Kohler 15REYG Installation Manual
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Kohler 15REYG Installation Manual

Kohler 15REYG Installation Manual

Commercial generator sets
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Installation
Commercial Generator Sets
Models:
15REYG
30REYG
TP-6727 10/11c

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Summary of Contents for Kohler 15REYG

  • Page 1 Installation Commercial Generator Sets Models: 15REYG 30REYG TP-6727 10/11c...

  • Page 2: Product Identification Information

    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. Product Identification Information Product identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Section 4 Accessories ..............Introduction .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 6 Battery short circuits. Explosion Exhaust System possible, seek fresh air immediately can cause severe injury or death. and remain active. Do not sit, lie down, Short circuits can cause bodily injury or fall asleep. Alert others to the WARNING and/or equipment damage.
  • Page 7 Gas fuel leaks. Explosive fuel Installing battery charger. WARNING vapors can cause severe injury or Hazardous voltage cause death. Fuel leakage can cause an severe injury death. explosion. Check the LP vapor gas or ungrounded battery charger may natural gas fuel system for leakage by cause electrical shock.
  • Page 8 Hot Parts Notice WARNING NOTICE WARNING This generator set has been rewired from its nameplate voltage Airborne particles. cause severe injury Hot coolant and steam. blindness. Can cause severe injury or death. Wear protective goggles and clothing Before removing the pressure cap, 246242 when using power tools, hand tools, stop the generator set and allow it to...

  • Page 9: Introduction

    Only trained and qualified personnel should install or service the Information in this publication represents data available generator set. at the time of print. Kohler Co. reserves the right to change this publication and the products represented Literature Type Part Number...

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 11: Section 1 General

    Meet applicable fire rating codes and standards. The generator set and accessories must be installed by Position the generator set over a noncombustible a trained, authorized Kohler distributor, dealer, or surface. Do not allow accumulation of combustible authorized representative. The installation must comply materials under the generator set.

  • Page 12: Unit-Mounted Radiator Cooling

    1.6 Unit-Mounted Radiator Cooling Pipe length Other appliances on the same fuel supply The generator set is equipped with a unit-mounted Number of fittings radiator common cooling system. Flexible connections. Rigid-mount the piping but protect it from vibration. Use flexible connections 1.6.1 System Features spanning a minimum of 152 mm (6 in.) between the...

  • Page 13: Electrical Connections

    GND inside the junction box or customer connection box. See Section 3.4 for the ground lug location. Kohler generator sets are shipped from the factory with the neutral attached to the alternator in the junction box. At installation, the neutral can remain grounded at the...

  • Page 14: Batteries

    Tightening Torque, Nm (in. lb.) Hexagonal Head—External Wire Size for Unit Drive Socket Wrench Connection Slot Head 4.7 mm (No. 10) or Larger* Slot Width <1.2 mm (0.047 in.) Slot Width >1.2 mm (0.047 in.) Split-Bolt Other Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections...

  • Page 15: Remote Start Connection (Optional)

    1.8.8 Remote Start Connection and the generator set master switch is in the AUTO position, the transfer switch contacts close to start the (optional) generator set. Connect leads 3 and 4 from the ADC 2100 controller to The engine start terminals are usually located near the the automatic transfer switch’s engine start terminals or transfer switch contactor with an engine start decal to an optional remote start/stop switch.
  • Page 16 Notes Section 1 General TP-6727 10/11...

  • Page 17: Section 2 Open Units

    Section 2 Open Units 2.1 Introduction For the protection of the building’s occupants, install carbon monoxide (CO) detectors on each level of the This section contains installation information specific to building. Locate the detectors to adequately warn the open (unhoused) commercial generator sets. Review building’s occupants of the presence of carbon the precautions in the Safety Precautions section and monoxide.

  • Page 18: Air And Cooling

    2.2 Air and Cooling Combustion and heat dissipation require an ample flow of clean, cool air. To prevent accumulation of explosive gases, ventilate compartments containing batteries. 2.2.1 Installation Considerations Intake and outlet openings. Provide air intake and air outlet openings for generator sets located in a building or enclosure.

