Kohler 10REODB Installation Manual
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Kohler 10REODB Installation Manual

Kohler 10REODB Installation Manual

Industrial generator sets
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Installation
Industrial Generator Sets
Models:
10/15/20REODB/REOZDB
Controller:
KPC 1000
TP-6609 6/08

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Summary of Contents for Kohler 10REODB

  • Page 1 Installation Industrial Generator Sets Models: 10/15/20REODB/REOZDB Controller: KPC 1000 TP-6609 6/08...

  • 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 Generator Set Identification Numbers Controller Identification Record the product identification numbers from the Record the controller description from the generator set generator set nameplate(s).

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Section 5 Electrical System ..............Introduction .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets WARNING accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act Explosion.
  • Page 6 Battery gases. Explosion can cause Servicing the fuel system. A flash Engine Fluids and severe injury or death. Battery gases fire can cause severe injury or death. Chemical Products can cause an explosion. Do not smoke Do not smoke or permit flames or or permit flames or sparks to occur near sparks near the fuel injection system, a battery at any time, particularly when...
  • Page 7 Used engine oil. Contact with used Carbon monoxide symptoms. WARNING engine oil may cause severe skin Carbon monoxide can cause severe irritation. Repeated and prolonged nausea, fainting, or death. Carbon skin exposure may have other monoxide is a poisonous gas present in health risks.
  • Page 8 Hazardous Noise Welding on the generator set. Can WARNING cause severe electrical equipment damage. Before welding on the CAUTION generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module Hazardous voltage.
  • Page 9 Short circuits. Hazardous Hot Parts Moving Parts voltage/current can cause severe injury or death. Short circuits can WARNING WARNING cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Remove all jewelry before servicing the equipment.
  • Page 10 Notice NOTICE This generator set has been rewired from its nameplate voltage 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from authorized service...

  • Page 11: Introduction

    Information in this publication represents data available List of Related Literature at the time of print. Kohler Co. reserves the right to change this publication and the products represented Figure 1 identifies related literature available for the without notice and without any obligation or liability generator sets covered in this manual.

  • Page 12: 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 13: Section 1 Location And Mounting

    Section 1 Location and Mounting 1.1 Introduction Open generator sets do not include a factory-supplied weather or sound enclosure. Open units may be installed inside an unoccupied structure only if the WARNING exhaust is piped safely outside and adequate air for combustion and cooling is provided.

  • Page 14: Location Factors

    1.2 Location Factors Ideally, the generator set should be mounted on concrete at ground level. For above-ground installations, including roof installations, weight considerations are especially important. The building engineer must determine whether the structure can support the weight of the generator set. The location of the generator set must: Support the weight of the generator set and related equipment such as batteries, radiators, and mounting...

  • Page 15: Prepare The Site

    1.5 Prepare the Site clearance beyond the exhaust end of the generator set. Plan the installation so that the exhaust end of the See Section 1.2 for important factors to consider in generator set is not directed toward the building or any choosing the generator set location.

  • Page 16: Lifting

    1.6 Lifting insert lifting hooks or lifting bars through the holes in the mounting skid. The placement of the holes prevents the lifting cables from damaging the WARNING generator set components and maintains balance during lifting. If the lifting cables contact the air cleaner, guards, or other protruding components, use spreader bars on the cables.

  • Page 17: Section 2 Exhaust Systems

    Section 2 Exhaust Systems 2.1 Introduction WARNING Carbon monoxide. cause severe nausea, fainting, or death. exhaust system must leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an TP-5700-5 odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.

  • Page 18: Piping

    2.5 Piping thimble, use a mesh large enough to allow unrestricted air circulation through the thimble. See Section 2.7 for Note: Select piping with a diameter that is the same size additional exhaust outlet location and protection as or larger than the manifold outlet’s inside considerations.

  • Page 19: Exhaust Outlet

    2.7 Exhaust Outlet 2.8 Exhaust System Back Pressure Outlet location. Engine performance and efficiency depend on the location of the exhaust outlet. Direct the Exhaust back pressure limits engine power and exhaust outlet away from the air inlet to prevent exhaust excessive back pressure causes serious engine gases from entering the air inlet and clogging the damage.
  • Page 20 Notes Section 2 Exhaust Systems TP-6609 6/08...

  • Page 21: Section 3 Air And Cooling

    Section 3 Air and Cooling 3.1 Air Requirements highly contaminated with impurities such as dust and chaff. Combustion and heat dissipation require an ample flow Air restrictions. When using a filter, screen, or other air of clean, cool air regardless of whether the generator is restriction, increase the inlet opening size by the air- or liquid-cooled.

  • Page 22: Air Requirements

    3.2 Unit-Mounted Radiator Cooling 3.2.1 System Features system’s major components include engine-driven fan and circulating water pump, a radiator, and a thermostat. The pump circulates water through the engine until it reaches operating temperature. Then the engine thermostat opens, allowing water circulation through the radiator. The thermostat restricts water flow as necessary to prevent overcooling.
  • Page 23 Avoid suction fan use. The generator airflow should inside the building. Low building pressure can move in the same direction as the engine’s standard extinguish pilot lights on gas-fired appliances or cause pusher fan. Using a suction fan to reverse airflow is not problems with the building ventilation system.

