Kohler 15RYG Installation Manual
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Kohler 15RYG Installation Manual

Kohler 15RYG Installation Manual

Commercial generator sets
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Installation
Commercial Generator Sets
Models:
15/30RYG
TP-6329 8/07c

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Summary of Contents for Kohler 15RYG

  • Page 1 Installation Commercial Generator Sets Models: 15/30RYG TP-6329 8/07c...

  • 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, and 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 or fall asleep. Alert others to the can cause severe injury or death. possibility carbon monoxide Short circuits can cause bodily injury poisoning. Seek medical attention if WARNING and/or equipment damage. the condition of affected persons does Disconnect battery before...
  • 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 Flexible connections. Rigid-mount the piping but protect it from vibration. Use flexible connections The generator set is equipped with a unit-mounted spanning a minimum of 152 mm (6 in.) between the radiator common cooling system. stationary piping and the engine fuel inlet connection. 1.6.1 System Features 1.8 Electrical System...

  • Page 13: Load Lead Connections

    Kohler generator sets are shipped with the generator 1.8.4 Load Lead Connections neutral attached to the generator in the junction box. At Feed load leads to the generator set junction box installation, the neutral can be grounded at the through the back of the box. See Figure 1-2. Route DC generator set or lifted from the ground stud and isolated leads in separate conduit from AC conductors.

  • Page 14: Batteries

    Note: If a connector has a clamp screw such as a When the engine is not operating, a very low charge rate slotted, hexagonal head screw with more than from an AC-powered battery charger is usually sufficient one means of tightening, test the connector using to maintain a full charge on the batteries.

  • Page 15: 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 16: 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 17: 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 18: 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 19: 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 20: Exhaust System Backpressure

    Exhaust pipe backpressure = 1.7 kPa (0.5 in. Hg) 1. Rain cap (or gradual U bend) 2. Rain shield Backpressure, kPa (in. Hg.) 3. 254 mm (10 in.) minimum 15RYG 30RYG Silencer Type 4. 25 mm (1 in.) minimum Residential, SIEO, 2 in. NPT 1.5 (0.47)
  • Page 21 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 22 Q Engine Exhaust Flow m3/min. 28.3 1000 25.5 d Pipe Diameter inches 22.7 25.4 19.8 17.0 Δ P Backpressure kPa per m in. Hg per foot 14.2 31.8 1.25 10.33 5.15 11.3 38.1 1.04 44.5 1.75 0.52 0.05 50.8 0.09 0.01 0.05 0.005...

  • Page 23: Section 3 Installation Instructions

    To install optional accessories, follow the instructions provided with each kit. Have the generator set installed by a trained, authorized Kohler distributor, dealer, or authorized representative. WARNING Note: These instructions outline one procedure for installing the generator set. Local codes may require different procedures.

  • Page 24: Prepare Site

    Carbon monoxide detectors. Carbon monoxide can 3.2 Prepare Site cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of the building. Locate the See Section 1.3 for important factors to consider in detectors to adequately warn the building’s occupants of the choosing the generator set location.

  • Page 25: Lifting Generator Set

    3.3 Lifting Generator Set Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box. At installation, the neutral can be WARNING grounded at the generator set or lifted from the ground stud and isolated if the installation requires...

  • Page 26: Exhaust Pipe Orientation (Dropover Sound Enclosures)

    Load Lead and Engine Start Connections Lead P24 Pin Number Number Connection 1. Install a 120 VAC receptacle for the generator set Common fault relay normally open battery charger and block heater, if equipped. Common fault relay common Supply power to the receptacle through a circuit Common fault relay normally closed that is powered at all times, by the utility and by the Run relay normally open...

  • Page 27: Install Engine Starting Battery

    Gas Flow Rate, Btu/hr. 6. Connect the red battery cable to the positive (+) Natural Gas Model battery terminal. 15RYG 205,000 212,500 7. Connect the black battery cable to the negative (--) 30RYG 548,000 547,500 battery terminal.
  • Page 28 (in. H 4-6 (7-11) Nominal Fuel Rating, Btu/ft 1000 Natural gas 2500 LP vapor Figure 3-5 Fuel Requirements Fuel Consumption 15RYG 30RYG Natural Gas, m /hr. (cfh) at % load 100% 5.7 (200) 12.7 (450) 4.5 (160) 10.6 (375) 3.5 (125) 8.5 (300)

  • Page 29: Fuel Conversion Procedures

    4. Check that the fuel system is set up for the fuel 3.8.1 Fuel Conversion Procedures being used (natural gas or LP). When converting the generator set to operate with LP a. Check the orientation of the fuel regulator and gas, remove the internal spring from the secondary check the hang tag attached to the regulator.

