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Related Manuals for Kohler Generator Sets 20--2800 kW
Summary of Contents for Kohler Generator Sets 20--2800 kW
- Page 1 Installation Industrial/Commercial/Residential Generator Sets Models: 20- -2800 kW TP-5700 7/93d...
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Page 2: California Proposition
Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits. -
Page 3: Table Of Contents
Product Identification Information Safety Precautions and Instructions Introduction ................Service Assistance . - Page 4 Table of Contents, continued Section 7 Electrical Requirements Batteries Electrical Connections Load Lead Connections Terminal Connector Torque Automatic Transfer Switches Control Connections Remote Annunciator Audiovisual Alarm Remote Emergency Stop Switch 7.10 Dry Contact Kit 7.11 Wiring Appendix A Abbreviations Table of Contents .
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Page 5: Safety Precautions And Instructions
IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment, including generator sets, transfer switches, switchgear, and 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 safely. Read and follow all safety precautions and instructions. -
Page 6: Exhaust System
Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect battery before generator installation maintenance. Remove wristwatch, rings, other jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead... - Page 7 The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
- Page 8 WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection standby normal sources of supply. Grounding electrical equipment. Hazardous voltage cause...
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Page 9: Hot Parts
Servicing transfer switch controls and accessories within the enclosure. Hazardous voltage can cause severe injury or death. Disconnect the transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load. - 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...
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Page 11: Introduction
20--2800 kW generator sets. Operation manuals and wiring diagram manuals are available separately. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. -
Page 13: Section 1 General
Industrial power systems give years of dependable service if installed using the guidelines provided in this manual and in applicable codes. Incorrect installation can cause continuing problems. Figure 1-1 illustrates a typical installation. Your authorized generator set distributor/dealer may also provide advice about or assistance with your installation. - Page 14 1. Exhaust thimble (for wall or ceiling) 2. Silencer 3. Supports 4. Flexible sections 5. Duct work for cooling air outlet Figure 1-1 Typical Stationary-Duty Generator Set Installation Section 1 General 6. Mounting base 7. Controller 8. Electrical conduit 9. Water trap with drain 10.
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Page 15: Section 2 Load And Transport
To ensure personal safety while preventing damage to the product, we strongly recommend the following guidelines be observed when loading and transporting standby generator sets. Due to the different designs, dimensions and weights of the generators involved, specific instructions for each model are not provided. However, these guidelines are applicable to the full standby line (although minor procedural changes may be necessary between sets). - Page 16 A four-point lifting method is necessary to lift the generator set. To maintain generator balance during lifting, the lifting apparatus must utilize the four skid lifting holes mentioned in the previous paragraph. One method of lifting standby generators uses an apparatus of hooks and cables joined at a single rigging point.
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Page 17: Weather Housing
Do not attach lifting hooks to outside reinforcing plate on skid. Attach lifting hooks to skid exactly as shown in Figure 2-4. This method utilizes the strongest portion of the mounting skid and also prevents the lifting hooks from slipping. Generators without skid reinforcing plates can be raised with lift hooks on the inside or outside of the skid. - Page 18 Notes Section 2 Load and Transport TP-5700 7/93...
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Page 19: Section 3 Location
3.1 Location Factors Location is the key to a proper installation. The following sections will deal with the factors to consider in a proper installation. Before final plans are made for locating a generator set, the following questions should be raised concerning the set and the proposed site. -
Page 20: Mounting
3.3 Mounting Typical mounting surface details and dimensions are shown in Figure 3-1. The recommended mounting surface is a concrete mounting pad. This must be a level surface as shown in Figure 3-2, or raised pads as shown in Figure 3-3 and Figure 3-4. The advantage of the arrangement shown in Figure 3-3 is that the engine oil can be drained more conveniently. -
Page 21: Vibration Isolation
The composition of the mounting pad should follow standard practice for the required loading. Common specifications call for 2500-3000 psi (176-211 kg/cm concrete reinforced with eight-gauge wire mesh or number 6 reinforcing bars on 12-inch (30-cm) centers. The total weight of the mounting pad should be at least equal to the weight of the generator set (a density of 150 lbs. - Page 22 Notes Section 3 Location TP-5700 7/93...
