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Kohler 14EKOZD Installation Manual

Marine generator sets
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Installation
Marine Generator Sets
Models:
14/16/21/24/32/40EKOZD
12/13.5/17/18/20.5/28/35EFKOZD
Controller:
Decision-Makerr 3500
TP-7045 3/18c

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Summary of Contents for Kohler 14EKOZD

  • Page 1 Installation Marine Generator Sets Models: 14/16/21/24/32/40EKOZD 12/13.5/17/18/20.5/28/35EFKOZD Controller: Decision-Makerr 3500 TP-7045 3/18c...
  • Page 2 TP-7045 3/18c...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 9.1.2 Paralleling Functions ......... . . Paralleling Considerations .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Engine Backfire/Flash IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 6 Exhaust System Fuel System Hazardous Noise WARNING CAUTION WARNING Carbon monoxide. Hazardous noise. Explosive fuel vapors. cause severe nausea, Can cause hearing loss. Can cause severe injury or death. fainting, or death. Never operate the generator set Use extreme care when handling, exhaust system must...
  • Page 7 Notice Disconnecting the electrical load. Testing live electrical circuits. Hazardous voltage will cause severe Hazardous voltage or current will injury or death. Disconnect the cause severe injury or death. Have NOTICE generator set from the load by turning trained and qualified personnel take off the line circuit breaker or by diagnostic measurements...
  • Page 8 Notes Safety Precautions and Instructions TP-7045 3/18c...

  • Page 9: Section 1 Introduction

    For operating instructions, refer Information in this publication represents data available to the operation manual. at the time of print. Kohler Co. reserves the right to Marine generator set installations must comply with all change this publication and the products represented applicable regulations and standards.

  • Page 10: Decision-Maker 3500 Controller Information

    The following data must be resident for the controller to Site Program—Yes. function. Note: After the unit is set up on the vessel, Kohler Application program contains the software that authorized distributor/dealer saves any user controls system operation. The application file was parameter changes to an external medium.

  • Page 11: Section 2 Location, Lifting, And Mounting

    Kohler Co. recommends mounting the generator set on 3. Seal the generator set’s engine room from the a flat board attached to the craft stringers. Craft...
  • Page 12 Notes Section 2 Location, Lifting, and Mounting TP-7045 3/18c...

  • Page 13: Section 3 Cooling System

    ≤ 5982--3.1 Model (in. H 1. Inside packing 2. Outside packing 14EKOZD (1 and 3 Phase) 2.4 (9.6) 3. Seacock cover 16EKOZD (1 and 3 Phase) 4. Direction of vessel movement 5. Typical intake through-hull strainers 12EFKOZD (1 and 3 Phase) 1.5 (6.0)

  • Page 14: Seacock

    3.2.2 Seacock Mount the seacock to the hull, assemble it to the intake, and ensure that it is accessible for operation. Figure 3-2 shows a typical installation. Avoid overcaulking the seacock. Excess caulk reduces water flow and, in some cases, develops a barrier that can force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down.

  • Page 15: Water Lines

    3.2.4 Water Lines Water lines from the seacock to the engine-driven seawater pump are usually constructed of flexible hose. Connect a flexible section of hose to the seawater pump to allow the generator set to vibrate during operation. Support a nonflexible water line within 102 mm (4 in.) of its connection to the flexible section.

  • Page 16: Closed Heat Exchanger

    3.2.5 Closed Heat Exchanger A closed heat exchanger is the best cooling method for most applications. See Figure 3-6 for a typical installation. Provide space to access the water-cooled exhaust manifold pressure cap. Seawater Freshwater (Coolant/Antifreeze) 1. Engine block 7. Intake strainer (customer-supplied) 2.

  • Page 17: Section 4 Exhaust System

    Kohler Co. requires a downward pitch of at least 13 mm Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of per 30.5 cm (1/2 in.