  • Page 19: Cooling Air Requirements

    In cold climate interior installations using controlled Since the exhaust air of larger units is both high volume recirculation to recover heat, install thermostatically and high velocity, direct the exhaust flow away from activated louvers and fans to prevent the generator set areas occupied by people or animals.

  • Page 20: Flexible Exhaust Line

    Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside.

  • Page 21: Piping

    When planning exhaust silencer and piping placement, consider the location of combustible materials. If the proximity of the exhaust system to the combustible materials cannot be avoided, follow a regular maintenance schedule to ensure that combustible materials are kept away from the exhaust pipes after installation.

  • Page 22: Exhaust System Backpressure

    Rain cap. To prevent precipitation from entering the 2.3.6 Exhaust System Backpressure exhaust pipe, install a rain cap on vertical outlets. See Exhaust backpressure limits engine power and Figure 2-11. In a climate where freezing is common, do excessive backpressure causes serious engine...
  • Page 23 3. Refer to the generator set specification sheet for: Equivalent of straight pipe: 3.0 + 2.8 = 5.8 equiv. straight ft. a. Engine exhaust flow at rated kW in m /min. 0.9 + 0.86 = 1.76 equiv. straight m (cfm) 6.
  • Page 24 d Pipe Diameter inches Δ P Backpressure kPa per m in. Hg per foot Figure 2-13 Backpressure using Pipe Size 4 in., 152 m or Less Section 2 Open Units TP-6727 10/11...

  • Page 25: Section 3 Installation Instructions

    Section 3 Installation Instructions 3.1 Introduction WARNING Have the generator set installed by a trained, authorized Kohler distributor, dealer, or authorized representative. Note: These instructions outline one procedure for installing the generator set. Local codes may Hazardous voltage. require different procedures.

  • Page 26: Prepare Site

    Tools Required: 3.2 Prepare Site Multimeter (for measuring voltage and current) See Section 1.3 for important factors to consider in Frequency meter (may be part of multimeter) choosing the generator set location. Torque wrench Wrenches 3.2.1 Indoor Installations, Open Units Screwdrivers Socket wrenches or nut drivers Maintain a minimum of 457 mm (18 in.) between the...

  • Page 27: Lifting Generator Set

    GND terminals on terminal block TB2. 3.3 Lifting Generator Set Kohler generator sets are shipped from the factory with the neutral attached to the alternator in the junction box. At installation, the neutral can remain...

  • Page 28: Generator Set Electrical Connections

    3.5 Generator Set Electrical Connections Note: Have a licensed electrician make the following electrical connections. All connections must comply with state and local codes. Size the wire according to the length of run and 115% of the circuit current (amperage) as directed by the National Electrical Coder (NEC) in ANSI/NFPA 70.

  • Page 29: Install Engine Starting Battery

    5. Use a minimum of 16 gauge wire for the engine 1. Verify that the generator set master switch is in the start connections. Connect the engine start leads OFF/RESET position. to leads 3 and 4 at the customer interface 2.

  • Page 30: Install And Connect Fuel Supply

    3.7 Install and Connect Fuel Gas Flow Rate, Btu/hr. Supply Natural Gas Model 15 kW 205,000 212,500 30 kW 548,000 547,500 WARNING Figure 3-3 Natural Gas Flow Rate Fuel Supply Specifications Fuel type LP Gas or Natural Gas Fuel supply inlet 3/4-14 NPT Explosive fuel vapors.
  • Page 31 ADV-7692 Note: UL 2200-listed units include a second fuel valve. See Figure 3-9. 1. Fuel supply connection, 3/4 NPT 2. Fuel solenoid valve Figure 3-8 Fuel Supply Connection Location (Generator set enclosure not shown) Figure 3-7 Manual Fuel Shut-Off Valve (outdoor installation shown) 3.