  • Page 24: Remote Radiator Cooling

    (known as static head) is units. within the engine manufacturer’s recommendations, Kohler Co. offers radiator assemblies that meet the and the pressure drop through the piping and remote radiator does not exceed the engine manufacturer’s requirements to adequately cool the generator set.

  • Page 25: Radiator Location

    3.3.2 Radiator Location Locate the radiator to prevent recirculation of the heated exhaust air back into the intake stream. When choosing the radiator’s location: Mount the radiator in an area where prevailing winds For economical installation and operation, locate the do not hamper free airflow.

  • Page 26: Remote Radiator Installation

    3.3.3 Remote Radiator Installation the fan side of the radiator, through the core, and out the front side. When installing the remote radiator: Preferably, connect no devices to either side of the Use a remote radiator setup kit to aid installation. See radiator.

  • Page 27: Surge (Expansion) Tank For Horizontal Discharge Radiator

    3.3.4 Surge (Expansion) Tank for Shutoff valves. Locate shutoff valves between the engine and cooling system to allow for isolation of both Horizontal Discharge Radiator the radiator and the engine. A shutoff valve eliminates the need to drain the entire cooling system during A horizontal discharge remote radiator requires the use of a surge (expansion) tank.

  • Page 28: Block Heaters

    3.4 Block Heaters Note: Block heater damage. The block heater will fail if the energized heater element is not immersed Block heaters are available as installed accessories on in coolant. Fill the cooling system before turning all generator sets. Use block heaters on all standby on the block heater.

  • Page 29: Section 4 Diesel Fuel System

    Section 4 Diesel Fuel System Comply with applicable state and local codes when The main components of a typical diesel fuel system are installing any fuel system. a main fuel storage tank, a day tank, fuel lines, and an auxiliary fuel pump. See Figure 4-1. Refer to the generator set specification sheet for fuel consumption rates.

  • Page 30: Main Tank

    4.1 Main Tank Tank venting. Vent the main fuel tanks to allow air and other gases to escape to the atmosphere without Tank location. Comply with local regulations for diesel allowing dust, dirt, and moisture to enter the tank. storage tank placement. Locate fuel storage tanks Fuel expansion.
  • Page 31 GM62494 1. Fuel inlet location 4. Fuel fill cap 2. Fuel return line 5. Fuel gauge 3. Fuel supply 6. Fuel return Figure 4-3 Fuel Line Connections for Subbase Tanks TP-6609 6/08 Section 4 Diesel Fuel System...

  • Page 32: Day Tanks

    4.2 Day Tanks electric fuel transfer pumps. Because engines are subject to fuel temperature derating above 38_C terms tank transfer tank (100_F) and are subject to damage if operated with fuel interchangeable. Having a day tank adjacent to the temperatures above 60_C (140_F), a day tank providing engine allows the engine fuel transfer pump to easily at least four hours of fuel consumption should be used to draw fuel during startup and provides a convenient...