  • Page 18: Exhaust System Location, Mounting, And Installation

    Figure 4-2 for allowable back pressures. Allowable Exhaust Back Pressure ≤ (in. H Model 14EKOZD (1 and 3 Phase) 8.5 (34.1) 16EKOZD (1 and 3 Phase) 12EFKOZD (1 and 3 Phase) 5.0 (20.0) 13.5EFKOZD (1 and 3 Phase) 21EKOZD (1 and 3 Phase) 8.5 (34.1)

  • Page 19: Above-Waterline Installation

    17. Maximum silencer vertical lift of 1.2 m (4 ft.) 4. Exhaust mixer elbow 18. If the total exhaust length exceeds 4.6 m (15 ft.), Kohler 5. Heat exchanger (locations vary by model) recommends increasing the exhaust hose to the next 6.

  • Page 20: Mid/Below-Waterline Installation

    Exhaust Hose Diameter Models without Sound Shield Models with Sound Shield mm (in.) 14EKOZD/12EFKOZD (1 and 3 Phase) 14EKOZD/12EFKOZD (1 and 3 Phase) 16EKOZD/13.5EFKOZD (1 and 3 Phase) 16EKOZD/13.5EFKOZD (1 and 3 Phase) 21EKOZD/18EFKOZD (1 Phase) 21EKOZD/18EFKOZD (1 Phase) 76 (3.0)
  • Page 21 Note: Read the text for complete explanation of dimensions and other installation considerations. Note: Use two hose clamps on each end of all flexible exhaust hose connections. Note: Data applies to both rear- and side-exhaust installations. Note: Damage caused by water ingestion will not be covered by the generator warranty.
  • Page 22 21. Exhaust hose (see Figure 4-5 for hose sizes) 6. Minimum siphon break distance above waterline of 30.5 cm 22. If the total exhaust length exceeds 4.6 m (15 ft.), Kohler (1 ft.) recommends increasing the exhaust hose to the next larger 7.
  • Page 23 23. Height of internal lift tube to be below generator exhaust 11. Seawater strainer manifold 12. Seacock 24. Kohler recommends generator be located at elevation that 13. Intake strainer exhaust mixer elbow is above silencer exhaust outlet 14. Engine-driven seawater pump 25.
  • Page 24 Notes Section 4 Exhaust System TP-7045 3/18c...

  • Page 25: Section 5 Fuel System

    Section 5 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. Note: Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements.

  • Page 26: Fuel Lines

    Note: Do not tee into the main propulsion engine’s fuel mm (in.) line. Fuel Fuel Inlet Return Note: Fuel Return Dip Tube. Kohler Co. recommends Model utilizing a fuel return dip tube located below the 14--24EKOZD/12--20.5EFKOZD 8 (5/16) 6 (1/4) fuel supply dip tube. This will prevent air from min.

  • Page 27: Fuel Line Selection And Application For 32/40Ekozd And 28/35Efkozd Models

    Copper (Cu) Fuel Pump Lead (Pb) Lift Model m (ft.) Magnesium (Mg) Phosphorous (P) 14EKOZD/12EFKOZD (1 and 3 Phase) Potassium (K) 16EKOZD/13.5EFKOZD (1 and 3 Phase) Sodium (Na) 21EKOZD/18EFKOZD (1 Phase) Zinc (Zn) 21EKOZD/17EFKOZD (3 Phase) 1.2 (4) These metals react adversely with diesel fuel to form 24EKOZD/20.5EFKOZD (1 and 3 Phase)
  • Page 28 Notes Section 5 Fuel System TP-7045 3/18c...

  • Page 29: Section 6 Electrical System

    Section 6 Electrical System 6.2 Circuit Protection DANGER The AC circuit breakers (optional) protect the wiring from the AC circuit breakers to the vessel’s distribution panel. AC circuit breakers trip when they detect a fault in the output circuit. Hazardous voltage. Moving parts. Will cause severe injury or death.

  • Page 30: Circuit Breaker Installation

    Electrical backfeed to the utility. Hazardous backfeed WARNING voltage can cause severe injury or death. Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is turned off. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area.
  • Page 31 Note: Wire material. Use stranded copper for all wiring. Use wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and overcurrent protection (circuit breakers, fuses) that conform to standards and codes. Note: Follow USCG Regulations CFR33, Part 183 (Pleasurecraft) and CFR46 (Commercial Craft) for marine applications.

