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Kohler 1250-2250 kW, Operation

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Kohler 1250-2250 kW Operation Download Page 76

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2004, 2005, 2006, 2007, 2008, 2012 by Kohler Co. All rights reserved.

TP-6161

1/12g

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455

Summary of Contents for 1250-2250 kW

Page 1: ...Industrial Generator Sets Models 20 2250 kW Controllers Decision Makerr 3 16 Light Software Code Version 1 10 or higher Decision Makerr 1 TP 6161 1 12g Operation...

Page 2: ...eadily 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...

Page 3: ...ller 20 2 4 1 Generator Set Starting 20 2 4 2 Generator Set Stopping 20 2 4 3 Fault Shutdowns 20 2 4 4 Controller Resetting After a Fault Shutdown 20 Section 3 Scheduled Maintenance 21 3 1 Alternator...

Page 4: ...tomer Connection Kit DEC 3 51 6 1 4 Engine Prealarm Senders for NFPA 110 DEC 3 51 6 1 5 FASTCHECKr Diagnostic Tester DEC 3 52 6 1 6 Float Equalize Battery Charger Kit with Alarm Option DEC 3 52 6 1 7...

Page 5: ...tor 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...

Page 6: ...r rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System...

Page 7: ...enerator set without a muffler or with a faulty exhaust system CAUTION Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels gr...

Page 8: ...perate automatically 600 volts and under Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air WARNING Servic...

Page 9: ...shown for the first time in a section Appendix A Abbreviations also includes many abbreviation definitions List of Related Materials Separate literature contains communication and software informatio...

Page 10: ...eadquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Offic...

Page 11: ...troller The 16 light controller features include annunciator panel lamps analog meters switches and controls and fuses and terminal strips For identification and an explanation of the functions see Se...

Page 12: ...s not start after 30 seconds of continuous cranking or 75 seconds of cyclic cranking See Section 2 3 1 Normal Operation Note The engine ECM may limit the crank cycle even if the controller is set to a...

Page 13: ...s and the lamp is unlit Does not require manual reset X Overvoltage Shutdown Lamp lights and the engine shuts down immediately if an overvoltage condition arises if equipped with overvoltage shutdown...

Page 14: ...measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC...

Page 15: ...IP Switch Open Position Typically the factory default settings have all the DIP switches in the closed position except the crank mode selection switch SW3 which is open for cyclic cranking The overspe...

Page 16: ...igh engine temperature low water level low oil pressure overcrank or overspeed See Section 2 4 3 Fault Shutdowns for additional shutdown information Frequency meter Meter displays the frequency Hz of...

Page 17: ...d fill the tank s regularly to ensure adequate fuel supply Ignition System Ensure that the ends of all spark plug wires are properly seated onto the coil distributor and the spark plug Lamp Test Press...

Page 18: ...ging the battery when the generator set is not operating Moving the generator set master switch to the OFF RESET position disables all controller functions Moving the generator set master switch to th...

Page 19: ...in the operating range Low coolant level if equipped The low coolant level shutdown shuts down the unit 5 seconds after the fault The shutdown does not function during the first 30 seconds following s...

Page 20: ...Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See t...

Page 21: ...battery WARNING 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...

Page 22: ...nator belts D D R Monthly Coolant temperature protection level D Six Months Lubricate fan bearings 1200 2000 kW X X 200 Hours or Six Months Air ducts louvers X X Yearly Coolant D Yearly Heat exchanger...

Page 23: ...Hours Bolt torque D D 3 Years or 500 Hours Remote Control System etc Compartment condition X X Weekly Remote control X Monthly Run generator set X Monthly Alternator General inspection X Weekly Rotor...

Page 24: ...engine to bleed air from the fuel system Note Bleed air from the fuel system according to the engine manufacturer s instructions Trapped air in the fuel system causes difficult starting and or errati...

Page 25: ...ter a fault alarm 1 Move alarm switch to the SILENCE position to stop alarm horn Lamp will remain lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Repa...

