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Kohler 20--2800 kW User's Manual

1. AV 13H JNV NONWWOO V9 02 81 XVN S3HIM SAIHOSSFIIV U3WOLSNO LOVLNOD NOILOANNOO YAWOLSNO HOIVHHN39 IV GALNNOW 38 LSNW 02 81 02 81 S3UIM SAYIM UFTIOULNOD 195 HOLVU3N3Dd AONADYAWA 3IOWJH INnsIAOIanv 40 Section 7 Electrical Requirements 5700 7 93 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC ADC adj ADV AHWT AISI ALOP alt ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BDC BHP blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cow CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Te
2. Safety Precautions and Instructions 111 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 of standby normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery
3. ey 10 Pusher fan 11 Flexible section 12 Support legs 7 Self supporting duct work 8 Air out 9 Air inlet opening Figure 4 8 Radiator Cooled Generator Set Installation 16 Section 4 Air Requirements TP 5700 7 93 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 anunrestricted area 150 greater than that enclosed by the radiator duct flange The inlet air opening should be atleast as large as the outlet but preferably 50 larger If screens louvers or filters are used openings should be increased in size according to the recommendations given in the Air Requirements General section Ductwork should be designed to allow ease of service in the event the radiator would have to be removed Air inlet and outlet locations should be chosen to prevent air recirculation inside or outside the enclosure Consideration should also be given to prevailing winds facing inlets into the expected winds and outlets on the downwind side where possible Inlets and outlets should be located where they will not be blocked by accumulated snow or any other obstruction Keep in mind that the exhaust air of larger units is both high volume and high velocity It may be accompanied by a high sound level and should be directed away from
4. Remove the sound shield if installed from the generator set before lifting the generator set The sound shield attaching bolts may be hidden by the sound shield insulation To locate the hardware carefully lift the sound insulation near the skid Remove the wood skid before lifting the sound shield using the eye bolts Use the sound shield eye bolts if equipped to lift only the sound shield Reinstall the sound shield after lifting and mounting the generator set TP 5700 7 93 21 3 Subbase Fuel Tank The lifting contractor determines the type and suitability of the subbase fuel tank lifting device Lift the subbase fuel tank as one unit if shipped separately from the generator set Use lifting eyes if equipped on subbase fuel tank otherwise use chains or cables to lift the subbase fuel tank If using lifting straps protect the strap from sharp fuel tank edges Lift the generator set up to 400 kW and subbase fuel tank together provided the fuel tank is empty and the subbase fuel tank does not extend beyond the perimeter of the generator set skid In all other cases remove the mounting hardware and wiring between the the generator set and subbase fuel tank Lift the generator set and subbase fuel tank separately It is not necessary to drain fuel tank when lifting just the fuel tank 2 2 Transporting the Generator Set e The transporting vehicle trailer must be sized for the dimension and weight of the generator set
5. AWG AI AWG 90 C 194 F Use No t AWG 90 C Use 90 C wire either No AWG Cu or Use 90 C wire No t wire No AWG AI AWG The wire size for 60 C 140 F wire is not required to be included in the marking If included the wire size is based on ampacities for the wire given in Table 310 16 of the National Electrical Code in ANSI NFPA 70 and on 115 of the maximum current that the circuit carries under rated conditions The National Electrical Code is a registered trademark of the National Fire Protection Association Inc Usethelarger ofthefollowing conductors the same size conductor as that used for thetemperature test or one selected usingthe guidelines in the preceding footnote Figure 7 2 Terminal Markings for Various Temperature Ratings and Conductors 7T 3 Load Lead Connections Load leads being brought into the generator can enter in a number of different areas On generators 300 kW and below the most commonly used is the bottom entry where conduit is stubbed up into the junction box from below Other methods include flexible conduit roughed into the sides or top of the junction box When using this method be sure not to block the front or rear of the controller as doing so will prevent access to it for service purposes See Figure 7 3 On generators larger than 300 kW a junction box is mounted on the rear of the generator Larger sets may have oversize junction boxes suppli
6. digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP
7. hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix A 1 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liter
8. Controlled air outlet louvers Figure 4 9 Air Control Louvers Ui EF A 5 From radiator Cool side Hot well From engine Hot side Auxiliary pump To radiator Remote radiator Engine water pump Suction side Maximum allowable vertical head varies with engine gt O O O N O QI gt QO N Figure 4 10 Schematic Diagram of Remote Radiator System Section 4 Air Requirements 17 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 This is important because greater height will result in excessive head pressure on engine components causing problems such as leaking water pump seals The piping between the engine and remote radiator must be sized for a maximum of 2 psi 0 141 kg cm pressure drop at the rated flow of the engine water pump A vent line from the engine to the radiator may be necessary to purge air from the cooling system When either horizontal or vertical distances exceed the above limitations a hot well tank or heat exchanger and auxiliary circulating pump as shown in Figure 4 10 should be used The ci
9. SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s Sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency w watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 5700 7 93 TP 5700 7 93d 1993 2001 2003 by Kohler Co All rights reserved KOHLER POWER SYSTEMS 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 s
10. Systems 33 6 14 Dual Systems Natural and LP Gas 33 6 15 Natural Gas iis zo dp ep stb Roi 34 6 16 Combination Gas Gasoline 34 TP 5700 7 93 Table of Contents Table of Contents continued Section 7 Electrical Requirements 35 TA Batteries uerbi node esed odds 35 7 22 Electrical Connections 36 7 3 Load Lead Connections 36 7 4 Terminal Connector Torque 37 7 5 Automatic Transfer Switches 38 7 6 Control Connections 38 7 7 Remote Annunciator 38 758 Audiovisual Alarm u eee Dalmatien 38 7 9 Remote Emergency Stop Switch 39 AO Dry Contact ez vei n ata Y led ee 39 7 11 WINNG he en niue aie aan Ea ede etur ive hA 39 Appendix A Abbreviations A 1 Table of Contents TP 5700 7 93 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment inclu
11. anti siphon fuel solenoid valve or air bleed hole in the fuel tank dip tube near the top of the tube inside the tank should be used to prevent siphoning Section 6 Fuel Systems 29 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 e Gas Vapor Figure 6 5 and Figure 6 6 e LP Gas Liquid Withdrawal Figure 6 7 e Combination Natural Gas and LP Gas Figure 6 8 and Figure 6 9 e Natural Gas Figure 6 10 e Combination LP Gas or Natural Gas and Gasoline Figure 6 11 The engine mounted components of all these systems are similar and usually include a carburetor secondary gas regulator electric gas fuel solenoid shutoff valve and flexible fuel connector J Primary regulator supplied by gas supplier or customer Pressure gauge Solenoid valve 4 Secondary regulator 5 Carburetor Figure 6 5 LP Gas Vapor Fuel System 30 Section 6 Fuel Systems 1 Carburetor 2 Secondary regulator 3 Solenoid
12. 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 1 Is the structure strong enough to support the set and related equipment such as fuel storage tanks batteries and radiators 2 Can vibration be effectively isolated dampened to reduce noise and prevent damage 3 Is the area clean dry and not subject to flooding 4 15 the area large enough to provide easy access for servicing and repair 5 Can adequate ventilation be attained in the area with a minimum amount of ductwork 6 Can exhaust gases be expelled safely out of and away from the structure and other buildings 7 Will an adequate supply of fuel be available to sustain operation during emergencies 8 Will fuel tank location be within the vertical lift capabilities of the fuel pump TP 5700 7 93 Section 3 Location The location of the generator set must e Meet applicable fire rating codes and standards e Position the generator set over a noncombustible surface Ifthe mounting surface directly under or near the generator set is porous or deteriorates from exposure to engine fluids construct a containment pan for spilled fuel oil coolant and battery electrolyte Do notallow accumulation of combustible materials under the generator set 3 2 Weight The weight of the generator set will determine the type of construction at t
13. most common cooling system used for engine driven generator sets 20 kW and larger The major system components are an 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 and allows circulation through the radiator It can also close restricting the flow as necessary to prevent overcooling The fan blows air from the engine side of the radiator across the cooling surface as shown in Figure 4 8 Cooling air flow can be reversed by using a suction fan but this is generally not recommended because it may interfere with generator cooling air flow which moves in the same direction as the engine s standard pusher fan Also a suction fan would result in higher temperature combustion air being drawn into the air cleaner reducing the maximum engine power available Whenever a generator set is installed inside a building or enclosure the radiator air should be ducted outside the room or enclosure A typical arrangement is shown in Figure 4 8 Ductwork should be as short straight and unobstructed as possible Static pressure restrictions of more than 1 2 inch 1 3 cm water column on the radiator outlet or inlet air will reduce air flow to the point of limiting maximum power and or ambient temperature that causes overheating ine il
