Kohler 15REYG Installation Manual Download

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Table of Contents

TP-6727 10/11

Table of Contents

Product Identification Information

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Safety Precautions and Instructions

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Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty Registration

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Service Assistance

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Section 1 General

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1.1

Introduction

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1.2

Enclosed and Open Generator Sets

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1.3

Location Factors

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1.4

Mounting Surface

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1.5

Vibration Isolation

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1.6

Unit-Mounted Radiator Cooling

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1.6.1

System Features

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1.6.2

Recommended Coolant

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1.7

Fuel Supply

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1.7.1

Fuel Lines

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1.7.2

Gas Regulators

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1.8

Electrical System

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1.8.1

Line Circuit Breakers

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1.8.2

Electrical Connections

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1.8.3

Ground and Neutral Connections

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1.8.4

Load Lead Connections

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1.8.5

Terminal Connector Torque

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1.8.6

Batteries

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1.8.7

Battery Chargers

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1.8.8

Remote Start Connection (optional)

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1.8.9

Automatic Transfer Switches

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Section 2 Open Units

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2.1

Introduction

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2.2

Air and Cooling

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2.2.1

Installation Considerations

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2.2.2

Cooling Air Requirements

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2.3

Exhaust System

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2.3.1

Flexible Exhaust Line

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2.3.2

Condensation Trap

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2.3.3

Piping

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2.3.4

Double-Sleeved Thimbles

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2.3.5

Exhaust Outlet

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2.3.6

Exhaust System Backpressure

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Section 3 Installation Instructions

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3.1

Introduction

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3.2

Prepare Site

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3.2.1

Indoor Installations, Open Units

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3.2.2

Outdoor Installations, Enclosed Units

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3.3

Lifting Generator Set

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3.4

Mount and Ground Generator Set

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3.5

Generator Set Electrical Connections

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3.6

Install Engine Starting Battery

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3.7

Install and Connect Fuel Supply

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3.7.1

Fuel Conversion Procedures

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3.7.2

Add Coolant

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3.8

Operation Tests

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Summary of Contents for 15REYG

Page 1: ...Commercial Generator Sets Models 15REYG 30REYG TP 6727 10 11c Installation...

Page 2: ...y 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 name...

Page 3: ...3 1 8 6 Batteries 14 1 8 7 Battery Chargers 14 1 8 8 Remote Start Connection optional 15 1 8 9 Automatic Transfer Switches 15 Section 2 Open Units 17 2 1 Introduction 17 2 2 Air and Cooling 18 2 2 1 I...

Page 4: ...ADC 2100 37 5 2 Firmware Version 37 5 3 Controller Automatic Power Down 37 5 4 Controller Configuration 37 5 5 Voltage Adjustments 41 Section 6 Generator Reconnection 45 6 1 Voltage Reconnection 45 6...

Page 5: ...harger 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...

Page 6: ...r death Install carbon monoxide detectors on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operation...

Page 7: ...lectrocution Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2...

Page 8: ...vere 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 sever...

Page 9: ...y Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference List of Related Materials Figure 1 identifies related literature availab...

Page 10: ...dquarters 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 Office...

Page 11: ...erations are especially important The building engineer must determine whether the structure can support the weight of the generator set The location of the generator set must D Support the weight of...

Page 12: ...ss factors D Pipe length D Other appliances on the same fuel supply D Number of fittings Flexible connections Rigid mount the piping but protect it from vibration Use flexible connections spanning a m...

Page 13: ...onfiguration Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding of the n...

Page 14: ...16 13 8 120 5 6 7 32 17 0 150 6 4 1 4 22 6 200 7 9 5 16 31 1 275 9 5 3 8 42 4 375 12 7 1 2 56 5 500 14 3 9 16 67 8 600 Note For values of slot width or length not corresponding to those specified sele...

Page 15: ...tch uses a set of contacts to signal the engine generator to start When the normal source fails and the generator set master switch is in the AUTO position the transfer switch contacts close to start...

Page 16: ...TP 6727 10 11 16 Section 1 General Notes...

Page 17: ...ical open unit installation For the protection of the building s occupants install carbon monoxide CO detectors on each level of the building Locate the detectors to adequately warn the building s occ...

Page 18: ...igure 2 2 When using ductwork and ventilating fans check the exhaust fan capacity in m3 min cfm If using exhaust fans install fan operated louvers with exhaust fans to regulate airflow See Figure 2 5...

