Installation Industrial/Commercial/Residential Generator Sets Models: 20--2800 kW TP-5700 7/93d
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.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Service Assistance . . .
Table of Contents, continued Section 7 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE 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 the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors.
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 and normal sources of supply. 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. Disconnect the power to the day tank before servicing.
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 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.
Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. VI Safety Precautions and Instructions NOTICE NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware.
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 the products represented without notice and without any obligation or liability whatsoever.
Section 1 General Industrial power systems give years of dependable service if installed using the guidelines provided in this manual and in applicable codes. Incorrect installation can cause continuing problems. Figure 1-1 illustrates a typical installation. Your authorized generator set distributor/dealer may also provide advice about or assistance with your installation.
3 2 1 5 9 10 4 8 7 6 TP-5700-1 1. 2. 3. 4. 5. Exhaust thimble (for wall or ceiling) Silencer Supports Flexible sections Duct work for cooling air outlet Figure 1-1 2 6. 7. 8. 9. 10.
Section 2 Load and Transport To ensure personal safety while preventing damage to the product, we strongly recommend the following guidelines be observed when loading and transporting standby generator sets. Due to the different designs, dimensions and weights of the generators involved, specific instructions for each model are not provided. However, these guidelines are applicable to the full standby line (although minor procedural changes may be necessary between sets).
D A four-point lifting method is necessary to lift the generator set. To maintain generator balance during lifting, the lifting apparatus must utilize the four skid lifting holes mentioned in the previous paragraph. One method of lifting standby generators uses an apparatus of hooks and cables joined at a single rigging point. See Figure 2-2. The use of spreader bars is necessary with this method to avoid damage to the set during the lifting procedure.
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 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. 2.1.
Notes 6 Section 2 Load and Transport TP-5700 7/93
Section 3 Location 3.1 Location Factors The location of the generator set must: 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. D Meet applicable fire rating codes and standards. 1.
3.3 Mounting Typical mounting surface details and dimensions are shown in Figure 3-1. The recommended mounting surface is a concrete mounting pad. This must be a level surface as shown in Figure 3-2, or raised pads as shown in Figure 3-3 and Figure 3-4. The advantage of the arrangement shown in Figure 3-3 is that the engine oil can be drained more conveniently. An oil drain piped to the side of the mounting base is usually available as an accessory from the manufacturer.
The composition of the mounting pad should follow standard practice for the required loading. Common specifications call for 2500-3000 psi (176-211 kg/cm2) 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 m3] for concrete can be used for this calculation).
Notes 10 Section 3 Location TP-5700 7/93
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. 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.
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.
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 for confined areas unless intake and/or exhaust fans are used to achieve the required air circulation. See Figure 4-5. 1 2 3 4 5 1. Air oulet 2. Air inlet opening 3.
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 finned areas, and then out into the scroll located at the front of the engine.
4.5 Air Vent The air vent system is used on some air-cooled gas and has been used on some diesel models. It includes special ductwork which directs the flow of heated air to the outlet at the top or side of the engine. The air vent air flow is not reversed as it is with the Air-Vac 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.
4.6 Liquid-Cooled Models The three most common liquid cooling systems used for generator sets are unit-mounted radiator, city water, and remote radiator cooling. Since each involves somewhat different installation considerations, they will be discussed separately. 4.7 Unit-Mounted Radiator Cooling This is the most common cooling system used for engine-driven generator sets 20 kW and larger. The major system components are an engine-driven fan and circulating water pump, a radiator, and a thermostat.
The connection from the radiator duct flange to the ductwork should be heavy canvas, silicone or similar flexible material to prevent noise and vibration transmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should have an unrestricted area 150% greater than that enclosed by the radiator duct flange. The inlet air opening should be at least as large as the outlet but preferably 50% larger.
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.
