information in this publication represents data available at time of printing. Kohler Co. reserves the Certification right to change this literature and the products represented without incurring obligation. If your engine/generator has this identification label, it is Read through this manual and carefully follow all certified for operation in the state of California.

  • Page 17: Service Assistance

    For sales and service outside the U.S.A. and Canada, contact your local distributor. For further information or questions, contact the company directly at the following address or number: KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone: 414-565-3381 Fax: 414-459-1646 (U.S.A. Sales)

  • Page 18: Section 1. Specifications

    Generator The generator is equipped with Kohler’ s PowerBoostt PowerBoostt utilizes a voltage monitoring system that voltage regulation system which provides instant employs a winding independent of the field to monitor response to load changes.

  • Page 19: Controller

    Controller Controller Features The generator set is equipped with either a relay D Analog meters, 3.5 in. (89 mm): controller or a 5-light microprocessor controller. For a d AC ammeter, 2% full-scale accuracy specific description of the controller, see Section 2, d AC voltmeter, 2% full-scale accuracy Operation.

  • Page 20: Accessories

    Contact your service, and to comply with state and local codes. local Kohler Dealer/Distributor to obtain the most Accessories vary with each generator set model and current information. Accessories available at the time of controller.

  • Page 21: Remote Annunciator Kit (Microprocessor Controller)

    Remote Annunciator Kit (microprocessor controller) The remote annunciator allows convenient monitoring and the same lamp indicators as the 5-light of the generator set’ s condition from a remote location. microprocessor controller, plus the following: The remote annunciator kit is available in surface mount Line Power Lamp.

  • Page 22: Audio-Visual (A/V) Alarm (Microprocessor Controller)

    Audio-Visual (A/V) Alarm Line Circuit Breaker (microprocessor controller) The line circuit breaker interrupts generator output in the event of an overload or short circuit. Use the line circuit An A/V alarm warns the operator of fault shutdowns and breaker to manually disconnect the generator set from pre-alarm conditions (except battery charger fault and the load when servicing the generator set.

  • Page 23: Remote Emergency Stop Kit (Microprocessor Controller)

    Remote Emergency Stop Kit Single-Relay Dry Contact Kit (microprocessor controller) (microprocessor controller) The emergency stop kit allows immediate shutdown of The single-relay dry contact kit uses one set of relay the generator set from a remote location. contacts to trigger customer-provided warning devices Figure 1-6.

  • Page 24: Ten-Relay Dry Contact Kit (Microprocessor Controller)

    Ten-Relay Dry Contact Kit (microprocessor controller) The ten-relay dry contact kit allows monitoring of the Typical Contact Kit Output Connections: standby system and/or the ability to activate Overspeed accessories such as derangement panels. The kit Overcrank includes ten sets of relay contacts for connection of Low Oil Pressure customer provided devices to generator set functions.
  • Page 25 ** Common Fault Indicator System Ready Activated By: HET Fault Not In Auto LOP Fault LWT Fault PHET OC Fault OS Fault PLOP AUX Fault Common Fault ** Remove Jumper if Connect A/V Alarm or Emergency Stop is Common Fault Relay Kit Low Fuel Used.

  • Page 26: Section 2. Operation

    Section 2. Operation Prestart Checklist To ensure continued satisfactory operation, check the Consult the engine manufacturer’ s operation manual for following items before each startup and at regular engine coolant specifications. intervals. Refer to the engine service manual for Do not add coolant to a hot engine. Wait until engine has specific service procedures.

  • Page 27: Microprocessor Controller Operation

    Microprocessor Controller Operation 5-Light Microprocessor Controller A-225183A-K 1. Selector switch 12. Hourmeter 2. Alarm silence switch 13. 15-amp engine and accessories fuse 3. Lamp test 14. 3-amp controller fuse 4. Overcrank 15. 3-amp remote annunciator fuse 5. Generator master switch 16.

  • Page 28: Microprocessor Controller Features

    Microprocessor Controller Features D The auxiliary lamp lights and engine shuts down immediately if activated by any customer- Microprocessor controller features include supplied sensing devices connected auxiliary immediate shutdown ports (P1-17 and annunciator panel lamps, analog meters, switches and P1-18). controls, fuses, and terminal strip.
  • Page 29 Switches and Controls Fuses and Terminal Strip Alarm Horn. Horn sounds if any fault or anticipatory Fuses. Fuses are located on controller circuit board. condition exists. Place the generator set master switch D 3-amp Remote Annunciator (F1). Fuse in the AUTO position before silencing alarm horn. See protects remote annunciator circuit, A/V alarm, Controller Resetting Procedure later in this section.
  • Page 30 ** Common Fault Indicator System Ready Activated By: HET Fault Not In Auto LOP Fault LWT Fault PHET OC Fault OS Fault PLOP AUX Fault Common Fault ** Remove Jumper if Connect A/V Alarm or Emergency Stop is Common Fault Relay Kit Low Fuel Used.