  • Page 32: Installation In Steel Or Aluminum Vessels

    6.3 Installation In Steel or 6.4 Installation Regulations Aluminum Vessels The U.S. Coast Guard governs generator set installation in U.S. pleasurecraft and commercial Installation of a generator set in a vessel constructed of vessels. Refer to the applicable regulations below: a material capable of conducting current (e.g., steel or aluminum) is subject to considerations not normally encountered in fiberglass or wood vessels.

  • Page 33: Battery

    6.5 Battery Kohler Co. recommends using one 12-volt battery (or two for 24-volt systems, as the spec requires) to start the Batteries and their installation must conform to USCG generator. See Figure 6-4 for minimum cold cranking Regulations 183.420 (a) through (g). Provide generator amps (CCA) recommendations.
  • Page 34 Notes Section 6 Electrical System TP-7045 3/18c...

  • Page 35: Section 7 Installation Drawings

    Section 7 Installation Drawings Use the drawings in this section for installation Model No. Drawing Page purposes. Consult the supplier and verify that the 14EKOZD/12EFKOZD ADV-8880A- drawings are the most current for your specifications. 16EKOZD/13.5EFKOZD ADV-8880B- Installation drawings show exhaust outlet locations, fuel...
  • Page 36 NOTE: Dimensions are shown in mm [in.]. ADV-8880A- Figure 7-2 Dimension Drawing, 14/16EKOZD and 12/13.5EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 37 NOTE: Dimensions are shown in mm [in.]. ADV-8880B- Figure 7-3 Dimension Drawing, 14/16EKOZD and 12/13.5EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 38 NOTE: Dimensions are shown in mm [in.]. ADV-8883A- Figure 7-4 Dimension Drawing, 21--24EKOZD and 17--20.5EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 39 NOTE: Dimensions are shown in mm [in.]. ADV-8883B- Figure 7-5 Dimension Drawing, 21--24EKOZD and 17--20.5EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 40 NOTE: Dimensions are shown in mm [in.]. ADV-8881A-A Figure 7-6 Dimension Drawing—Sound Shield, 14--24EKOZD and 12--20.5EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 41 NOTE: Dimensions are shown in mm [in.]. ADV-8881B-A Figure 7-7 Dimension Drawing—Sound Shield, 14--24EKOZD and 12--20.5EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 42 NOTE: Dimensions are shown in mm [in.]. ADV-8882A- Figure 7-8 Dimension Drawing—Accessories, 14--24EKOZD and 12--20.5EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 43 NOTE: Dimensions are shown in mm [in.]. ADV-8882B- Figure 7-9 Dimension Drawing—Accessories, 14--24EKOZD and 12--20.5EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 44 NOTE: Dimensions are shown in mm [in.]. ADV-8857A-B Figure 7-10 Dimension Drawing, 32/40EKOZD and 28/35EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 45 NOTE: Dimensions are shown in mm [in.]. ADV-8857B-B Figure 7-11 Dimension Drawing, 32/40EKOZD and 28/35EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 46 NOTE: Dimensions are shown in mm [in.]. ADV-8858-B Figure 7-12 Dimension Drawing—Sound Shield, 32/40EKOZD and 28/35EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 47 NOTE: Dimensions are shown in mm [in.]. ADV-8858-B Figure 7-13 Dimension Drawing—Sound Shield, 32/40EKOZD and 28/35EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 48 NOTE: Dimensions are shown in mm [in.]. ADV-8859A-A Figure 7-14 Accessory Drawing—Keel Cooling with Dry Exhaust, 32/40EKOZD and 28/35EFKOZD (Sheet 1 of 2) Section 7 Installation Drawings TP-7045 3/18c...
  • Page 49 NOTE: Dimensions are shown in mm [in.]. ADV-8859B-A Figure 7-15 Accessory Drawing—Siphon Break Connection, 32/40EKOZD and 28/35EFKOZD (Sheet 2 of 2) TP-7045 3/18c Section 7 Installation Drawings...
  • Page 50 Notes Section 7 Installation Drawings TP-7045 3/18c...

  • Page 51: Section 8 Reconnection

    Section 8 Reconnection 8.1 Voltage Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the Use the following voltage reconnection procedure to generator set as follows: (1) Press the generator set off/reset change the voltage of 4- and 12-lead generator sets.
  • Page 52 Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load...