Page 26: ...om the fuel solenoid valve D Connect lead 73B to the fuel solenoid valve LPG vapor D Connect lead 65 to lead N5 ground LPG Liquid Withdrawal Operation D Disconnect lead 73A from the fuel solenoid valv...

Page 27: ...TP 6161 1 12 27 Section 3 Scheduled Maintenance ADV 7600B B Figure 3 6 Gas Fuel Connections Wiring Diagram...

Page 28: ...essure cap 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...

Page 29: ...radiator still has mineral deposits use a radiator cleaner to remove the remaining deposits following the manufacturer s instructions 3 Drain clean and flush the coolant recovery tank 3 7 5 Cooling S...

Page 30: ...rds screens and covers as necessary to access the radiator fan hardware 5 Inspect the blades for cracks or other damage Verify that all hardware is present Replace as needed 6 Retorque the 32 qty blad...

Page 31: ...g pressure relief port See Figure 3 10 Note The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication 5 Remove excess grease from the bearin...

Page 32: ...tes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spatteri...

Page 33: ...er Do not add fresh electrolyte Tighten the filler caps After adding water during freezing temperatures run the generator set 20 30 minutes to mix the electrolyte and the water to prevent battery dama...

Page 34: ...rain the battery If there is no power source for a battery charger place the controller in the prime power mode if equipped or disconnect the battery from the generator set 3 11 Detroit Diesel Engine...

Page 35: ...occurrence The ECM memory stores inactive codes with time date identification and the following information D First occurrence of each diagnostic code in engine operating hours D Last occurrence of ea...

Page 36: ...the fuel filter separator and bleed the fuel system See the engine owner s manual Gas Fueled Engines 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the genera...

Page 37: ...2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to Section 3 10 1 for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a f...

Page 38: ...TP 6161 1 12 38 Section 3 Scheduled Maintenance Notes...

Page 39: ...ing battery or an open circuit breaker The chart includes a list of common problems possible causes of the problem recommended corrective actions and references to detailed information or repair proce...

Page 40: ...System x x Air openings clogged Clean the air openings x Coolant level low Restore the coolant to normal operating level Section 3 x Cooling water pump inoperative Tighten or replace the belt Replace...

Page 41: ...e valves Eng S M x Vibration excessive Tighten all loose hardware x x x Ignition system inoperative gas gasoline only Check the ignition system spark plugs spark plug wires etc Eng O M Fuel System x x...

Page 42: ...open or grounded Test and or replace the rotor Gen S M x Stator inoperative open or grounded Test and or replace the stator Gen S M x Vibration excessive Tighten loose components x x Voltage regulator...

Page 43: ...ing on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFFposition 2 Disconnectthepowertothebatterycharger 3 Remove the batt...

Page 44: ...TP 6161 1 12 44 Section 5 Generator Set Reconnection Figure 5 1 20 150 kW Permanent Magnet and Wound Field Single Phase Alternators ADV 5875A M...

Page 45: ...TP 6161 1 12 45 Section 5 Generator Set Reconnection Figure 5 2 20 300 kW Permanent Magnet and 20 60 kW Wound Field Alternators ADV 5875B M...

Page 46: ...TP 6161 1 12 46 Section 5 Generator Set Reconnection Figure 5 3 60 with Oversize Alternator 300 kW Wound Field Alternators ADV 5875C M...

Page 47: ...TP 6161 1 12 47 Section 5 Generator Set Reconnection Figure 5 4 350 2250 kW Pilot Excited Permanent Magnet Alternator ADV 5875D M...

Page 48: ...on the generator set controller front panel or switchgear See Figure 5 6 ADV 5849A 1 1 Output voltage adjustment control EMERGENCY STOP ONLY OFF RESET PREALARM HIGH ENGINE TEMPERATURE PREALARM LOW OI...

Page 49: ...uctions provided with the accessory kit supersede these instructions where there are differences In general run AC and DC wiring in separate conduit Use shielded cable for all analog inputs Observe al...

Page 50: ...View A 292887 Figure 6 2 Audiovisual Alarm GM13984 328912A H CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX Figure 6 3 Audiovisual Alarm Connections 6 1 2 Common Failure Relay Kit DEC 3 The common...