  • Page 31: Start/Stop Procedure

    Start/Stop Procedure controller circuit board terminal strip. For cyclic cranking, leave circuit board terminal TB1-9 open. Run Local Starting a jumper between circuit board terminal TB1-2 (ground) and terminal TB1-9 for continuous cranking. Place the generator set master switch in the RUN position to start the generator set at the controller.

  • Page 32: Circuit Protection (Microprocessor Controller)

    Circuit Protection (microprocessor controller) An optional line circuit breaker (sized for generator output) is available to protect the generator from damage because of overload or short circuits. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position, the generator set runs but there is no output voltage.

  • Page 33: Fault Shutdowns

    Fault Shutdowns seconds). Shutdown occurs after 15 seconds if engine or starter will not turn (locked rotor). The generator set shuts down automatically under the Overspeed. Generator set shuts down immediately following fault conditions. The generator set will not run when governed frequency exceeds 70 Hz (2100 rpm) on until the fault condition has been corrected.

  • Page 34: Controller Resetting Procedure

    Controller Resetting Procedure NOTE (Following Fault Shutdown) Place generator set master switch in the AUTO position before silencing alarm horn. Use the following procedure to restart the generator set 8. Place controller alarm horn switch in the NORMAL after a fault shutdown. Refer to Resetting Emergency position.

  • Page 35: Relay Controller Operation

    Relay Controller Operation Generator sets equipped with a relay controller refer to Figure 2-5 and the following descriptions to identify controller components. Fault Lamp. Lamp lights to indicate a fault condition. Generator set shuts down on Overcrank, Overspeed, and Low Oil Pressure faults. See Fault Shutdowns following.

  • Page 36: Starting/Stopping Procedure (Relay Controller)

    Starting/Stopping Procedure (relay controller) Starting If the generator set does not start after three attempts, see Section 4. Troubleshooting for possible causes. Place the controller or remote Start/Stop switch in the Stopping RUN position until the engine starts. If the engine fails to start after three 8 second attempts, the generator set 1.

  • Page 37: Circuit Protection (Relay Controller)

    Circuit Protection (relay controller) An optional line circuit breaker (sized for generator output) is available to protect the generator from damage because of overload or short circuits. If the circuit breaker trips, reduce the load and switch the breakers back to the ON position. With the breaker in the OFF position, the generator set runs but there is no output voltage.

  • Page 38: Controller Resetting Procedure

    Controller Resetting Procedure (following fault shutdown) Use the following procedure to restart the generator set 3. Place generator set master switch in the RUN position to restart the generator set. Refer to after a fault shutdown. Reset the controller and correct Section 4 Troubleshooting for possible causes of the fault before resetting the generator set.

  • Page 39: Section 3. Scheduled Maintenance

    Section 3. Scheduled Maintenance The generator set alternator does not require regular or WARNING scheduled service under normal operating conditions. The prestart checklist lists the main areas of the generator set that require attention. If generator set operates under dusty or dirty conditions, use DRY compressed air to blow dust out of the generator.

  • Page 40: Fuel Regulators

    Fuel Regulators Fuel regulators are compatible with both natural gas and LP gas. The spring and retainer are installed when used with natural gas. Some models require removal of the spring and retainer, while other models maintain the spring and retainer, when using LP gas.

  • Page 41: Electronic Governor

    Electronic Governor The governor control system consists of an electronic frequency of these pulses to a preset reference and isochronous governor, an electro-mechanical actuator, provides a signal to the actuator which, in turn, controls and a magnetic pickup. Electrical pulses are supplied the carburetor and hence the engine speed.

  • Page 42: Cleaning

    Explosion can cause severe injury or death. Battery WARNING gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc. to prevent burns and to prevent sparks that could cause an explosion.

  • Page 43: Checking Specific Gravity

    Checking Specific Gravity It is not possible to check the specific gravity of a maintenance free battery. Use a battery hydrometer to Correction ° ° check the specific gravity of the electrolyte in each 71.1 + .032 battery cell. While holding the hydrometer vertical, read + .030 the number on the glass bulb at the top of the electrolyte 65.6...

  • Page 44: Generator Service

    Generator Service Have an authorized service distributor/dealer perform Replace the end bracket bearing every 10,000 hours of all generator set service. Under normal conditions, operation in standby and prime power applications. regular generator service is not required. For operation Service more frequently if bearing inspection indicates under dusty and dirty conditions, use dry compressed excessive rotor end play or bearing damage from air to blow dust out of the generator.

  • Page 45: Section 4. Troubleshooting

    Section 4. Troubleshooting When troubles occur, do not overlook simple causes problems, refer to the Troubleshooting Table below. If which might seem too obvious to be considered. A the trouble cannot be corrected through routine starting problem, for example, could be attributed to an servicing, contact authorized...

