Kohler Generator Sets 20--2800 kW manual

Industrial/Commercial/Residential Generator Sets Models: 20 - - 2800 kW TP-5700 7/93d Installation[...]

Engine exhaust fr om t his produc t cont ains chemic als known t o the S tat e of California t o cause canc er , birt h defec ts , or ot her reproduc t ive harm. W ARNING California Propos ition 65 Product Identifica tion I nformat ion Produc t ident if icat ion number s det ermine serv ice part s. Record t he produc t ident if icat ion numbers in [...]

T able of Contents TP-5700 7/93 T able of Contents Product Identification Information Inside front cover ............................................ Safety Precautions and Instructions I ........................................................ Introduction i ............................................................................... Service As[...]

T able of Contents, continued TP-5700 7/93 T able of Contents Section 7 Electrical Requirements 35 .......................................................... 7.1 Batteries 35 ............................................................. 7.2 Electrical Connections 36 ................................................. 7.3 Load Lead Connections 36 ....[...]

TP-5700 7/93 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS . Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent acciden[...]

TP-5700 7/93 II 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 in[...]

TP-5700 7/93 III Safety Precautions and Instructions The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels i naw e l l - v e n t i l a t e da r e aa w a yf r o m spark-producing equipment and out of the reach of children. Never ad[...]

TP-5700 7/93 IV Safety Precautions and Instructions 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 and normal sources of supply . W ARNING Grounding electrica[...]

TP-5700 7/93 V Safety Precautions and Instructions Servicing the transfer switch controls and accessories within the enclosure. Hazardous voltage can cause severe injury or death. Disconnect the transfer switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply p[...]

TP-5700 7/93 VI Safety Precautions and Instructions Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE V oltage 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 s[...]

TP-5700 7/93 i Introduction Introduction 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 th[...]

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TP-5700 7/93 1 Section 1 General Section 1 General Industrial power systems give years of dependable service if installed using the guidelines provided in this manual and in applicable codes. Incorrect installation can cause continuing problems. Figure 1-1 illustrates a typical installation. Y our authorized generator set distributor/dealer may als[...]

TP-5700 7/93 2 Section 1 General TP-5700-1 1. Exhaust thimble (for wall or ceiling) 2. Silencer 3. Supports 4. Flexible sections 5. Duct work for cooling air outlet 6. Mounting base 7. Controller 8. Electrical conduit 9 . W a t e rt r a pw i t hd r a i n 10. Fresh air intake 1 2 3 4 5 6 7 8 9 10 Figure 1-1 T ypical Stationary-Duty Generator Set Ins[...]

TP-5700 7/93 3 Section 2 Load and Transport Section 2 Load a nd T ransport T o 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 instr[...]

TP-5700 7/93 4 Section 2 Load and Transport D A four-point lifting method is necessary to lift the generator set. T o 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 [...]

TP-5700 7/93 5 Section 2 Load and Transport D Do not attach lifting hooks to outside reinforcing plate on skid. Attach lifting hooks to skid exactly as shown in Figure 2-4. This method utilizes the strongest portion of the mounting skid and also prevents the lifting hooks from slipping. Generators without skid reinforcing plates can be raised with [...]

TP-5700 7/93 6 Section 2 Load and Transport Notes[...]

TP-5700 7/93 7 Section 3 Location Section 3 Location 3.1 Location Factors Location is the key to a proper installation. The following sections will deal with the factors to consider in a proper installation. Before final plans are made for locating a generator set, the following questions should be raised concerning the set and the proposed site. 1[...]

TP-5700 7/93 8 Section 3 Location 3.3 Mounting T ypical mounting surface details and dimensions are shown in Figure 3-1. The recommended mounting surface is a concrete mounting pad. This must be a level surface as shown in Figure 3-2, or raised pads as shown in Figure 3-3 and Figure 3-4. The advantage of the arrangement shown in Figure 3-3 is that [...]