14. or decal on the unit for specific information regarding spring retainer usage Gas fuels may require the fuel regulator to be mounted in a given position The fuel regulator will function properly with the fuel regulator pointing downward for both natural gas and LP gas The fuel regulator may be positioned so that it is pointing upward for use with natural gas only 32 Section 6 Fuel Systems Two regulators are used in the typical gaseous fuel system e Primary Regulator This regulator provides initial control of the gas from the fuel supply The primary regulator reduces line pressures to allowable inlet pressures for the secondary regulators on the system This regulator would drop high pressure from a tank or transmission line to a low pressure typically 4 6 ounces per square inch 1 7 2 6 kPa or 7 11 inches 178 279 mm of water column This regulator is not usually supplied with the generator set as conditions that dictate the type used vary depending on the method in which the fuel is supplied Secondary Regulator This low pressure type regulator is mounted on the engine and is designed for a maximum inlet pressure of six ounces per square inch 2 6 kPa or 11 inches 279 mm of water column The engine will operate satisfactorily at four ounces per square inch 1 7 kPa or 7 inches 179 mm of water column or less but lower pressures may result in poor response to load changes or lack of power where the primary regula
15. s installation A few of the more common accessories and their functions are listed on the following pages 7 7 Remote Annunciator The remote annunciator allows monitoring of the standby power system from a location remote from the generator set Individual lamps identifying fault shutdowns and or prealarms are located on the remote annunciator along with an alarm horn and silence switch There are both surface and flush mount models available The remote annunciator is typically located in an area that is monitored on a full time basis This allows the operator to be aware of any alarm conditions when they occur without having to be physically present at the generator set See Figure 7 6 38 Section 7 Electrical Requirements Remote Annunciator OR Og GENERATOR IN AUTO SLENCE NORMAL LAMP O TEST A 258782 e s al ILI x HU TR SE SAL SB FS Figure 7 6 Remote Annunciator with 14 Relay Dry Contact Kit 7 8 Audiovisual Alarm The audiovisual alarm warns the operator of a fault shutdown or prealarm condition at a remote location See Figure 7 7 Front View Side View Figure 7 7 Audiovisual Alarm TP 5700 7 93 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 activate
16. valve 4 Pressure gauge 5 Primary regulator supplied by gas supplier or installer Figure 6 6 Typical LP Gas Vapor Withdrawal System 1 7 1 Carburetor 2 Converter vaporizer 3 Solenoid valve 4 LP gas filter supplied by gas supplier or installer Figure 6 7 LP Gas Liquid Withdrawal System TP 5700 7 93 TP 5700 6 Primary regulator supplied by gas supplier or installer Pressure gauge Solenoid valve Secondary regulator Carburetor 7 5700 6 7 Figure 6 10 Natural Gas Fuel System Carburetor Load adjustment valve Converter vaporizer Solenoid valve LP gas filter supplied by gas supplier or installer LP gas supply Natural gas supply Primary regulator supplied by gas supplier or installer Secondary regulator Pressure gauge gt GQ O EF Figure 6 8 Natural Gas and LP Gas System Liquid Withdrawal 7 Fuel pump Gasoline shutoff Gasoline carburetor Fuel mixer Secondary regulator Solenoid valve Gas fuel supply Gasoline fuel supply m 5700 6 Figure 6 11 Combination Gas Gasoline Fuel System Carburetor Load adjustment v
17. with Heat Exchanger 001000 1 Engine water pump 3 Cooling tower 5 Heat exchanger 2 Surge tank 4 Drain 6 Auxiliary water pump Figure 4 12 Cooling Tower System TP 5700 7 93 Section 4 Air Requirements 19 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 Note BLOCK HEATER DAMAGE Do not energize block heater until engine block is filled with coolant and the generator set is run to remove trapped air Otherwise block heater failure will result Unplug block heater prior to draining cooling system 20 Section 4 Air Requirements 4 12 Recommended Coolant Antifreeze coolant protection will be required for most applications This must be performed prior to startup of generator set and energizing block heater s A solution of 50 ethylene glycol and 50 clean softened water is recommended to provide freezing protection to 34 F 37 C and boiling protection to 256 F 129 C A50 50 solution will also inhibit rust and corrosion Follow the engine manufa
18. 2 0 53 5 67 4 43 5 20 3 180 3 0 4 0 85 0 107 2 56 5 28 2 250 250 350 127 177 73 4 36 7 325 400 203 93 2 36 7 825 500 253 93 2 42 4 875 600 750 304 380 113 0 1000 42 4 375 800 1000 406 508 E 124 3 1100 56 5 500 1250 2000 635 1016 124 3 1100 67 8 600 For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Note lfaconnector has a clamp screw such as a slotted hexagonal head screw with more than one means of tightening test the connector using both applicable torque values Figure 7 4 Tightening Torque for Screw Type Pressure Wire Connectors Socket Size Across Flats Tightening Torque Nm in Ib 32 5 1 4 0 11 4 4 8 13 8 5 6 17 0 6 4 22 6 7 9 81 1 9 5 42 4 127 56 5 14 3 9 16 67 8 Note For values of slot width or length not corresponding to those specified selectthe largesttorque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Figure 7 5 Tightening Torque for Pressure Wire Connectors with Internal Drive Socket Head Screws TP 5700 7 93 Section 7 Electrical Requirements 37 7 5 Automatic Transfer Sw
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20. Consult the set dimensional drawing or contact the factory for information weight dimensions pertinent to planning transport The overall height of a generator set in transit including vehicle trailer must not exceed 13 5 ft 4 1 m unless special hauling permits are obtained check Federal State and local laws prior to transporting Larger units above 1000 kW should be transported on low boy type trailers with a deck height of 25 in 635 mm or less to meet clearance requirements Large unboxed generators with radiators should be loaded with the radiator facing the rear to reduce wind resistance while in transit Radiators with free wheeling fans must have the fan secured to prevent rotation that might introduce flying objects to the radiator core or fan blades e Be sure the generator set is securely fastened to the vehicle trailer and covered with a tarpaulin Even the heaviest of units is capable of movement during shipment unless properly secured Fasten the set to the vehicle trailer bed with properly sized chain routed through the mounting holes of the skid Use chain tighteners to remove slack from the mounting chain Cover the entire unit with a heavy duty tarpaulin and secure tarpaulin to the generator or trailer Section 2 Load and Transport 5 Notes 6 Section 2 Load and Transport TP 5700 7 93 3 1 Location Factors Location is the key to a proper installation The following sections will deal with the factors to
21. E Eee i Section t General isis ron Iu LE IDE ee 1 Section 2 Load and 3 21 Lifting the Generator Set 3 2 1 1 Weather Housing 5 2 1 2 So nd Shield 5 2 1 3 Subbase Fuel Tank 2 0 nd ese eR per E En 5 2 2 Transporting the Generator Set 5 Section 3 Locations 2 yu eso een 7 gf Location Factors idee dene len 7 3 2 r Rem dte els E DLE ed 7 3 9 Mounting zi RI nee wen E WASA asya 8 3 4 Vibration Isolation eee ee emet ene te e pet eh en 9 Section 4 Air Requirements 11 AAS Geheral ov hp ERIT UR ITE PRU eim ens 11 4 2 Air Cooled Generators 12 4537 Forced AI veces AERE e ebd ERU R 13 4 4 Air Vac Cooling System 14 phu Da vates Q uma a dicant 15 4 6 Liquid Cooled 16 16 4 7 Unit Mounted Radiator 0 16 4 8 Remote Radiator 17 4 9 City Water Cool
22. Figure 1 1 Typical Stationary Duty Generator Set Installation 2 Section 1 General TP 5700 7 93 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 Itis the responsibility of the dealer distributor to see that generator loading and transport be performed within the framework of these guidelines Obviously prepackaged crated sets may be exempt from certain aspects of this section Prepackaged generators generally are loaded in their containers with the aid of lift trucks TP 5700 7 93 Section 2 Load and Transport 2 1 Lifting the Generator Set e Do not lift the generator set by the lifting eyes attached to the engine and or alternator These lifting eyes are only used during generator assembly and are not capable of supporting the entire weight of the generator The mounting skid of each standby generator set includes four holes for attaching the lifting device These holes are strategically placed to avoid damage to generator components by lifting cables and to maintain balance during lifting In some cases it may be necessary to remove protru
23. Installation Industrial Commercial Residential Generator Sets Models 20 2800 kW c2 9001 KOHLER mmm GENERATORS INTERNATIONALLY REGISTERED KOHLER POWER SYSTEMS sss ra 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 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 Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information Inside front cover Safety Precautions and Instructions Introduction ui rs ye aad Ee a UAR onan i Service Assistance T uu u
24. Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s sec second SI Systeme international d unites International System of Units SI EO side in end out sil silencer
25. ains bars are properly sized for the weight of the generator set 1 ZA 19 cou JL eine D Lj Near 4 AAAS H 6 2E TP 5700 2 1 Lifting fixture Figure 2 3 Generator Set with Lifting Fixture TP 5700 2 1 Spreader bars may be necessary to protect generator set 2 Lifting bars Figure 2 1 Generator Set with Lifting Bars in Skid 4 Section 2 Load and Transport TP 5700 7 93 e Do notattach 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 The following information pertains to lifting a generator set with subbase fuel tank weather housing and or sound shield 1 Reinforcing plate Figure 2 4 Lifting Hook Placement above 1000 kW 2 1 14 Weather Housing Lift the weather housing and generator set together as one unit using the generator set guidelines 2 1 2 Sound Shield If the generator set has an installed sound shield and subbase fuel tank the assembly can be lifted as one unit provided the subbase fuel tank has lifting eyes installed and meets the criteria of subbase fuel tank paragraph 2 In all other cases remove the sound shield per the following paragraphs
26. alve Secondary regulator Solenoid valve LP gas supply Natural gas supply Low pressure switch Figure 6 9 Natural Gas and LP Gas System Vapor Withdrawal TP 5700 7 93 Section 6 Fuel Systems 31 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 Copper tubing may be used if the fuel does not contain hydrogen sulfide or other ingredients which will react chemically with copper Fuel piping should never be used to ground electrical equipment Piping should be sized according to the requirements of the equipment to be operated Refer to the dimensional drawing for detailed information on your unit In addition to the actual fuel consumption the following factors must be considered e Pressure loss due to length of pipe e Pressure loss due to other appliances on the same fuel supply e Pressure loss due to number of fittings 6 10 Fuel Regulators Fuel regulators are compatible with both natural gas and LP gas When used with natural gas the spring and retainer are installed The spring and retainer are usually removed from the fuel regulator when used with LP gas Refer to the appropriate generator set operation manual and
27. ameter should be used The exhaust outlet must be located in a manner that will prevent exhaust fumes from entering a building or enclosure Exhaust wall thimble Muffler 45 Y fitting Water trap Drain petcock Outer diameter adapter and clamp Flexible section Manifold 45 elbow 1 2 3 4 5 6 7 8 9 Figure 5 2 Exhaust System Side Inlet Silencer Section 5 Exhaust System 21 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 Never allow the engine manifold or turbocharger to support the silencer or exhaust piping weight The flexible section should be atleast 12 inches 805 mm long Where threaded flexible exhaust connectors are used a 6 8 inch 152 203 mm length of pipe should separate them from the exhaust manifold This will serve to reduce the temperature of the flexible connection and extend its life It also makes it easier to remove the flexible section if necessary without putting excessive strain on the engine manifold The flexible section should not be bent or used to make up for misalignment between the engine exhaust and the exhaust piping Since typical exhaust temperatures range from 800 F 427 C to
28. and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies IV Safety Precautions and Instructions Servicing the day tank Hazardous voltage can cause severe injury or death Service the day tank electrical control module ECM as prescribed in the equipment manual Disconnectthe power to the day tank before servicing Press the day tank ECM OFF pushbutton to disconnect the power Notice that line voltage is still present within the ECM when the POWER ON light is lit Ensure that the generator set and day tank are electrically grounded Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connect
29. areas that may be occupied by people or animals Be sure to design any temperature controlling louvers so that inlet air is not restricted to the point that pressure inside the building is reduced Low pressure can cause pilot lights on gas fired appliances to be extinguished or problems with the building ventilation system Bringing large quantities of winter air into a building can waste building heat and even result in frozen water pipes in normally heated spaces An arrangement as shown in Figure 4 9 using thermostatic controls can eliminate such problems and allow recovery of engine heat to supplement the building heating system For cold outdoor ambients louvers to the exterior would be closed with those to the interior open Controls would be set to reverse the condition for warm outdoor temperatures 4 8 Remote Radiator Cooling If the generator set is located in an area into which it is difficult to bring the volume of air required to cool the radiator such as a basement a remote radiator can be mounted outside the building See Figure 4 10 TP 5700 7 93 The top of the remote radiator must be at the highest point in the system to function properly The fan motor is connected to the generator output and will run when the generator is operating The radiators can be set up for either horizontal or vertical air discharge Exterior Interior Air outlet duct Generator set Dampers
30. ately 18 psi 124 Some primary regulators will not operate if tank pressure drops below 30 psi 207 kPa while others operate at incoming pressures as low as to 3 5 psi 20 7 34 5 kPa The fuel mixture and its vaporization pressure at the anticipated TP 5700 7 93 temperatures influence the selection of regulatory equipment The components of the vapor withdrawal System used in a typical stationary application are shown in Figure 6 5 and Figure 6 6 6 13 Liquid Withdrawal Systems Liquid withdrawal fuel systems can be supplied for generator sets but are not recommended for automatic standby service With these systems high pressure LP at 150 200 psi 1034 1379 kPa is piped to the engine in liquid form A combination of converters vaporizers and regulators can then reduce the gas to acceptable pressures In Figure 6 7 a converter combination of vaporizer primary and secondary regulators changes the liquid to vapor using heat from the engine cooling system In such a system for a short period after start up there may be problems vaporizing enough fuel for an engine running under load The engine which supplies heatto the converter vaporizer needs time to warm sufficiently to allow the converter to vaporize enough fuel to supply the engine Many areas have codes prohibiting gas fuel at more than 5 psi 34 5 kPa inside of buildings This might preclude the use of a liquid withdrawal system In order to meet codes co
31. ator sets should be anchored to concrete with bolts buried in the surface of the pad Expansion type anchors are not acceptable Note Always refer to the dimensional drawings for the generator and accessories when considering placement of conduits and fuel lines Dimensions are provided on these drawings for rough ins and stub ups of electrical and fuel connections 3 4 Vibration Isolation Mounting bases for generator sets 30kW and larger are typically made from I or section fabricated steel with a width of 2 3 inches per channel Length varies with the size of the unit resulting in a static load on the mounting base of 10 25 psi 0 703 1 758 kg cm if the total bottom surface of the channel is in contact with the mounting base All generator sets should have vibration isolation between the engine generator and skid or mounting base See Figure 3 5 This may consist of neoprene or combination spring and neoprene isolators between the engine generator and skid or spring type mounts between the skid and mounting pad An advantage of factory installed mounts between the engine generator and the skid is that engine generator alignment is not affected by stress induced in handling shipment or mounting on an uneven surface A less rigid skid may be used reducing weight and installation time All connections between the generator and mounting base such as conduits fuel lines exhaust piping etc must have flexible sections to pr
32. aust cannot avoid these concerns use a regular maintenance routine to remove combustible materials Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material whether or not seasonal a safe distance from the exhaust system TP 5700 7 93 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 They are usually fabricated at a local sheet metal shop to the specifications furnished by the installation engineer The thimbles should be constructed so that they extend atleast 10 inches 25 40 cm both ways from the surface of the wall or roof Holes are provided at both ends to allow cooling air to circulate through the thimble If screening is used on the outer end to keep birds rodents etc from entering the thimble make sure that the mesh is large enough so that it doesn t impair air circulation through the thimble If the exhaust pipe must exit through a roof a rain shield must be included above the thimble as shown in Figure 5 4 The rain cap as shown on the end of the exhaust pipe is recommended only in areas not subject to freezing temperatures I
33. bels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 TP 5700 7 93 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Fax X in 008 001a Introduction i 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 yo