  • Page 32: Fuel Conversion Procedures

    3.7.1 Fuel Conversion Procedures Note: The Integrated Electronic Pressure Regulator (IEPR) and air/fuel mixer are specially calibrated emission-control devices. Do not adjust the IEPR or the air/fuel mixer. Check the connections to the fuel solenoid valve to verify that the fuel system is set up for the type of fuel that will be used.

  • Page 33: Add Coolant

    3.7.2 Add Coolant 3. Check the oil level before operating the engine. Follow the instructions below to fill the cooling system. 4. Operate the engine with the radiator’s pressure cap removed until the thermostat opens and the 1. Close the radiator’s coolant drain valve and tighten radiator upper hose becomes hot.

  • Page 34: Operation Tests

    3.8 Operation Tests 3. Use a digital voltmeter (DVM) to check the output voltage from the generator set. If voltage adjustments are required, refer to Section 5.5 for WARNING instructions to use the ADC 2100 voltage adjustment menu. 4. Perform voltage checks as described in the ATS Operation and Installation manual.
  • Page 35 16 gauge or larger leads for the customer connections. Have accessories installed by a trained, authorized See Figure 4-3 and the wiring diagram for connection Kohler distributor, dealer, or authorized representative. details. Follow the installation instructions provided with each kit.
  • Page 36 4.3 Block Heaters 4.5 Dropover Sound Enclosures Block heaters are available as installed accessories on The dropover sound enclosure is available as a loose kit all generator sets. Use block heaters on all standby for field installation. The enclosure kit includes the applications where the generator set is subject to assembled enclosure, radiator duct flanges, and temperatures below 16°C (60°F).
  • Page 37 Section 5 Controller 5.1 Advanced Digital Control If the ADC 2100 is not configured for a CAN gauge (communications parameter setting Cn00, (ADC 2100) Section 5.4), the controller will power down after 48 hours of no activity. If the generator set has been The generator sets use the Advanced Digital Control started, the controller will power down 48 hours after the (ADC 2100).
  • Page 38 127/220 Three phase, 4 wire Unit configuration Uc01 Standby Engine type Ec11 * 30REYG Ec12 * 15REYG Engine data input types Ed01 15/30REYG factory setup Battery voltage Bt12 12 VDC Communications Cn00 No CAN communications, 48-hour power down (factory setting)
  • Page 39 Controller Configuration Mode: Hold the Select button: Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 3 2 5 firmware version number. (The number may be different than the one shown here.) Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.
  • Page 40 Pressing the up arrow key at the Adnc display (See Figure 5-2) puts you into the Advanced Configuration Mode. Press: E d 0 1 To set the engine data input type to Ed01. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. Set this B t 1 2 parameter to 12 VDC.
  • Page 41 5.5 Voltage Adjustments Pressing the Select button when SAVE is displayed returns to the first parameter, voltage adjust (1P). WARNING Voltage Adjustment Procedure Note: Refer to the flowcharts in Figure 5-6 and Figure 5-7 during voltage adjustment procedure. Hazardous voltage. Moving parts.
  • Page 42 Output Voltage Adjustment Mode: Display :* x x x x Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 43 Display : * Continued from Figure 5-6: To enter coarse voltage stability (gain) adjustment mode. To raise or lower the voltage stability (gain) in large increments. To enter fine voltage stability (gain) adjustment mode. To raise or lower the voltage stability (gain) in smaller increments.
  • Page 44 Notes Section 5 Controller TP-6727 10/11...
  • Page 45 Section 6 Generator Reconnection 6.1 Voltage Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator reconnection procedure explains voltage set as follows: (1) Move the generator set master switch to the reconnections only.
  • Page 46 6.2 Four-Lead (Single-Phase) 6.3 12-Lead (Three-Phase) Generator Sets Generator Sets Figure 6-1 shows the factory connection for the single- Note: The current transformers (CTs) shown on the phase 120/240 V 60 Hz generator set. Single-phase following diagrams are not used on generator models are not reconnectable.
  • Page 47 Note: The current transformers (CTs) shown are not used on generator sets equipped with the Advanced Digital Control (ADC 2100). ADV-5875B-J Figure 6-2 12-Lead Generator Reconnection TP-6727 10/11 Section 6 Generator Reconnection...
  • Page 48 Notes Section 6 Generator Reconnection TP-6727 10/11...