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Page 23: Section 4 Air Requirements
4.1 General An ample flow of clean, cool air is required to support combustion and dissipate heat. Approximately 70% of the heat value of fuel consumed by an engine will be rejected to the cooling system and exhaust. Battery compartment ventilation. accumulation explosive compartments containing batteries. -
Page 24: Air-Cooled Generators
In many installations it may be desirable to install louvers in the inlet and outlet openings. Louvers may be either stationary or movable. In areas of great temperature variation, it is often best to install movable louvers that can be thermostatically adjusted to regulate air flow and room temperature. -
Page 25: Forced Air
4.3 Forced Air With the forced-air system, cooling air is drawn in through the front of the engine, circulated around finned areas of the cylinder block and head, then ejected 1. Air oulet 2. Air inlet opening 3. Blower housing Figure 4-5 Standard Forced-Air Cooling System TP-5700 7/93 toward the rear or generator end of the set. -
Page 26: Air-Vac Cooling System
4.4 Air-Vac Cooling System The air flow direction with the Air-Vac system is the opposite of the conventional forced air cooling system. Use the Air-Vac system in confined areas since it includes a blower scroll which easily connects to the ductwork. -
Page 27: Air Vent
4.5 Air Vent The air vent system is used on some air-cooled gas and has been used on some diesel models. It includes special ductwork which directs the flow of heated air to the outlet at the top or side of the engine. The air vent air flow is not reversed as it is with the Air-Vac... -
Page 28: Liquid-Cooled Models
4.6 Liquid-Cooled Models The three most common liquid cooling systems used for generator sets are unit-mounted radiator, city water, and remote radiator cooling. Since each involves somewhat different installation considerations, they will be discussed separately. 4.7 Unit-Mounted Radiator Cooling This is the most common cooling system used for engine-driven generator sets 20 kW and larger. -
Page 29: Remote Radiator Cooling
The connection from the radiator duct flange to the ductwork should be heavy canvas, silicone or similar flexible material to prevent noise and vibration transmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should have an unrestricted area 150% greater than that enclosed by the radiator duct flange. -
Page 30: City Water Cooling
The engine water pump can be used to circulate water through the remote radiator providing that the vertical distance from the engine water pump does not exceed the engine manufacturer’s recommendations. The allowable static head may range from 17-50 feet (5.2-15.2 m). Consult the Specification Sheet for the unit. - Page 31 1. Ventilation fan (for heat rejected from exhaust and engine) 2. City water in 3. Flexible section 4. Manual shutoff valve Figure 4-11 Installation Using City Water Cooling System with Heat Exchanger 1. Engine water pump 2. Surge tank Figure 4-12 Cooling Tower System TP-5700 7/93 5.
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Page 32: Block Heaters
4.11 Block Heaters Block heaters are recommended on all standby applications where the generator is subject to temperatures below 60° F (16°C) and are available as installed accessories on all generator sets. The block heater should be connected to a source of power, which is determined by the particular size and type of heater. -
Page 33: Section 5 Exhaust System
Proper installation of the exhaust system is essential to obtain satisfactory performance from a generator set. The most important factor is that the installed system must not exceed the engine manufacturer’s maximum exhaust back pressure limit. Any exhaust back pressure will limit the maximum power available from the engine. -
Page 34: Flexible Section
5.1 Flexible Section A section of flexible exhaust line should be installed within 2 feet (51 mm) of the engine exhaust outlet. This limits the stress on the engine exhaust manifold or turbocharger resulting from engine motion on its vibration mounts and temperature-induced changes in pipe dimensions. -
Page 35: Double-Sleeve Thimbles
5.4 Double-Sleeve Thimbles If the exhaust pipe should need to pass through a wall or roof, an exhaust thimble must be used to prevent exhaust pipe heat from being transmitted to the combustible material. Construction details for a typical double-sleeve thimble to be used where exhaust piping passes through a combustible roof or wall are shown in Figure 5-4. - Page 36 Notes Section 5 Exhaust System TP-5700 7/93...