Page 51: ...mote terminal strip is identical to that of the controller Connect all accessories except the emergency stop kit to the controller connection kit terminal strips See Figure 6 6 See Section 6 2 Accesso...

Page 52: ...t Temperature D Anticipatory Low Engine Oil Pressure D Engine Crank D Engine Overspeed D Engine Running D High Engine Coolant Temperature D Low Engine Coolant Temperature D Low Engine Oil Pressure D L...

Page 53: ...ator set nonoperation periods and when the generator set battery cannot be maintained by an AC battery charger Refer to Section 2 3 2 Prime Power Mode Operation for additional information 6 1 10 Remot...

Page 54: ...ng for the Emergency Stop Switch Resetting Procedure See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification A 222654 TP 5352 1 Figure 6 13 Emergency Stop Kit...

Page 55: ...vices Up to five RSA slave devices can be used with an RSA master device All RSA annunciators factory default to the master device but can be changed with RSA II setup software that can be connected t...

Page 56: ...SF Green or Off Green Red SF On On Battery Charger Fault Yellow Green Green or Off Green Off On On High Battery Voltage Yellow Green Green or Off Green Off On On Low Battery Voltage Yellow Green Green...

Page 57: ...TP 6161 1 12 57 Section 6 Accessories Figure 6 19 RSA Wiring Connections GM62554A G...

Page 58: ...TP 6161 1 12 58 Section 6 Accessories Figure 6 20 RSA Wiring Connections GM62554B G...

Page 59: ...TP 6161 1 12 59 Section 6 Accessories Figure 6 21 RSA Wiring Connections GM62554C G...

Page 60: ...TP 6161 1 12 60 Section 6 Accessories Figure 6 22 RSA Wiring Connections GM62554D G...

Page 61: ...TP 6161 1 12 61 Section 6 Accessories Figure 6 23 RSA Wiring Connections GM62554E G...

Page 62: ...Figure 6 24 Remote Speed Adjustment Potentiometer Connection Typical 6 1 14 Run Relay Kit The run relay kit includes three sets of contacts that energize only during generator set operation The run r...

Page 63: ...hunt Trip Wiring Kit Connections 6 1 17 Single Relay Dry Contact Kit DEC 3 The single relay dry contact kit uses one set of contacts to trigger customer provided warning devices if a fault condition o...

Page 64: ...controller fault output to the ten relay dry contact kit Typically lamps audible alarms or other devices signal the fault conditions Refer to Figure 6 31 for an internal view of the contact kit See F...

Page 65: ...oring of the generator set Typically lamps audible alarms or other devices signal faults or status conditions Connect any generator set fault output to the dry contact kit Refer to Figure 6 33 for an...

Page 66: ...d terminal strip Place the controller circuit board panel flat to ensure adequate slack in the dry contact relay leads For specific information on accessory connections refer to the accessory wiring d...

Page 67: ...engine temperature AHET signal 41 Anticipatory low oil pressure ALOP signal 42A Battery voltage fuse 1 protected Accessory power supply Customer may also provide separate accessory power source 48 Em...

Page 68: ...TP 6161 1 12 68 Section 6 Accessories Figure 6 38 Accessory Connections 328912A H...

Page 69: ...TP 6161 1 12 69 Section 6 Accessories Figure 6 39 Accessory Connections 328912B H...

Page 70: ...TP 6161 1 12 70 Section 6 Accessories Figure 6 40 Accessory Connections 328912C H...

Page 71: ...also be occupied by an interface circuit board with gauge drivers required for some models Do not confuse the function of these circuit boards See the Introduction section and refer to Tech Tools Eng...

Page 72: ...GM49791 2 Circuit Board This is the interface circuit board with the gauge drivers required on the 450 500REOZVB models only For communication purposes replace GM49791 2 with GM49791 1 GM49791 2 is mo...

Page 73: ...ter s Laboratories CUL Canadian Underwriter s Laboratories cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibe...

Page 74: ...ersize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phi...

Page 75: ......

Page 76: ...HLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Head...

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