  • Page 33: Fuel Lines

    4.3 Fuel Lines the day tank size requirements in Section 4.2, Day Tanks. Note: Never use fuel piping to ground electrical A properly designed fuel return line is unrestricted and equipment. as short as possible, and it allows gravity return of fuel to Line Type.
  • Page 34 Notes Section 4 Diesel Fuel System TP-6609 6/08...
  • Page 35 Section 5 Electrical System 5.1 Introduction WARNING Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Route DC leads in separate conduit from AC conductors. Route wiring to Hazardous voltage.
  • Page 36 Comply with all governing standards and codes. Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box. At installation, the neutral can be grounded at the 5.5 Remote Start Connection...
  • Page 37 5.7 Engine Starting Battery 7. Connect the black battery cable to the negative (--) battery terminal. WARNING 8. Place the boots over the battery terminals. 9. Plug the battery heater and battery charger, if equipped, into the 120 VAC power supply. Explosion.
  • Page 38 5.9 Terminal Connector Torque Socket Size Across Flats, Tightening Torque, mm (in.) Nm (in. lb.) Use the torque values shown in Figure 5-2 or Figure 5-3 (1/8) (45) for terminal connectors. Refer to UL-486A, UL-486B, (5/32) 11.4 (100) and UL-486E for information on terminal connectors for (3/16) 13.8 (120)
  • Page 39 5.10 Accessories Relay Internal Wiring: This section illustrates several accesory kits available at the time of print. Obtain the latest accessory information from your authorized distributor/dealer. Follow the installation and operation instructions provided with the accessory kit. Run AC and DC wiring in separate conduit.
  • Page 40 5.10.2 Remote Serial Annunciator 5.10.3 Remote Emergency Stop Kit The remote serial annunciator (RSA, see Figure 5-5) Figure 5-6 shows the remote emergency stop switch monitors the condition of the generator set from a (ESS). Activating the emergency stop switch in the location remote from the generator set.
  • Page 41 Section 6 Reconnection/Adjustments 6.1 Reconnection mechanically attached together. Leads L1 and L2 are for different phases; never connect them together. Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection SINGLE PHASE decal 246242 from an authorized service distributor/ dealer...
  • Page 42 6.3 Twelve-Lead Reconnection precautions at the front of this manual and in the text during reconnection procedure. The reconnection procedure that follows details voltage Twelve-Lead Reconnection Procedure reconnections only. If the generator set requires frequency changes, adjust the governor and voltage 1.
  • Page 43 Section 7 Diagrams and Drawings Diagram or Drawing Drawing Number Page Dimension Drawings 10 kW ............ADV-7418 Sheet 1 Sheet 2...
  • Page 44 Figure 7-1 Dimension Drawing, 10 kW, ADV-7418, Sheet 1 Section 7 Diagrams and Drawings TP-6609 6/08...
  • Page 45 Figure 7-2 Dimension Drawing, 10 kW, ADV-7418, Sheet 2 TP-6609 6/08 Section 7 Diagrams and Drawings...
  • Page 46 Figure 7-3 Dimension Drawing, 15/20 kW, ADV-7419, Sheet 1 Section 7 Diagrams and Drawings TP-6609 6/08...
  • Page 47 Figure 7-4 Dimension Drawing, 15/20 kW, ADV-7419, Sheet 2 TP-6609 6/08 Section 7 Diagrams and Drawings...
  • Page 48 Figure 7-5 Dimension Drawing, Enclosures, ADV--7420 Section 7 Diagrams and Drawings TP-6609 6/08...
  • Page 49 Figure 7-6 Schematic Diagram, ADV-7446 TP-6609 6/08 Section 7 Diagrams and Drawings...
  • Page 50 Figure 7-7 Wiring Diagram, GM55021, Sheet 1 Section 7 Diagrams and Drawings TP-6609 6/08...
  • Page 51 Figure 7-8 Wiring Diagram, GM55021, Sheet 2 TP-6609 6/08 Section 7 Diagrams and Drawings...
  • Page 52 Figure 7-9 Accessory Interconnection, GM62883 Section 7 Diagrams and Drawings TP-6609 6/08...
  • Page 53 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute ext. external ABDC after bottom dead center center of gravity Fahrenheit, female alternating current cubic inch displacement fglass. fiberglass analog to digital centerline flat head machine (screw)
  • Page 54 kiloampere MTBO mean time between overhauls rly. relay kilobyte (2 bytes) mtg. mounting root mean square kilogram megawatt rnd. round kg/cm kilograms per square milliwatt read only memory centimeter μF microfarad rot. rotate, rotating kilogram-meter N, norm. normal (power source) revolutions per minute kg/m kilograms per cubic meter...
  • Page 55 Appendix B Exhaust System Back Pressure Exhaust back pressure limits engine power and 3. Refer to the submittal catalog for: excessive back pressure causes serious engine a. The recommended critical silencer part number damage. Excessive back pressure usually results from Example: 343616 one or more of the following reasons: b.
  • Page 56 5. Refer to Figure 2. Use the exhaust gas velocity Example: Exhaust velocity, 3075 m/min. determined in step 4 and find the exhaust gas (10100 ft./min.) intersects with critical silencer velocity value in thousands on the bottom scale. curve B and the corresponding back pressure Move vertically up until this value intersects the value is approximately 2.8 kPa (0.85 in.
  • Page 57 mm of Water in. of Water 660.4 609.6 558.8 508.0 457.2 406.4 Pressure Drop 355.6 304.8 254.0 203.2 152.4 101.6 50.8 (m/min.) 3.1 3.4 (ft./min.) Exhaust Gas Velocity in Thousands A = Hospital Silencer B = Critical Silencer C = Residential Silencer D = Industrial Silencer Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa (86 mm of water or 3.4 in.
  • Page 58 6. Total the number of elbows and flexible sections in 8. Refer to Figure 7-10 if the pipe size is 102 mm the exhaust system between the engine and the (4 in.) or less or Figure 7-11 if the pipe size is exhaust system outlet.
  • Page 59 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 Back Pressure kPa per m in. Hg per foot 14.2 31.8 1.25 1.033 0.515 11.3 38.1 0.104 44.5 1.75 0.052 0.05 50.8 0.009 0.01 0.005...
  • Page 60 d Pipe Diameter Q Engine Exhaust Flow inches m3/min. 76.2 453.1 16000 Δ P Back Pressure 339.8 12000 kPa per m in. Hg per foot 1.033 101.6 283.2 10000 0.515 254.9 9000 226.6 8000 198.2 7000 127.0 0.104 169.9 6000 0.052 0.05 141.6...
  • Page 61 Appendix C Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.
  • Page 62 Appendix D General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Aluminum Aluminum Torque Torque Grade 2 Grade 5 Grade 8 Measurement Size Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) —...
  • 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-6609 6/08 7 Jurong Pier Road Singapore 619159 E 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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