  • Page 46: General Troubleshooting Chart (Sheet 2 Of 2)

    General Troubleshooting Chart (Sheet 2 of 2) Problem Possible Cause Corrective Action No AC output No AC output AC circuit breaker in OFF position Place circuit breaker in ON position AC circuit breaker tripping because of overload Reduce load on generator set AC circuit breaker tripping because of short Correct cause of short circuit circuit...

  • Page 47: Section 5. Generator Reconnection

    Section 5. Generator Reconnection Voltage Reconnection Procedure reconnection procedure explains voltage Disabling generator set. Accidental starting can reconnections only. If frequency changes are required, cause severe injury or death. Turn generator set master switch to OFF position, disconnect power to the governor and voltage regulator need adjustment.

  • Page 48: Four-Lead (Single-Phase) Generator Sets

    Four-Lead (Single-Phase) LO (Neutral) Generator Sets Ground NOTE Current transformers (CTs) are used only on generator Load sets equipped with controllers with meters. Factory Side Two-Pole NOTE or (2) 1-Pole Position current transformers CT1, CT2, and CT3 with Circuit dot or HI side toward generator set. Line Breakers Side...

  • Page 49: 100-120/200-240 Volt

    100-120/200-240 Volt 200-240 Volt Jumper lead not used. If the generator set was originally Jumper lead not used. If the generator set was originally wired for straight 100-120 volt 3 wire, be sure to remove wired for straight 100-120 volt, 3 wire, be sure to remove jumper lead.

  • Page 50: 12-Lead (Three-Phase) Generator Sets

    12-Lead (Three-Phase) Generator Sets NOTE Three-phase, 12-lead generator sets are reconnectable to the voltages and phases shown in Figure 5-6. If the Current transformers (CTs) are used only on generator generator set is reconnected to obtain a different output sets equipped with controllers with meters. voltage, voltage regulator voltage adjustments may be necessary to obtain desired voltage.

  • Page 51: Reconnection Procedure (Microprocessor Controller Only)

    Reconnection Procedure For all other voltages, remove J1 jumper from the overvoltage circuit board. See Figure 5-7 for J1 (Microprocessor Controller only) jumper location on the overvoltage circuit board. 1. Place the generator set master switch in the 6. If the controller is equipped with meters, turn the OFF/RESET position.
  • Page 52 TP-5631-5 TP-5631-5 1. Lamp jumper 1. Voltage adjustment potentiometer Figure 5-8. Meter Scale Lamp Jumper Figure 5-9. Voltage Adjustment (typical) 5-6 Generator Reconnection TP-5631 7/96...

  • Page 53: Section 6. Installation

    6.5RMY. Use specifications and drawings provided required to complete the installation. The information here only in initial planning. Use respective spec contained in this section is specific for the 6.5RMY sheets, dimension drawings, and wiring diagrams for model. installation. Contact...

  • Page 54: Exhaust Requirements

    Exhaust Requirements The exhaust muffler is located in a compartment in the skid under the engine end of the generator set. See Figure 6-2. The exhaust system is complete for generator sets installed outdoors. The screened piece covering the muffler compartment prevents contact with the hot exhaust system and keeps rodents and other animals out.

  • Page 55: Electrical Connections

    Electrical Connections Battery The battery is mounted in a skid compartment located on the generator end of the skid. Standard battery cables provide easy connection to the battery. A battery rack is available to secure the battery if required. Remove the hole plug located on the right side of the skid to connect battery charger cables and any other battery connections.

  • Page 56: Ac Load Lead Connections

    AC Load Lead Connections Make the AC output lead connections in the 1. Connect L1/L2 black leads to AC circuit breaker load side. compartment where the AC circuit breakers are located. Route the building distribution panel or transfer switch 2. Connect L0 white lead to neutral stud. leads through the bottom of generator set or flexible 3.

  • Page 57: Appendix A. Glossary Of Abbreviations

    Appendix A. Glossary of Abbreviations Abbreviations are used throughout this manual. abbreviated form. The commonly used abbreviations Normally they will appear in the text in complete form are shown below. Some items may not apply to this with the abbreviation following in parentheses the first application.
  • Page 58 Abbreviation Description Abbreviation Description International Standards Organization no., nos. number, numbers joule, joules National Standard taper pipe thread Japanese Industry Standard per general use kilogram, kilograms not required kg/cm kilograms per square centimeter overcrank kilogram meter(s) outside diameter kilojoules (btu cal) original equipment manufacturer kilometer, kilometers overspeed...
  • Page 59 KOHLER CO. Kohler, Wisconsin 53044 Phone 414-565-3381 TP-5631 7/96 Fax 414-459-1646 (U.S.A. Sales), Fax 414-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 PRINTED IN U.S.A.

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