  • Page 30: Fuel System Adjustment Procedures

    8. Reinstall the cover plug. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely 9. Check the fuel connections for leaks with the hot during operation.

  • Page 31: Operation Tests

    10. Allow the generator set to run until the generator 15. Repeat steps 11 through 14 to verify the settings. set reaches normal operating temperature. The 16. Place the generator set master switch in the OFF time required reach normal operating position to stop generator set.
  • Page 32 Notes Section 3 Installation Instructions TP-6329 8/07...
  • Page 33 Have accessories installed by a trained, authorized Kohler distributor, dealer, or authorized representative. Follow the installation instructions provided with each kit. Use separate conduit for AC and DC leads to reduce the possibility of electrical interference.
  • Page 34 4.3 Remote Digital Gauge Use one or more remote extension harness kits to connect the gauge to the generator set. Do not use The digital gauge allows for remote starting/stopping more than 3 remote harness kits and do not exceed and monitoring of certain generator set functions.
  • Page 35 Section 5 Controller 5.1 Advanced Digital Control 5.3 Controller Configuration (ADC 2100) The controller configuration for each generator model is set at the factory and should not normally require The Model 15/30RYG generator sets use the Advanced changes. The controller’s configuration mode allows Digital Control (ADC 2100).
  • Page 36 Frequency, Hz Phases, Wires Connection Parameter Setting Unit’s system voltage and Uu01 Single phase, 3 Wire 120/240 1 PH frequency, 15RYG Uu04 Three phase, 4 Wire 277/480 Uu10 * Three phase, 4 Wire Delta 120/240 Uu10 * 139/240 Three phase, 4 Wire...
  • Page 37 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 1 0 4 program 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 38 Pressing the up arrow key at the Adnc display (See Figure 5-2) puts you into the Advanced Configuration Mode. Press: E d 0 0 To set the engine data input type to Ed00. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. Set this B t 1 2 parameter to 12 VDC.
  • Page 39 5.4 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 40 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 41 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 42 Notes Section 5 Controller TP-6329 8/07...
  • Page 43 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 44 6.2 Four-Lead (Single-Phase) Three-phase, 12-lead generator sets are reconnectable to the voltages and phases shown in Figure 6-2. Use Generator Sets the following procedure to reconnect the generator to the desired voltage configuration, change the system Figure 6-1 shows the factory connection for the voltage setting, and adjust the output voltage.
  • Page 45 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-6329 8/07 Section 6 Generator Reconnection...
  • Page 46 Notes Section 6 Generator Reconnection TP-6329 8/07...
  • Page 47 Section 7 Dimension Drawings This section contains the dimension drawings listed in Figure 7-1. Note: For wiring diagrams, refer to TP-6347, Wiring Diagram Manual. Dimension Drawing Drawing Description Number Page Generator Set ADV-6916A-E Exhaust and Duct Flange ADV-6916B-E Weather Housing ADV-6916C-E Sound Upfit ADV-6916D-E...
  • Page 48 Figure 7-2 Dimension Drawing, ADV-6916A-E, Sheet 1, Generator Set Section 7 Dimension Drawings TP-6329 8/07...
  • Page 49 Figure 7-3 Dimension Drawing, ADV-6916B-E, Sheet 2, Exhaust Options and Duct Flange TP-6329 8/07 Section 7 Dimension Drawings...
  • Page 50 Figure 7-4 Dimension Drawing, ADV-6916C-E, Sheet 3, Weather Housing Section 7 Dimension Drawings TP-6329 8/07...
  • Page 51 Figure 7-5 Dimension Drawing, ADV-6916D-E, Sheet 4, Weather Housing with Sound Upfit Kit TP-6329 8/07 Section 7 Dimension Drawings...
  • Page 52 Figure 7-6 Dimension Drawing, ADV-6916E-E, Sheet 5, Sound Enclosure Section 7 Dimension Drawings TP-6329 8/07...
  • Page 53 Figure 7-7 Dimension Drawing, ADV-6916F-E, Sheet 6, Drop-Over Sound Housing TP-6329 8/07 Section 7 Dimension Drawings...
  • Page 54 Figure 7-8 Dimension Drawing, ADV-6916G-E, Sheet 7, High-Wind Mounting Detail Section 7 Dimension Drawings TP-6329 8/07...
  • Page 55 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 56 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
  • Page 57 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 58 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 59 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 60 Notes TPMPFP-6329 8/07...
  • Page 61 Notes TPMPFP-6329 8/07...
  • Page 62 Notes TPMPFP-6329 8/07...
  • Page 64 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-6329 8/07c 7 Jurong Pier Road Singapore 619159 E 2004, 2006, 2007, 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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30ryg

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