  • Page 49: Adv-7692

    Section 7 Dimension Drawings This section contains dimension drawings for the Note: For wiring diagrams, refer to TP-6719, Wiring geenrator sets and accessories. Drawings are Diagram Manual. arranged in numerical order. Refer to Figure 7-1 to find the drawings for generator sets with and without the customer connection box and enclosure.
  • Page 50 Figure 7-2 Dimension Drawing, ADV-7692, Sheet 1, Generator Set Section 7 Dimension Drawings TP-6727 10/11...
  • Page 51 Figure 7-3 Dimension Drawing, ADV-7692, Sheet 2, Generator Set TP-6727 10/11 Section 7 Dimension Drawings...
  • Page 52 Figure 7-4 Dimension Drawing, ADV-7693, Accessories Section 7 Dimension Drawings TP-6727 10/11...
  • Page 53 Figure 7-5 Dimension Drawing, ADV-7695, Sheet 1, Weather Enclosure and Weather Enclosure with Sound Kit TP-6727 10/11 Section 7 Dimension Drawings...
  • Page 54 Figure 7-6 Dimension Drawing, ADV-7695, Sheet 2, Sound Enclosure Section 7 Dimension Drawings TP-6727 10/11...
  • Page 55 Figure 7-7 Dimension Drawing ADV-7695, Sheet 3, Dropover Sound Enclosure TP-6727 10/11 Section 7 Dimension Drawings...
  • Page 56 Figure 7-8 ADV-7695, Sheet 4, 150 MPH High Wind Mounting Details Section 7 Dimension Drawings TP-6727 10/11...
  • Page 57 Figure 7-9 Dimension Drawing, ADV-8159, Sheet 1, Generator Set with Customer Connection Box TP-6727 10/11 Section 7 Dimension Drawings...
  • Page 58 Figure 7-10 Dimension Drawing, ADV-8159, Sheet 2, Generator Set with Customer Connection Box Section 7 Dimension Drawings TP-6727 10/11...
  • Page 59 (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TPMPFP-6727 10/11 Appendix 59...
  • Page 60 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 61 Appendix B Fuel Physical Properties Physical Property Manufactured or @ 15°C (60°F) Sewage Gas Butane Propane Natural Gas Gasoline Diesel Fuel Normal atmospheric state Liquid Liquid Boiling point, Initial, °C (°F) — — — — 36 (97) 177 (350) End, °C (°F) 0 (32) 42 (--44 ) --162 (--259)
  • Page 62 Appendix C Gas Fuel Vapor Pressures 14.06 kg/cm (200 psi) 12.65 kg/cm (180 psi) 11.25 kg/cm (160 psi) 9.84 kg/cm (140 psi) 8.44 kg/cm (120 psi) 7.03 kg/cm (100 psi) 5.62 kg/cm (80 psi) 4.22 kg/cm (60 psi) 2.81 kg/cm (40 psi) 1.41 kg/cm (20 psi)
  • Page 63 Appendix D Gas Fuel System Installation Planning Determining Propane Cylinder Determining Propane Vaporization Quantity Capacity Guide for Installing 100 lb. Cylinders Guide for ASME LP Gas Storage Containers For continuous draws where temperatures may reach --18°C (--0°F). Assume the vaporization rate of 100 lb. cylinder as approximately 50000 Btu/hr.
  • Page 64 Notes TP-6727 10/11...
  • Page 65 Notes TP-6727 10/11...
  • Page 66 Notes TP-6727 10/11...
  • Page 68 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6727 10/11c 7 Jurong Pier Road Singapore 619159 E 2009, 2010, 2011 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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