34. cal 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 for connection and location Most field installed accessory kits include installation instructions For customer supplied wiring select the wire temperature rating in Figure 7 2 based upon the following criteria Temp Rating 60 C 140 F Copper Cu Only Use No AWG 60 C wire or use No AWG 75 C wire or 75 C 167 F Cu Aluminum Al Combinations Use 60 C wire either No AWG Cu or Use 60 C wire No No AWG Al or use 75 C wire either No AWG Cu or No AWG Al e Select row 1 2 3 or 4 if the circuit rating is 110 amperes or less or requires 1 AWG 42 4 mm or smaller conductors e Select row 3 or 4 if the circuit rating is greater than 110 amperes or requires 1 AWG 42 4 mm or larger conductors Comply with applicable national and local codes when installing a wiring system AWG or use 75 C wire No AWG 60 C 140 F Use No AWG 60 C Use 60 C wire either No AWG Cu or wire No AWG AI AWG Use 60 C wire No 75 C 167 F Use No t AWG 75 C Use 75 C wire either No AWG Cu or Use 75 C wire No t wire No
35. ced Air toward the rear or generator end ofthe set This system is best suited to wide open well ventilated areas It is not recommended for confined areas unless intake and or exhaust fans are used to achieve the required air circulation See Figure 4 5 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 4 Cooling air inlet 2 Air inlet opening 5 Heated air outlet 3 Blower housing Figure 4 5 Standard Forced Air Cooling System TP 5700 7 93 Section 4 Air Requirements 13 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 For duct dimensions refer to the dimensional drawing for your model With Air Vac cooling air is drawn across the generator end of the unit into the 1 Air Vac scroll 2 Air inlet opening 3 Ductwork Figure 4 6 Air Vac Cooling System 14 Section 4 Air Requirements finned areas and then out into the scroll located at the front of the engine The heated air is forced through ductwork to the outside of the building See Figure 4 6 Note Order Air Vac cooling systems factory installed since major components of the engine are affected making it difficult and unecono
36. ctrical Code and NFPA 99 Standard for Health Care Facilities Diesel fuel will deteriorate if stored for more than a year so the tank should not be oversized to the point that its contents cannot be used in one year of regular exercising If there are no applicable code requirements a tank sized for eight hours operation at rated load is suggested Refer to the specification sheet for fuel consumption data Most diesel engines will operate satisfactorily on 2 domestic burner oil as furnished in most parts of the United States The engine can be supplied from the same tank used for heating oil if both use the same fuel This is desirable both because of the cost savings and 26 Section 6 Fuel Systems 3 3 Subbase fuel tank 4 End view the added advantage that fuel will be used and replaced regularly ensuring a fresh fuel supply for the engine Dual usage of the fuel can be done provided the fuel oil meets the engine manufacturers minimum requirements for such properties as wax point pour point and cetane number These factors influence cold weather starting power output of the engine generator Where more than one engine or an engine and another appliance s are fueled from the same main tank each engine should have its own supply line 6 3 Fuel Lines Fuel lines should be constructed of Schedule 40 black iron pipe or copper tubing Galvanized pipe fittings or tanks should never be used with diesel fuel systems T
37. cturer s recommendations when available For most diesel engines an additional inhibitor additive is required to prevent cavitation erosion Refer to the engine operation manual for inhibitor section and concentration level recommendations TP 5700 7 93 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 Excessive back pressure may cause serious engine damage Excessive back pressure usually results from one or a combination of the following e Exhaust pipe diameter too small e Exhaust pipe too long e Too many sharp bends in the exhaust system e Too small an exhaust silencer or incorrect silencer design Figure 5 1 and Figure 5 2 show the general arrangement of recommended exhaust systems TP 5700 5 Supports Pitch line downward Muffler Water trap Drain petcock Flexible section Solid section 6 8 in 152 208 mm Manifold O Q gt GQ N Figure 5 1 Exhaust System End Inlet Silencer TP 5700 7 93 Section 5 Exhaust System Exhaust lines should be as short and straight as possible Schedule 40 black iron pipe is the recommended material Where possible sweep elbows with a radius of at least three times the pipe di
38. d 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 See Figure 7 8 PULL TO BREAK GLASS GENERATOR EMERGENCY STOP Figure 7 8 Remote Emergency Stop Switch TP 5700 7 93 7 10 Dry Contact Kit The dry contact kit allows monitoring of the standby system and or the ability to activate accessories from a remote location Customer provided warning devices lamps horns etc can be connected to any of the generator controller s alarm indication outputs allowing the user to customize an alarm system to their needs 7 11 Wiring Connections between the components of a standby generator system differ based on the type of equipment used options and installation Figure 8 6 on the following page gives examples of the possible options and wire connections necessary to make a standby system operational You should always refer to the wiring diagram for details regarding wire sizing location and number Section 7 Electrical Requirements 39 9 5 9629 NO 9 JO 1 OV a 15 LNAWdINDA I VNOlLdO emm NOLLO3NNOO ANIDNA HALLISOd YOLVYANAD JHL OL 38 LSNW 10 1 HOLVIONNNNY SLOWSY AHL IVNIWHZAL NOLLO3NNOO ANIDNA SALIVO3N AH3 LIV8 HOIVH3N
39. d temperatures to start and operate the engine A local fuel supplier is likely to be the best source of information on what size tank will be necessary to provide adequate fuel vapor Since LP gas is supplied in pressurized tanks in liquid form it must be converted to a vapor state before being introduced into the carburetor There are 31 26 cubic feet 0 88 m of butane gas in each gallon 3 78 L of liquid and 36 39 cubic feet 1 03 m3 of propane in each gallon of liquid See the individual generator spec sheets for fuel consumption at different loads and contact your fuel supplier for information regarding tank sizes and fuel mixtures 6 12 Vapor Withdrawal Systems The liquid level in LP gas tanks must not exceed 9096 of the tank capacity Generally 10 to 20 percent of capacity is allowed for expansion of the gas from a liquid to a vapor state A vapor withdrawal system utilizes vapor forming in the space above the liquid Temperature of the air surrounding the tank must be high enough to sustain adequate vaporization of the liquid fuel In the colder climates an independent heat source may be necessary to supplement natural vaporization within the tank Fuel can be withdrawn in liquid form and vaporized in an electrically heated engine water jacket heated or LP gas heated vaporizer Straight butane gas has little or no vaporization pressure in temperatures below 40 F 4 C Even at 70 F 21 C the pressure is only approxim
40. ding generator components air cleaner shrouding to avoid damage by lifting cables Section 2 Load and Transport 3 e Afour 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 See Figure 2 2 The use of spreader bars is necessary with this method to avoid damage to the set during the lifting procedure The spreader bars should be slightly wider than the generator skid Ss so the set is not damaged by lifting cables and only DEN vertical force is applied to the skid while lifting The J generators may also be lifted by placing bars through the skid lifting holes and attaching hooks to the ends of the bars See Figure 2 1 Be sure the bars are properly sized for the weight of the generator set Precautions must be taken to prevent the lifting hooks from sliding off the ends of the bars Spreader bars may be necessary with this arrangement if lifting cables are in contact with the set A specially designed lifting fixture is often used to lift the larger standby generators The fixture usually includes adjustable cables to adapt to different size generators and to compensate for unit imbalance See Figure 2 3 In all cases be sure the components of the lifting device cables ch
41. ding 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 SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 5700 7 93 Accidental Starting WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when
42. disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop Switch or engine start command from a remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects R
43. e Figure 6 3 Vent Return line Main supply line Overhead main tank Maximum 25 ft 762 cm minimum 1 in 31 cm 6 Fuel shutoff solenoid 7 Transfer tank 8 Filter 9 Flexible line 10 Fuel pump Figure 6 3 Diesel Fuel System with Overhead Main Tank and Transfer Tank TP 5700 7 93 Section 6 Fuel Systems 27 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 ifthe 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 On engines using less than ten gallons 38 L of fuel per hour approximately 100 kW or less an electric fuel transfer pump powered by the engine starting battery can be installed in series with the engine driven transfer pump Best results are obtained when the electric pump is located near the fuel tank rather than near the engine Where fuel must be lifted 6 feet 1 8 m or more or long horizontal runs are involved an electric motor driven positive displacement pump should be used with a transfer tank and float switch The power supply for the 28 Section 6 Fuel Systems pump should a