TP-5700 7/93 9 Section 3 Location The composition of the mounting pad should follow standard practice for the required loading. Common specifications call for 2500-3000 psi (176-21 1 kg/cm 2 ) 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 lea[...]

TP-5700 7/93 10 Section 3 Location Notes[...]

TP-5700 7/93 11 Section 4 Air Requirements Section 4 Air Requirements 4.1 General An ample flow of clean, cool air is required to support combustion and dissipate heat. Approximately 70% of the heat value of fuel consumed by an engine will be rejected to the cooling system and exhaust. Battery compartment ventilation. T o prevent the accumulation o[...]

TP-5700 7/93 12 Section 4 Air Requirements 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. S[...]

TP-5700 7/93 13 Section 4 Air Requirements 4.3 Forced Air With the forced-air system, cooling air is drawn in through the front of the engine, circulated around finned areas of the cylinder block and head, then ejected toward the rear or generator end of the set. This system is best suited to wide-open, well-ventilated areas. It is not recommended [...]

TP-5700 7/93 14 Section 4 Air Requirements 4.4 Air - V ac  Cooling System The air flow direction with the Air-V ac  system is the opposite of the conventional forced air cooling system. Use the Air-V ac  system in confined areas since it includes a blower scroll which easily connects to the ductwork. For duct dimensions refer to the dimens[...]

TP-5700 7/93 15 Section 4 Air Requirements 4.5 Air V ent The air vent system is used on some air-cooled gas and has been used on some diesel models. It includes special ductwork which directs the flow of heated air to the outlet at the top or side of t he engine. The air vent air flow is not reversed as it is with the Air-V ac  system. Choose to[...]

TP-5700 7/93 16 Section 4 Air Requirements 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 Thi[...]

TP-5700 7/93 17 Section 4 Air Requirements The connection from the radiator duct flange to the ductwork should be heavy canvas, silicone or similar flexible material to prevent noise and vibration transmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should have an unrestricted area 150% greater than that enclose[...]

TP-5700 7/93 18 Section 4 Air Requirements 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 fo[...]

TP-5700 7/93 19 Section 4 Air Requirements 7 1 2 3 4 6 5 1. V entilation fan (for heat rejected from exhaust and engine) 2. City water in 3. Flexible section 4. Manual shutoff valve 5. Heated water into drain 6. Solenoid valve 7. Heat Exchanger Figure 4-1 1 Installation Using City Water Cooling System with Heat Exchanger 1 2 3 4 5 6 1. Engine water[...]

TP-5700 7/93 20 Section 4 Air Requirements 4.1 1 Block Heaters Block heaters are recommended on all standby applications where the generator is subject to temperatures below 60 ° F( 1 6 ° 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 part[...]

TP-5700 7/93 21 Section 5 Exhaust System Section 5 Exhaust System Proper installation of the exhaust system is essential to obtain satisfactory performance from a generator set. The most important factor is that the installed system must not exceed the engine manufacturer ’s maximum exhaust back pressure limit. Any exhaust back pressure will limi[...]

TP-5700 7/93 22 Section 5 Exhaust System 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 [...]

TP-5700 7/93 23 Section 5 Exhaust System 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 [...]

TP-5700 7/93 24 Section 5 Exhaust System Notes[...]

TP-5700 7/93 25 Section 6 Fuel Systems Section 6 Fuel Systems When planning an installation, check state and local regulations regarding fuel storage and handling. Piping and fuel system components must conform to these regulations. 6.1 Diesel Fuel Systems Since diesel fuel is less volatile than gas or gasoline, it may be considered safer fuel from[...]

TP-5700 7/93 26 Section 6 Fuel Systems 1 2 3 4 TP-5700-6 1. Generator set skid 2. Side view 3. Subbase fuel tank 4. End view Figure 6-2 Subbase Fuel T ank 6.2 Main Fuel T ank 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 s[...]