  • Page 53: Twelve-Lead Reconnection

    NOTICE Kraus Naimler/American Solenoid Voltage reconnection. Affix a notice to the generator set after 4-Wire, 3-Phase Generator Sets reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. Twelve-Lead Reconnection Procedure 1.
  • Page 54 Figure 8-3 Generator Reconnection (ADV-5875F-U) Section 8 Reconnection TP-7045 3/18c...

  • Page 55: Section 9 Paralleling Generator Sets

    Section 9 Paralleling Generator Sets Introduction WARNING Read and follow the safety precautions included in this manual. Pay attention to the decals on the equipment and follow the instructions below. All personnel involved in handling, site preparation, Accidental starting. installation, testing, operation, and maintenance Can cause severe injury or death.

  • Page 56: Paralleling Basics

    9.1.2 Paralleling Functions Decision-Makerr 3500 Controller Features Include: There are two methods of paralleling: Isochronous (real and reactive) load sharing with other Decision-Makerr 3500 equipped generator sets. 1. PGEN. Decision-Makerr 3500 full-featured paralleling controller. It offers Random first-on logic to prevent two or more integrated control for synchronizing, load sharing, generator sets from closing to a dead bus.
  • Page 57 Note: Non-ECM engines will require an electronic governor (Woodward APECs) and an Voltage Bias is the amount that the controller is appropriate Kohler governor calibration in attempting to adjust the output voltage (100% bias order to permit speed adjustment. = +10% on the output voltage, --100% = --10% on the output voltage).
  • Page 58 Note: The Voltage Bias can also be controlled by The synchronizer will issue a breaker close command an external device if the External Bias Inputs when the frequency difference, phase angle, and Enabled parameter is true, the Stand Alone voltage difference are within an acceptable range and Operation parameter is false, no generators the phase rotation matches.

  • Page 59: Paralleling Considerations

    CAN gauge on or off the bus. For motorized paralleling breakers, Modbusr there is one option: Kohler SiteTecht software Remotely mounted. Customer needs to wire to AUTO--RUN/AUTO--OFF button status, trip, close, charge motor, and bus sensing.

  • Page 60: Paralleling Set Up

    9.3 Paralleling Set Up Voltage and Reactive (kVAR) Power The Decision-Makerr 3500 controls the generator set’s 9.3.1 PGEN Communication Wiring output voltage. In order to parallel two or more generator sets using The generator set response to the signal varies PGEN, a communication wire is required.

  • Page 61: Paralleling Gain Setting

    9.3.2 Paralleling Gain Setting Tuning Example Before beginning, ensure that all generator set The Decision-Makerr 3500 controller is preset with controllers are connected to a PC via a USB cable and factory defaults for each generator model number in the that all controllers are shown in SiteTecht under the personality profile.

  • Page 62: Decision-Maker 3500 Paralleling Sequence Of Operation

    9.3.3 Decision-Makerr 3500 Paralleling Sequence of Operation Follow the instructions provided Install generators earlier in this manual. Note: Sequence of operation Connect circuit Consult the wiring diagrams is for unit-mounted breakers. Additional breaker control and provided in the operation manual. steps for remote-mounted breakers are status wiring shown in:...

  • Page 63: Troubleshooting When Breaker Does Not Close To Bus

    PGEN and assert it, or set Standalone mode in communication. The controller supports this Kohler SiteTecht. Note, Standalone mode scenario if the controller is configured in should only be asserted if there is only one Standalone mode.

  • Page 64: Faults Shown

    9.4.2 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: System Voltage Mismatch Between Generators System voltage is not One of the controllers on the network is Verify the system voltage of all the equivalent configured differently than the other generators match the requirements of the controllers.
  • Page 65 Step Potential Cause Explanation Troubleshooting Fault: Close Attempt Fault: Fail to Close (Continued) Breaker is not powered The 24V electronics on the circuit breaker Verify the 24V input which exists on require an external 24V source on a 12V paralleling generators is receiving 24VDC generator.