44. e flow of clean cool air is required to support combustion and dissipate heat Approximately 7096 of the heat value of fuel consumed by an engine will be rejected to the cooling system and exhaust Battery compartment ventilation To prevent the accumulation of explosive gases ventilate compartments containing batteries If a generator set is to be located in a building or enclosure make certain that adequate air intake and air outlet openings are provided If air flow provided by the engine generator cooling fan is not sufficient to prevent excessive temperatures other means such as ductwork and or ventilating fans will have to be used to provide adequate air flow If an exhaust fan is used Figure 4 1 and Figure 4 2 check the fan s capacity in cubic feet cubic meters per minute Follow the fan manufacturer s recommendations to determine the size of the inlet and outlet openings In certain cold climate applications controlled recirculation may be used as a means of heat recovery however special equipment such as thermostatically activated louvers and fans are needed to prevent engine and engine room overheating The uncontrolled recirculation of heated air within an enclosure must be prevented Otherwise the temperature in the enclosure quickly rises to a point where efficient cooling is no longer possible With a properly designed ventilation system a sufficient temperature differential is not hard to maintain even on th
45. e hottest days Make certain air inlets and outlets cannot be blocked by snow Air inlets and outlets should also be kept clean and unobstructed at all times The direction of the prevailing wind should be considered when positioning outlets If wind velocity is considerable it tends to cancel the effects of the engine or exhaust fan When strong prevailing winds are anticipated face the air inlet into the wind and the outlet in the opposite direction See Section 4 6 Liquid Cooled Models for additional suggestions TP 5700 7 93 Section 4 Air Requirements Figure 4 1 Exhaust Fan Operated Louvers fan not shown Figure 4 2 Fans Required On Some Installations Section 4 Air Requirements 11 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 See Figure 4 3 and Figure 4 4 If the set is to be installed in an atmosphere highly contaminated with impurities such as dust chaff etc it may be necessary to install a filter in the inlet opening Furnace type filters have been very satisfactory Again a certain amount of air flow i
46. ed as an option or to accommodate buss bar connections Consult the dimensional drawing on your unit for detailed information 36 Section 7 Electrical Requirements 1 Conduit from ceiling 2 Conduit stubbed up from below Figure 7 3 Typical Load Lead Connection TP 5700 7 93 7 4 Terminal Connector Torque with applicable national and local codes when installing a wiring system Use the torque values shown in Figure 7 4 or Figure 7 5 for terminal connectors Refer to UL 486A UL 486B Note If a connector has a clamp screw such as a and UL 486E for information on terminal connectors for slotted hexagonal head screw with more than aluminum and or copper conductors See Section 7 2 one means of tightening test the connector using Electrical Connections for information on the both applicable torque values provided in temperature rating of customer supplied wire Comply Figure 7 4 Tightening Torque Nm in Ib Wire Size for Unit Hexagonal Head External Connection Slot Head 4 7 mm No 10 or Larger Drive Socket Wrench Slot Width lt 1 2 mm 0 047 in Slot Width gt 1 2 mm 0 047 in Split Bolt Other AWG kcmil mm Slot Length 6 4 mm 0 25 in Slot Length gt 6 4 mm 0 25 in Connectors Connections 18 10 0 82 5 3 2 3 20 4 0 35 9 0 8 5 75 8 8 4 90 8 5 75 6 4 13 3 21 2 I 18 6 12 4 110 3 26 7 31 1 16 9 150 2 33 6 81 1 16 9 150 1 42 4 81 1 16 9 150 1 0
47. emove wristwatch rings and other jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Safety Precautions and Instructions Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove wristwatch rings and other jewelry before servicing the equipment Use tools with insulated handles Remove
48. engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donotoperatethe generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks TP 5700 7 93 Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor
49. ervice outlet in U S A and Canada Phone 1 800 544 2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
50. es and disable all generator sets as follows 1 Move all generator set master controller switches to the OFF position 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads lastwhen reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatic transfer switch remote start stop switch or engine start command from a remote computer Before servicing any components inside the enclosure 1 Remove rings wristwatch and jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized TP 5700 7 93 Servicing the transfer switch controls and accessories within the enclosure Hazardous voltage can cause severe injury or death Disconnectthe 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 Disconnect all power sources to accessories that are mounted within the enclosure but are not wired through the controls and deenergized by inline connector separation Test circuits with a voltmeter to verify that they are deenergized before servicing Heavy Equipment WARNING 4 Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eye
51. et with the air cleaner removed Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Copper tubing exhaust systems Carbon monoxide can cause severe nausea fainting or death Do not use copper tubing in diesel exhaust systems Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust leakage 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 exhaustfumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide pois
52. event breakage and isolate vibration to the generator set TP 5700 7 93 Generator sets 350 kW and larger are usually mounted directly to a structural steel base For these units the manufacturer s recommended vibration isolators should be installed between the base and mounting pad Because of the reduced mounting surface area of these individual mounts the static load on the mounting surface will increase to the range of 50 100 psi 8 515 7 03 kg cm The vibration isolation efficiency of neoprene pad type mounts is approximately 90 When installed at or below grade this degree of isolation will prevent transmission of objectionable vibration to the surrounding structure Spring type isolators can be expected to provide isolation efficiency of 9896 This type of mount may be desirable for above grade installations In some critical applications where the generator set is installed above grade or where earthquake proof mounts are specified it may be necessary to install spring type vibration isolators under the generator set mounting base Check state and local codes for such requirements Accessory vibration mounts should be installed at the locations of the standard predrilled mounting holes 1 To engine generator 2 Skid cross member 3 Neoprene vibration isolator Figure 3 5 Neoprene Type Integral Vibration Isolators Section 3 Location 9 Notes 10 Section 3 Location TP 5700 7 93 4 1 General An ampl
53. gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Electrical Shock A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure over 600 volts DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing over 600 volts WARNING Hazardous voltage Can cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing 600 volts and under A WARNING Hazardous voltage Can cause severe injury or death Disconnect all power sources before opening the enclosure 600 volts and under WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place
54. he fuel will react chemically with the galvanized coating causing it to peel and clog fuel filters and damage fuel injection components Fuel line sizes should be the minimum required to deliver the volume necessary to the equipment within an acceptable pressure drop 1 psi 0 07 kg cm The use of excessively large piping increases the chance that air will be introduced into the system and that fuel pumps will be damaged by operating dry when priming the system TP 5700 7 93 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 More fuel is delivered to the injectors than the engine will use and the excess must be returned to a transfer tank or the main storage tank Fuel return lines should be at least the size ofthe supply lines They should be unrestricted as short as possible and allow gravity return of fuel to the storage tanks In some installations it may be difficult or inconvenient to route return lines so that fuel will flow by gravity Before designing a system which will have any head of fuel on the return lines the details should be approved by the engine supplier Serious problems with engine hydraulic lock or uncontrollable overspeeding will resu
55. he site Most sets are mounted on concrete at ground level Some however are located on upper levels of steel concrete or wood construction The generator s weight will determine how strong this construction should be Generator weights can be found in the specification sheet for your particular model Be sure that the weight of accessory items is added to the total requirements This is especially important in upper story or roof installations Section 3 Location 7 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 alevel 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 An oil drain piped to the side of the mounting base is usually available as accessory from the manufacturer If there is not sufficient clearance below the oil outlet for a pan large enough to hold the full engine oil capacity it will be necessary to use a pump whenever oil is changed The double pedestal arrangement shown in Figure 3 4 has the advantage of providing more working room under the engine without raising the engine or generator set off its mountings With either arrangement the mounting pad should extend six inches 15 cm beyond the mounting base dimensions When using the double pedestal arra