1 7 3 4 6 1. 2. 3. 4. Ventilation fan (for heat rejected from exhaust and engine) City water in Flexible section Manual shutoff valve 2 5 5. Heated water into drain 6. Solenoid valve 7. Heat Exchanger Figure 4-11 Installation Using City Water Cooling System with Heat Exchanger 2 1 3 6 1. Engine water pump 2. Surge tank 5 3. Cooling tower 4. Drain 4 4 5. Heat exchanger 6.
4.11 Block Heaters 4.12 Recommended Coolant 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. Antifreeze/coolant protection will be required for most applications.
Section 5 Exhaust System Proper installation of the exhaust system is essential to obtain satisfactory performance from a generator set. The most important factor is that the installed system must not exceed the engine manufacturer’s maximum exhaust back pressure limit. Any exhaust back pressure will limit the maximum power available from the engine. Excessive back pressure may cause serious engine damage. Exhaust lines should be as short and straight as possible.
5.1 Flexible Section 5.3 Piping 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 at least 12 inches (305 mm) long.
5.4 Double-Sleeve Thimbles 6 3 9 4 8 7 The thimbles should be constructed so that they extend at least 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.
Notes 24 Section 5 Exhaust System TP-5700 7/93
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. 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. 6.
2 1 4 3 TP-5700-6 1. Generator set skid 2. Side view Figure 6-2 3. Subbase fuel tank 4. End view 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.
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.
6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop a maximum of 7 psi (48 kPa) pressure and have a lift capacity of 4-6 feet (1.2-1.8 m). Even if the engine pump can draw fuel a greater distance, a more reliable system results if a transfer tank and/or auxiliary pump are used when the vertical lift exceeds three feet or fuel must be drawn horizontally more than 20 feet (6.1 m).
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 up to 20 feet (6.01 m).
6.7 Natural or LP Gas Fuel Systems 1 2 3 4 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.
1 4 1 2 2 3 4 5 3 5 9 10 6 4 TP-5700-6 1. 2. 3. 4. 5. TP-5700-6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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.
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.
6.15 Natural Gas 6.16 Combination Gas-Gasoline 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.
Section 7 Electrical Requirements Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible connections. Comply with all applicable codes when installing a wiring system. AC circuit protection. All AC circuits must include circuit breaker or fuse protection.
D Select row 1, 2, 3, or 4 if the circuit rating is 7.2 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Because of the large number of accessories and possible combinations, this manual does not address specific applications. Refer to the submittal catalog accessory drawings and wiring diagrams for connection and location. Most field-installed accessory kits include installation instructions.
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, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. See Section 7.2, Electrical Connections, for information on the temperature rating of customer-supplied wire.
7.5 Automatic Transfer Switches Remote Annunciator 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.
7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdown of the generator from a remote location. If the emergency stop switch is activated, the emergency stop lamp on the generator controller lights and the unit shuts down immediately. The generator cannot be restarted until the emergency stop switch is reset. See Figure 7-8. PULL TO BREAK GLASS 7.
TP-5700 7/93 Section 7 Electrical Requirements 40 CUSTOMER ACCESSORIES 3 WIRES MAX. 18-20 GA. Figure 7-9 TP-5700 7/93 Generator Set Connections, Typical SEE NOTE 2 TRANSFER SWITCH (OPTIONAL) RUN RELAY KIT SAFEGUARD CIRCUIT BREAKER TERMINAL STRIP (IN JUNCTION BOX) GENERATOR BATTERY POSITIVE CONNECTION LOW FUEL SWITCH KIT BATTERY CHARGER KIT 2 WIRES 18-20 GA. 1 WIRE 18-20 GA. GENERATOR BATTERY NEGATIVE CONNECTION CUSTOMER ACCESSORIES 30 WIRES MAX. 18 GA.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw.
kg kg/cm2 kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ 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 L x W x H length by width by height lb. pound, pounds lbm/ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd.
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 TP-5700 7/93d E 1993, 2001, 2003 by Kohler Co. All rights reserved.