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Page 37: Section 6 Fuel Systems
When planning an installation, check state and local regulations regarding fuel storage and handling. Piping and fuel system components must conform to these regulations. 6.1 Diesel Fuel Systems Since diesel fuel is less volatile than gas or gasoline, it may be considered safer fuel from the standpoint of storage and handling. -
Page 38: Main Fuel Tank
1. Generator set skid 2. Side view Figure 6-2 Subbase Fuel Tank 6.2 Main Fuel Tank All main tanks should be vented so that air and other gases can escape to the atmosphere. The vent must prevent dust, dirt, and moisture from entering the tank. Return lines should be spaced as far away from the pick-up or fuel dip tube as possible. -
Page 39: Transfer Tanks
Flexible connections must be used wherever there may be relative motion between piping and supplied equipment. Always use flexible lines at the engine connections. These should be a minimum of six inches (15.3 cm) long. Diesel engines require at least two fuel lines: one supply and at least one return from the fuel injectors. -
Page 40: Auxiliary Fuel Pumps
6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop a maximum of 7 psi (48 kPa) pressure and have a lift capacity of 4-6 feet (1.2-1.8 m). Even if the engine pump can draw fuel a greater distance, a more reliable system results if a transfer tank and/or auxiliary pump are used when the vertical lift exceeds three feet or fuel must be drawn horizontally more than 20 feet (6.1 m). -
Page 41: Gasoline Fuel Systems
6.6 Gasoline Fuel Systems Due to code restrictions which do not allow storage of more than one gallon (3.8 L) of gasoline inside a building, gasoline fuel systems are usually limited to housed generator sets installed outdoors or portable trailer-mounted units. Gasoline will deteriorate if stored for more than six months, so storage tank size should be kept to the minimum required by code. -
Page 42: Natural Or Lp Gas Fuel Systems
6.7 Natural or LP Gas Fuel Systems Natural and LP (liquified petroleum) gas fuel systems should be designed and installed in accordance with the requirements of NFPA 54, National Fuel Gas Code, and all applicable local codes. Various types of gas fuel systems are available as follows: LP Gas Vapor (Figure 6-5 and Figure 6-6) LP Gas-Liquid Withdrawal (Figure 6-7) - Page 43 1. Carburetor 2. Load adjustment valve 3. Converter (vaporizer) 4. Solenoid valve 5. LP gas filter (supplied by gas supplier or installer) 6. LP gas supply 7. Natural gas supply 8. Primary regulator (supplied by gas supplier or installer) 9. Secondary regulator 10.
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Page 44: Flexible Connector
6.8 Flexible Connector An approved flexible connector should always be used between stationary gas piping and the engine-mounted fuel system components. It should be at least six inches (15.3 cm) long or as recommended by the generator supplier based upon engine specifications. 6.9 Gas Piping Gas piping should be Schedule 40 black iron pipe. -
Page 45: Lp Gas Fuel Characteristics
6.11 LP Gas Fuel Characteristics LP gas is supplied as a liquid in pressure tanks. It is easily adaptable to stationary applications where complete independence of an outside fuel supply is required. Since LP gas does not deteriorate in long periods of storage as gasoline is known to do, a large supply of fuel can be kept on hand indefinitely for operation during emergency conditions. -
Page 46: Natural Gas
6.15 Natural Gas Natural gas is in a vapor state as supplied from the utility. This fuel system, therefore, consists of the same basic components and is used in the same general sequence as LP gas systems. When the heating content of the fuel falls below 1000 BTU, as it does with manufactured sewage and some natural gas fuels, the set will not produce rated power. -
Page 47: Section 7 Electrical Requirements
Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible connections. Comply with all applicable codes when installing a wiring system. -
Page 48: Electrical Connections
7.2 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Because of the large number of accessories and possible combinations, this manual does not address specific applications. Refer to the submittal catalog accessory drawings and wiring diagrams connection... -
Page 49: Terminal Connector Torque
7.4 Terminal Connector Torque Use the torque values shown in Figure 7-4 or Figure 7-5 for terminal connectors. Refer to UL-486A, UL-486B, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. See Section 7.2, Electrical Connections, information temperature rating of customer-supplied wire. -
Page 50: Automatic Transfer Switches
7.5 Automatic Transfer Switches A typical standby system has at least one automatic transfer switch connected to the generator set output to automatically transfer the electrical load to the generator set if the normal source fails. When normal power returns, the switch transfers the load back to the normal power source and then signals the generator set to stop. -
Page 51: Remote Emergency Stop Switch
7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdown of the generator from a remote location. If the emergency stop switch is activated, the emergency stop lamp on the generator controller lights and the unit shuts down immediately. The generator cannot be restarted until the emergency stop switch is reset. - Page 52 TP-5700 7/93 Section 7 Electrical Requirements...
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Page 53: Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center alternating current analog to digital analog to digital converter adj. adjust, adjustment advertising dimensional drawing AHWT anticipatory high water temperature AISI American Iron and Steel Institute ALOP... - Page 54 kilogram kg/cm kilograms per square centimeter kilogram-meter kg/m kilograms per cubic meter kilohertz kilojoule kilometer kOhm, kΩ kilo-ohm kilopascal kilometers per hour kilovolt kilovolt ampere kVAR kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical liter local area network L x W x H length by width by height pound, pounds lbm/ft pounds mass per cubic feet...
- Page 56 TP-5700 7/93d E 1993, 2001, 2003 by Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada...
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