56. ing 18 4 10 Cooling TOWER sh uerbo DIIS Rude uev 18 4411 Block Heaters ra oo mehr alien rie a 20 4 12 Recommended Coolant 20 Section 5 Exhaust System 2 2 222 2 2 4 2 4 realen 21 5 1 Flexible eine are ce ea 22 5 2 Condensation Trap He RM El 22 5 9 PIPING ee ites een 22 5 4 Double Sleeve Thimbles 23 Section 6 Fuel Systems lt uuu auszahlen 25 6 1 Diesel F el Systemsa cene naar ne pasaqa 25 6 2 Main Fuel T nk kie RER dresden ah 26 6 3 FUEL EINES e ee en M E MO a RR 27 6 4 Transfer Tanks a un a en le a 27 6 5 Auxiliary Fuel Pumps 28 6 6 Gasoline Fuel Systems 29 6 7 Natural or LP Gas Fuel Systems 30 6 8 Flexible Connector 32 6 9 Gas PIPING uix RAT Ee IR ele e eH Re WW UP 32 6 10 Fuel Regulators ec boa he Hari ie 32 6 11 LP Gas Fuel Characteristics 33 6 12 Vapor Withdrawal Systems 33 6 13 Liquid Withdrawal
57. ions Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause serious injury or death to utility personnel working on power lines Installing accessories to the transformer assembly Hazardous voltage can cause severe injury or death To prevent electrical shock disconnect the harness plug before installing accessories that will be connected to transformer assembly primary terminals 76 77 78 and 79 Terminals are at line voltage Models with E33 S340 S340 340 R340 and H33 controls only Installing accessories to the transformer assembly Hazardous voltage can cause severe injury or death To prevent electrical shock disconnect the harness plug before installing accessories that will be connected to the transformer assembly primary terminals on microprocessor logic models Terminals are at line voltage Making line or auxiliary connections Hazardous voltage can cause severe injury or death To preventelectrical shock deenergize the normal power source before making any line or auxiliary connections Servicing the transfer switch Hazardous voltage can cause severe injury or death Deenergize all power sources before servicing Open the main circuit breakers of all transfer switch power sourc
58. itches 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 The transfer switch uses a set of contacts to signal the engine generator to start These contacts are terminals 3 and 4 on the generator set controller terminal strip or controller connection terminal strip if used inside the junction box When the normal source fails and the generator set master switch is in the AUTO position the transfer switch contacts close to start the generator set The location of the transfer switch contacts is usually near the contactor with an engine start decal to identify the correct terminals The terminals are identified as 3 and 4 or 57 and 58 Do not connect to terminals 57 and 58 on the inner panel circuit board Connection must be at the contactor location Verify the correct engine start terminals using the transfer switch wiring diagrams before making connections 7 6 Control Connections Most standby generators can be equipped with a myriad of optional equipment that will have to be connected to other components in the system These accessories will enable the generator set to meet standards for local and national codes or specific requirements of the customer
59. lt from any return fuel line restriction on some diesel fuel systems 6 4 Transfer Tanks The term transfer tank and day tank are often used interchangeably Both are used to ensure engine starting in the minimum possible time after a power failure by means of a quantity of fuel stored in a tank adjacent to the engine This allows the engine fuel transfer pump to easily draw fuel when starting and provides a convenient location to connect injector return lines Standard tanks are available in sizes from 5 275 gallons 19 1040 L with or without integral electric fuel transfer pumps They can also be provided with fuel level gauges manual priming pumps float switches for pump control float valves rupture basins and low level alarms A float switch controlled solenoid anti siphon valve or a float valve should be used whenever there is a possibility of siphoning fuel from the main storage tank or when the fuel level in the main tank may be above the level ofthe transfer tank inlet Engines are subjectto derating for fuel temperature above 100 F and are subject to damage if operated with fuel temperature above 140 F A day tank sized for two hours fuel consumption should prevent excessive fuel heating by fuel returned from the engine If smaller day tanks are used the engine supplier may recommend routing engine fuel return lines to the main storage or installation of a fuel cooler Se
60. lways be from the load side ofthe transfer Switch for maximum reliability Such pumps typically are capable of lifting fuel 18 feet 5 5 m or drawing it horizontally up to 200 feet 61 m Where vertical or horizontal runs exceed these limits the pump should be remote mounted adjacentto the fuel storage tank When so located these pumps can push fuel over 1 000 feet 305 m horizontally or more than 100 feet 30 5 m vertically and deliver adequate fuel for generator sets up to 2800 kW Positive displacement pumps should never be connected directly to an engine a transfer tank and float switch should always be used so the engine fuel system is not subjected to excessive fuel pressures A check valve or shutoff solenoid valve wired into the engine ignition can be used to help keep the fuel line primed If such a valve is included in the system it should be installed on the outlet side of the auxiliary fuel pump to minimize inlet restriction TP 5700 7 93 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 Engine fuel pumps usually will lift fuel up to four feet 1 20 m or draw it horizontally
61. mical to install at a later time sua E 5700 4 4 Register type cover suitable for smaller sets 5 Flexible section TP 5700 7 93 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 ofthe engine The air vent air flow is not reversed as it is with the Air Vac system Choose top or side outlet of the engine Additional ductwork connects to the engine ductwork carrying the heated air outside For duct dimensions refer to the dimensional drawing for the particular unit This system is also efficient in maintaining consistent operating temperatures in confined areas See Figure 4 7 Note Air vent requires very little engine modification making it practical for field installation TP 5700 4 4 Canvas section 5 Air inlet opening 6 Air vent adapter 1 Ductwork with gradual bend 2 Heated air out 3 Exhaust Muffler Figure 4 7 Air Vent Cooling System using an Air Cooled Generator Set TP 5700 7 93 Section 4 Air Requirements 15 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
62. n additional customer supplied valve may be used ahead ofthe entire system to manually shut off city water when servicing the generator 4 10 Cooling Tower In warm dry climates a cooling tower may be a suitable source of generator set cooling water A typical system is shown in Figure 4 12 This is a variation of the city water cooling with heat exchanger The engine system usually includes the engine water pump a heat exchanger a surge tank and the water jacket of the engine The raw water system consists of the cooling tower araw water pump and the tube portion ofthe heat exchanger Raw water is circulated through the heat exchanger tubes to absorb heat from the engine system which is circulated around the surrounding shell of the heat exchanger The heated raw water is directed into a pipe at the top of the cooling tower and sprayed down into the tower to cool by evaporation Since some water is constantly being lost by evaporation the system must include provision for make up water TP 5700 7 93 1 Ventilation fan for heat rejected from exhaust and engine 5 Heated water into drain 2 City water in 6 Solenoid valve 3 Flexible section 7 Heat Exchanger 4 Manual shutoff valve Figure 4 11 Installation Using City Water Cooling System
63. n an area where freezing is common extend the exhaust piping well beyond the roof and use a gradual U bend at the end to direct the exhaust outlet downward which will keep rain snow etc out ofthe pipe The outlet ofthe pipe should be far enough from the roof to prevent ignition of the roof material from hot exhaust TP 5700 7 93 Rain cap or gradual U bend Rain shield 10 in 254 mm minimum 1 in 25 mm minimum Exhaust pipe Ventilation holes at both ends 10 in 254 mm minimum Tin 25 mm minimum Flashing Inner sleeve Outer sleeve Thimble outer diameter 10 in 254 mm minimum outside 10 in 254 mm minimum inside Exhaust pipe diameter O gt G N Figure 5 4 Double Sleeved Thimbles and Rain Cap Section 5 Exhaust System 23 Notes 24 Section 5 Exhaust System TP 5700 7 93 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 This is often reflected in less stringent regulations for placement of tanks In some location
64. ne connection Figure 6 1 Diesel Fuel System TP 5700 7 93 Fuel supply line from main fuel tank to day tank Overflow line Foot valve Main fuel storage tank Fuel tank vent Tank filling inlet Section 6 Fuel Systems 25 1 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 If this is not done air bubbles could be drawn into the fuel supply line and cause erratic engine operation Also fuel returning from the engine will be warmed from passing through the engine This returning fuel if hot enough can cause a reduction in the power of the engine At least 596 capacity should be allowed in a diesel main tank for expansion of the fuel If the main tank is to be located overhead a fuel shutoff solenoid should be used to prevent hydraulic lock or tank overflowing due to excessive pressures caused by static head of fuel Codes requiring standby power often specify minimum on site fuel supply Such requirements are included in NFPA 70 National Ele
65. ngement the pedestals should extend atleast six inches 15 cm back from the location of the front engine mount and six inches 15 cm toward the engine from the generator mounting point A minimum of 18 inches 46 cm between the generator and any adjacent walls or other obstructions should be maintained for ease of servicing Engine end Battery rack Generator end Concrete surface Generator set mounting base 15 24 cm 18 in 45 72 cm Figure 3 1 Mounting Surface Detail 8 Section 3 Location Figure 3 4 Four Pad Mounting TP 5700 7 93 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 per cubic foot 68 4 kg per 0 03 m for concrete can be used for this calculation Suggested concrete mixture by volume is 1 2 3 parts of cement sand and aggregate A layer of 8 10 inches 21 26 cm of sand or gravel should surround the pad for proper support and isolation of a pad located at or below grade All gener