  • Page 66: Troubleshooting When Breaker Does Close To Bus

    9.5 Troubleshooting When Breaker Does Close to Bus 9.5.1 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: Close Attempt Fault: Fail to Close Breaker status feedback The breaker closes but the controller does Verify the wiring on the circuit breaker to is not valid, no bus not see a change in status.
  • Page 67 Step Potential Cause Explanation Troubleshooting Fault: Bus Voltage Amplitude Mismatch- -Phase A The phase A voltage of The voltage measured on the bus sensing Verify the bus sensing wire for phase A is the bus does not match for phase A does not match the voltage connected to phase A of the load side of the generator measured on phase A of the generator.
  • Page 68 Step Potential Cause Explanation Troubleshooting Fault: Bus Sensing Phases A and B are Reversed The bus sensing for Phase angle from generator to bus is about Verify wiring between bus sensing inputs phase A is connected to 180_ and bus rotation is backwards. and load side of paralleling breaker.
  • Page 69 Step Potential Cause Explanation Troubleshooting Fault: Bus Sensing Connected to Generator Side of Breaker Bus metering is The controller sees the bus voltage always Verify the bus metering is connected on the connected to the wrong matches the generator voltage, even when load side of the paralleling breaker.

  • Page 70: Troubleshooting When Running In Auto

    9.6 Troubleshooting When Running in AUTO 9.6.1 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: Generator Phase Rotation Mismatch This generator is wired The controller has validated that the bus Verify wiring between this generator and with the opposite phase metering is accurate relative to this the paralleling breaker.
  • Page 71 Step Potential Cause Explanation Troubleshooting Fault: Bus Frequency Out of Spec The generators which When the generators which are supplying a Verify the load requirements are met by a are connected to the load are overloaded, their engine speed will single generator.
  • Page 72 Step Potential Cause Explanation Troubleshooting Fault: AC Frequency: High Warning Attempting to operate a The speed bias and voltage bias control Install contacts in series with the base-load generator in base-load real and reactive load in base-load mode mode input to the controller which are mode while it is against a source with a nearly constant disconnected when the utility source is...
  • Page 73 Step Potential Cause Explanation Troubleshooting Fault: Generator Total Reactive Power: Low Warning Different sized units The reactive power may overshoot when in It may be necessary to adjust the kVAR a power control situation such as a load load sharing gains. ramp or a quickly changing customer load.

  • Page 74: Generator Management Setup

    9.7 Generator Management Setup Typical Applications for Fuel Level Order Selection Mode: Generator Management starts and stops generators Prime power applications where the generators have based on the requirements of the load. The order in individual fuel tanks and have level indication on the which the generators are started or stopped is fuel tanks.

  • Page 75: Paralleling Parameters

    all the generators are stopped. The generator with the Generator Start Percentage most fuel will be started first. The Generator Start Percentage is the percent load on the running generators above which this generator will Because a generator will not be consuming fuel when it begin timing for the Generator Start Delay.

  • Page 76: Load Add/Shed Configuration

    9.8 Load Add/Shed Configuration Load Priority Configuration The Load Shed priorities are events which can be The Load Add/Shed configuration (also known as load assigned to programmable IO. Priorities 1 and 2 are control) is intended to remove non-critical loads from the defaulted to RDO outputs 3 and 4.

  • Page 77: Appendix A Generator Selection And Wattage Requirements

    Appendix A Generator Selection and Wattage Requirements Consider total wattage requirements (lights, motors, are DC powered by a 12-volt battery. Make sure the appliances) when selecting a generator set or when calculated total wattage includes only lights actually on sizing wattage usage in which available space and the generator set AC circuit.

  • Page 78: Appendix B Abbreviations

    Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 79 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory F kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.
  • Page 80 Appendix C Generator Set Output Ratings Procedure Kohler Co. develops the kilowatt output rating of a Kohlerr generator set installation. Figure 1 outlines the marine generator set based upon the calculations calculations. Figure 2 contains examples of how heat specified in ISO 3046 and ISO 8528-1. The calculations variables affect generator set ratings.
  • Page 81 TP-7045 3/18c...
  • Page 82 TP-7045 3/18c...
  • Page 83 TP-7045 3/18c...
  • Page 84 TP-7045 3/18c KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Original Instructions (English) For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2016, 2017 and 2018 by Kohler Co. All rights reserved.

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