TP-5700 7/93 27 Section 6 Fuel Systems 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[...]

TP-5700 7/93 28 Section 6 Fuel Systems 6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop a maximum of 7 psi (48 kPa) pressure and have a lift capacity of 4-6 feet (1.2-1.8 m). Even if the engine pump can draw fuel a greater distance, a more reliable system results if a transfer tank and/or auxiliary pump are used when the v[...]

TP-5700 7/93 29 Section 6 Fuel Systems 6.6 Gasoline Fuel Systems Due to code restrictions which do not allow storage of more than one gallon (3.8 L) of gasoline inside a building, gasoline fuel systems are usually limited to housed generator sets installed outdoors or portable trailer-mounted units. Gasoline will deteriorate if stored for more than[...]

TP-5700 7/93 30 Section 6 Fuel Systems 6.7 Natural or LP Gas Fuel Systems Natural and LP (liquified petroleum) gas fuel systems should be designed and installed in accordance with the requirements of NFP A 54, National Fuel Gas Code, and all applicable local codes. V arious types of gas fuel systems are available as follows: D LP Gas V apor (Figure[...]

TP-5700 7/93 31 Section 6 Fuel Systems 1 2 3 5 TP-5700-6 4 91 0 87 6 1. Carburetor 2. Load adjustment valve 3. Converter (vaporizer) 4. Solenoid valve 5. LP gas filter (supplied by gas supplier or installer) 6. LP gas supply 7. Natural gas supply 8. Primary regulator (supplied by gas supplier or installer) 9. Secondary regulator 10. Pressure gauge [...]

TP-5700 7/93 32 Section 6 Fuel Systems 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[...]

TP-5700 7/93 33 Section 6 Fuel Systems 6.1 1 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 fue[...]

TP-5700 7/93 34 Section 6 Fuel Systems 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 [...]

TP-5700 7/93 35 Section 7 Electrical Requirements Section 7 Electrical Requirements Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible c[...]

TP-5700 7/93 36 Section 7 Electrical Requirements 7.2 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Because of the large number of accessories and possible combinations, this manual does not address specific applications. Refer to the submittal c[...]

TP-5700 7/93 37 Section 7 Electrical Requirements 7.4 T erminal Connector T orque Use the torque values shown in Figure 7-4 or Figure 7-5 for terminal connectors. Refer to UL-486A, UL-486B, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. See Section 7.2, Electrical Connections, for information on the temper[...]

TP-5700 7/93 38 Section 7 Electrical Requirements 7.5 Automatic T ransfer Switches A typical standby system has at least one automatic transfer switch connected to the generator set output to automatically transfer the electrical load to the generator set if the normal source fails. When normal power returns, the switch transfers the load back to t[...]

TP-5700 7/93 39 Section 7 Electrical Requirements 7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdown of the generator from a remote location. If the emergency stop switch is activated, the emergency stop lamp on the generator controller lights and the unit shuts down immediately . The generator cannot be restarted [...]

TP-5700 7/93 40 Section 7 Electrical Requirements TP-5700 7/93 GENERA TOR JUNCTION BOX SAFEGUARD CIRCUIT BREAKER TERMINAL STRIP (IN JUNCTION BOX) RUN RELA Y KIT BA TTERY HEA TER KIT GENERA TOR HEA TER KIT BLOCK HEA TER KIT AC CONNECTION BOX (Installer Supplied) BA TTERY CHARGER KIT LOW FUEL SWITCH KIT 10-RELA Y DRY CONT ACT KIT TRANSFER SWITCH (OPT[...]

TP-5700 7/93 Appendix A-1 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing AHWT anticipatory high water temperatur[...]

TP-5700 7/93 A-2 Appendix kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L [...]

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E 1993, 2001, 2003 by Kohler Co. All rights reserved. TP-5700 7/93d KOHLER CO. Kohler , Wisconsin 53044 Phone 920-565-3381, Web site www .kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquar[...]