66. nking periods are specified in NFPA 110 It allows a single 45 second cranking cycle for generator sets below 20 kW For larger models three 15 second crank cycles separated by 15 second rests are required The battery industry rating standard most commonly used to specify batteries is the cold cranking ampere rating Refer to the units specification sheet for battery cold cranking ampere rating Nickel cadmium batteries are sometimes used for standby generator sets because of their long life 20 years This is offset by their high initial cost larger space requirements and special charging requirements Conventional lead acid batteries have proven satisfactory for the majority of generator set applications Batteries are charged by engine driven battery charging alternators whenever the generator set operates These systems are normally capable of charge rates of 30 amperes or more and can restore the charge used in a normal cranking cycle within a short TP 5700 7 93 Section 7 Electrical Requirements period of operation When the engine is not operating a very low charge rate from an AC powered battery charger is sufficient to maintain the batteries fully charged These chargers may be automatic or manual with a high charge rate of 2 amperes and a trickle charge rate up to 300 milliamperes They can be separate self contained units or built into the automatic transfer Switch Due to the low maximum charge rate they are not
67. nverters are sometimes located outside of the building that houses the generator set This can cause start up problems because the great length of pipe between the converter and the carburetor does not allow sufficient heat buildup and heat retention 6 14 Dual Systems Natural and LP Gas In many applications natural gas is the main fuel and LP gas is used as the emergency fuel when natural gas is not available The dual fuel system in common use offers automatic changeover from one fuel to the other This is accomplished by the use of two separate regulators and solenoid valves A pressure switch placed on the primary source of fuel closes with a drop in pressure and energizes a relay which closes the primary fuel solenoid and opens the secondary or emergency fuel solenoid To ensure proper carburetion upon changeover to LP gas a separate LP gas load adjustmentis located in line between the secondary regulator and the carburetor See Figure 6 8 and Figure 6 9 Section 6 Fuel Systems 33 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 The primary regulator may or may not be furnished by the supplier It is the respon
68. on gas gasoline systems utilize the same basic components as those in the natural and LP gas systems See Figure 6 11 TP 5700 7 93 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 AC circuit protection All AC circuits must include circuit breaker or fuse protection Select a circuit breaker for up to 12596 of the rated generator set output current The circuit breaker must open all ungrounded connectors The circuit breaker or fuse must be mounted within 7 6 m 25 feet of the alternator output terminals 7 1 Batteries Batteries should be located in a clean dry area Position them so that the caps are readily accessible for checking the electrolyte level Keep batteries out of areas subject to high temperatures Locate them close to the set to keep cables short and thus insure maximum output Several types of battery racks are used throughout the product line be sure to refer to the submittal drawings for your unit Figure 7 1 shows atypical battery system Starting batteries are usually lead acid type sized according to the engine manufacturer s recommendation for a particular ambient temperature and required cranking time Recommended cra
69. oning is possible seek fresh air immediately andremain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Fuel System WARNING n F b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when drainingthe fuel system Wipe up spilled fuel after draining the system LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble TP 5700 7 93 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
70. over 1200 F 649 for some engines seamless stainless steel should be used for the flexible section 5 2 Condensation Trap A Y or tee type condensation trap with a drain plug or petcock should be installed between the engine and exhaust silencer as shown in Figure 5 3 This will prevent condensed moisture in the engine exhaust from draining into the engine when it is shut down The trap should be drained of collected moisture periodically TP 5700 5 1 Condensation trap Figure 5 3 Condensation Trap 22 Section 5 Exhaust System 5 3 Piping Exhaust piping should conform to all applicable codes In general exhaust temperatures will be less than 1000 F 538 C measured at the engine exhaust outlet except for infrequent brief periods and standards for low heat appliances will apply For units with exhaust temperatures below 1000 F 538 C exhaust piping should be routed a minimum of 18 inches 457 mm from any combustible materials If exhaust temperatures will exceed 1000 F 538 C the minimum distance should be 36 inches 914 mm The heat rejected by exhaust piping and consequently the amount of ventilating air required can be substantially reduced by insulating exhaust piping with suitable high temperature X insulation Exhaust temperatures are given on each generator model s specification sheet Placement of exhaust silencer and piping should consider location of combustible materials If location of exh
71. rculating pump should always be wired in parallel with the remote radiator fan so that both will operate whenever the generator set operates Heated water is forced by the engine pump into the hot side and then is drawn off by the auxiliary pump and forced into the radiator After circulating through the radiator coolant flows back to the cold side of the well where it is removed by the engine water pump Head pressures are thus isolated from the engine Pressure can also be isolated by installing a heat exchanger between the engine and remote radiator With the radiator at a remote location it is easily overlooked each time the generator is serviced For this reason low water alarms or automatic make up controls are often included in these systems Antifreeze is required if the radiator is subject to freezing temperatures Shutoff valves should be located between the engine and cooling system to allow for isolation of both systems This will eliminate the need to drain the entire system during service To determine radiator size and air requirements check the Specification Sheet for your model The amount of air required to ventilate the generator set room or enclosure determines the size of the air inlet and outlet a ventilating fan is usually necessary as generator heat loss as well as engine heat loss must be dissipated 4 9 City Water Cooling These systems utilizes city water and heat exchangers for cooling and are
72. rent hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 5700 7 93 This manual provides installation instructions for 20 2800 kW generator sets Operation manuals and wiring diagram manuals are available separately x in 001 001 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 Introduction Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference x in 001 002 a Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Lookatthe la
73. s Liftthe generator set using lifting bars inserted through the lifting holes on the skid WARNING 4 gt Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Use adequate lifting capacity Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized TP 5700 7 93 Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 hot during operation Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank Moving Parts A WARNING Hazardous voltage Moving rotor Can cause
74. s main tanks of considerable size are permitted inside the building or enclosure however local regulations must be checked before planning the installation The main components of a typical diesel fuel system are a main fuel storage tank fuel lines transfer tank and auxiliary fuel pump See Figure 6 1 Section 6 Fuel Systems Fuel storage tanks may be located above ground indoors or outdoors or buried underground Base mounted or subbase tanks are commonly used This is a tank that is contained in a base that the generator is mounted on See Figure 6 2 Fuel filters and sediment drains must be easily accessible for regular and frequent service Cleanliness of the fuel is especially important on diesel engines which have easily clogged precision fuel injectors and pumps Black iron pipe or steel tubing must be used for diesel fuel systems galvanized tanks and piping must not be used since the diesel fuel will react chemically with them to produce flaking which will quickly clog filters or causes failure of the fuel pump or injectors All flexible lines must be of the type approved for diesel fuels P 10 Injector return line Day tank vent Day tank Auxiliary fuel pump Tank drain Electric fuel level control switch Fuel supply line from day tank to engi
75. s lost that must be compensated for by increasing the size of the opening The following are minimum air inlet and outlet recommendations 1 If louvers are used the size of the opening should be increased approximately 5096 2 If window screening is used the opening should be increased approximately 8096 3 If furnace filters are used the opening should be increased 12096 4 2 Air Cooled Generators Air cooled generator sets are available with three basic types of air cooling systems that are discussed separately on the following pages For air cooled models 4 kW and smaller size the air inlet and outlet openings at least 1 square foot 0 092 m For larger sets determine inlet and outlet size on the basis of 0 25 square feet 0 023 m for each 1000 watts of capacity A 5000 watt set for example requires inlets and outlets of 1 25 square feet 0 115 m each 0 25 cu ft x 5 kW 1 25 cu ft 0 023 m x 5 kW 0 115 m Air requirements are listed in each model s specification sheet Remember to increase the size of openings for louvers screens filters etc as described earler in this section 12 Section 4 Air Requirements Figure 4 3 Stationary Louvers for Air Inlet Figure 4 4 Movable Louvers For Air Inlet TP 5700 7 93 4 3 For
76. s per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting A 2 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OS OSHA OV OZ p pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire
77. severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Safety Precautions and Instructions V Notice NOTICE This generator set has been rewired from its nameplate voltage to 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 an authorized service distributor dealer VI Safety Precautions and Instructions NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE Hardware damage The transfer switch may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in diffe
78. sibility of the supplier to insure that sufficient pressure is present at all times to operate the primary regulator Installation repair and alteration to gas piping should be undertaken only by the supplier or with supplier s permission Piping should never be used to ground any electrical apparatus The piping should be rigidly mounted but protected against damage from vibration Where flexible connections are needed use only fuel line approved for gas fuels See Figure 6 10 34 Section 6 Fuel Systems 6 16 Combination Gas Gasoline Most engines especially the smaller models will operate successfully on gas or gasoline without extensive modification or complicated mechanical changeover With a combination gas gasoline fuel system changeover involves only a few simple steps These systems normally utilize a gaseous fuel as the primary fuel with gasoline for emergency operation In some areas natural gas is available at reduced cost on an interrupted service basis In some cases a by product gas is the primary fuel but it may at times be unavailable Continued operation is assured under these conditions by switching over to gasoline The changeover is done manually at the generator set Either a combination gas gasoline carburetor or a gasoline carburetor with a gas adapter is used Natural or LP gas can be used with these carburetor combinations With the exception of the carburetor and addition of a gas adapter the combinati
79. similar to remote radiator systems in 18 Section 4 Air Requirements that they require less cooling air than unit mounted radiator systems Refer to Figure 4 11 for a view of some of the elements of a typical installation The heat exchanger the effects of city water lime deposits corrosion to one side of a heat exchanger which is relatively easy to clean or replace while engine coolant circulates in a closed system similar to a radiator system It allows better control of engine temperature permits the use of antifreeze and coolant conditioners and is suited to the use of an engine block heater as a starting aid Water inlet and outlet connections are mounted on the generator set skid and isolated from engine vibration by flexible sections If the generator set is vibration mounted to the skid and the skid is bolted directly to the mounting base no additional flexible sections are needed between connection points on the skid and city water lines If the generator set skid is mounted to the base with vibration isolators flexible sections must be used between connection points on the skid and city water lines A solenoid valve mounted at the inlet connection point automatically opens upon start up of the generator set providing water under pressure from city mains for engine cooling This valve automatically closes when the unit shuts down Be sure that the solenoid valve is located upstream of the supply flexible connection A
80. sting Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute TP 5700 7 93 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder
81. the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Engine Backfire Flash Fire WARNING Gh 2 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor l Safety Precautions and Instructions Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator s
82. tor is not near the engine Although regulators are designed to close and shut off fuel when the engine stops a solenoid valve should be located ahead of the regulator and the flexible fuel connector to prevent the accumulation of an explosive mixture of gas and air should either the flexible connection or regulator develop a leak The generator set installer normally wires the solenoid valve to the engine starting controls so it will open with battery power when the engine cranks or runs Some fuel regulators have provisions to install a pressure gauge to test inlet and outlet pressures If none are available install pipe tees in the fuel line to serve this purpose and use pipe plugs on any unused openings TP 5700 7 93 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 LP gas is propane butane or a mixture of the two gases The ratio of butane to propane is especially important when a large outdoor tank is used a fuel supplier may fill the tank in the warm summer months with a mixture composed mainly of butane however this mixture may not provide sufficient vaporized pressure at extremely col
83. up to 20 feet 6 01 m Auxiliary electric pumps powered by the engine starting battery can be connected in series with the engine pump See Figure 6 4 Auxiliary pump pressure should be limited to approximately 5 psi 84 5 kPa If the auxiliary pump is located at the fuel tank horizontal and vertical distance limits of approximately twice those for a lone engine pump are practical Fuel supply lines should be Schedule 40 black iron pipe steel tubing or copper tubing Galvanized pipe and fittings are not recommended Line size should be kept to the minimum necessary for the required flow TP 5700 6 1 Fuel tank 2 Fuel pump 3 Gasoline shutoff 4 Gasoline carburetor Figure 6 4 Gasoline Fuel System TP 5700 7 93 Flexible connections at least six inches 15 3 cm in length should be used between stationary piping and the engine fuel inlet connection WARNING Ze gt b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Combination natural gas gasoline fuel systems are sometimes used with gasoline as a standby fuel to meet code requirements for on site fuel supply Such systems are not recommended unless the engine will be operated on gasoline often enough to ensure that fuel does not deteriorate and the carburetor will not be disabled by accumulated gum and fuel deposits If a fuel storage tank is located above the engine an
84. ur installation This manual references several organizations and their codes that provide installation requirements and guidelines such as the National Fire Protection Association NFPA and Underwriter s Laboratories Inc UL e NFPA 54 National Fuel Gas Code e NFPA 70 National Electrical Code the National Electrical Code is a registered trademark of the NFPA TP 5700 7 93 Section 1 General e NFPA 99 Standard for Health Care Facilities e NFPA 101 Life Safety Code e NFPA 110 Emergency and Standby Power Systems e UL 486A The Standard for Wire Connectors and Soldering Lugs for Use with Copper Conductors e UL 486B The Standard for Wire Connectors for Use with Aluminum Conductors e UL 486E Equipment Wiring Terminals for Use with Aluminum and or Copper Conductors e UL 2200 Stationary Engine Generator Assemblies These organizations provide information specifically for US installations Installers must comply with their respective national and local codes Section 1 General 1 3 e d gt 5700 1 Exhaust thimble for wall or ceiling 6 Mounting base Silencer 7 Controller Supports 8 Electrical conduit Flexible sections 9 Water trap with drain Duct work for cooling air outlet 10 Fresh air intake
85. well suited to restoring fully discharged batteries Automatic float chargers with high charge rates of 10 amperes or more are available if full recovery capability independent of the engine driven charging System is required The most common reason for the failure of an emergency generator set to start when needed is starting battery failure Two common causes of battery failure are a manual charge rate set too low to maintain the battery or a manual chase rate set too high which results in loss of battery electrolyte For this reason automatic float chargers which vary the charge rate in response to battery condition are strongly recommended over manual types For large engines using two starters either one bank of batteries and chargers for both starters or separate battery systems may be used The latter system is preferable since it reduces the chance of one components failure making the entire system inoperative Battery cables A UL 2200 listed generator set requires battery cables with positive lead boots Factory supplied and optional battery cables include positive 4 lead boots When battery cables are not factory supplied source battery cables with positive 4 lead boots for UL 2200 compliance 1 Battery cables 2 Battery secured in mounting rack 3 End view 4 Generator set skid Figure 7 1 Typical Battery System Side View Section 7 Electrical Requirements 35 7 2 Electri

Kohler 20--2800 kW User's Manual

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