Page 19: ...erheating especially in high ambient air temperatures Use heavy canvas silicone rubber or similar flexible material for the connection between the radiator duct flange and the ductwork to prevent nois...

Page 20: ...ess on the engine exhaust manifold or turbocharger Never allow the engine manifold or turbocharger to support the silencer or exhausting piping Note Do not bend the flexible section or use it to compe...

Page 21: ...himbles If the exhaust pipe passes through a wall or roof use a double sleeved exhaust thimble to prevent the transmission of exhaust pipe heat to the combustible material Figure 2 11 shows constructi...

Page 22: ...r is too small D The exhaust pipe is too long D The exhaust system has too many sharp bends D The exhaust silencer is too small D The exhaust silencer is not the correct design for the application The...

Page 23: ...12 2 8 equiv ft or 0 86 equiv m Equivalent of straight pipe 3 0 2 8 5 8 equiv straight ft 0 9 0 86 1 76 equiv straight m 6 Determine the total length of straight pipe used in the exhaust system Add t...

Page 24: ...TP 6727 10 11 24 Section 2 Open Units P Backpressure in Hg per foot kPa per m inches d Pipe Diameter mm Figure 2 13 Backpressure using Pipe Size 4 in 152 m or Less...

Page 25: ...ons in this manual and observe the decals on the equipment Refer to the diagrams and drawings in Section 7 for dimensions and electrical connections during the installation procedure Read the entire i...

Page 26: ...jacent walls or obstructions to allow access for maintenance and service See Figure 2 1 for a typical open unit installation Prepare an area for mounting the generator set 1 Clear all combustible mate...

Page 27: ...still do not clear the protruding component s temporarily remove the component s 3 4 Mount and Ground Generator Set 1 Place the generator set on the concrete mounting pad Secure the generator set wit...

Page 28: ...end panel or make connections inside the junction box Load Lead and Engine Start Connections 1 Install a 120 VAC receptacle for the generator set battery charger and block heater if equipped Supply p...

Page 29: ...te the battery chargerfrom explosive fumes WARNING Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a...

Page 30: ...Check that the primary regulator and gas meter have sufficient capacity for the fuel requirements for the generator set plus all other gas fired equipment Have the fuel supplier install a larger gas...

Page 31: ...e the fuel valves disconnect the lines at the location of the leak clean the fittings and apply fresh pipe sealant Reconnect the lines and recheck for leaks Note After the system installation is compl...

Page 32: ...em is set up for the type of fuel that will be used See Figure 3 8 for the location of the fuel solenoid valve To change the fuel type change the connection to the fuel solenoid valve as described bel...

Page 33: ...ay not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix t...

Page 34: ...output voltage from the generator set If voltage adjustments are required refer to Section 5 5 for instructions to use the ADC 2100 voltage adjustment menu 4 Perform voltage checks as described in the...

Page 35: ...ctions The following sections detail a few common accessories and their functions The instructions provided with the accessory kit supersede these instructions if different 4 2 Common Fault and Run Re...

Page 36: ...ptional oil makeup kit available for 30 kW generator sets provides an additional 2 quarts of oil for extended run time Follow the instructions provided with the kit to add oil if necessary and to chec...

Page 37: ...ations parameter setting Cn00 see Section 5 4 the controller will power down after 48 hours of no activity If the generator set has been started the controller will power down 48 hours after the gener...

Page 38: ...es between 12 and 24 VDC for the engine starting battery voltage Communications setting Cn This setting allows the user to set the controller for communication with optional meters The factory setting...

Page 39: ...ype to Ec03 OR Ec06 if necessary See Figure 5 1 U u X X U c 0 1 U u 0 1 3 2 5 0 A d n c Press Now release the Select button or To enter advanced configuration mode Go to Figure 5 3 or To proceed to th...

Page 40: ...last saved settings when the master switch is moved to the OFF RESET position Figure 5 3 Advanced Configuration Mode engine data input types battery voltage and engine communications To save changes T...

Page 41: ...ting the configuration mode Voltage changes are lost if they are not saved before the generator set shuts down If the changes are not saved the generator set continues to run with the new settings unt...

Page 42: ...or Hold Wait about 5 seconds until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is...

Page 43: ...en the display says SAVE Press or To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 5 6 Yes or no flashes when the up or down arrow is pre...

Page 44: ...TP 6727 10 11 44 Section 5 Controller Notes...

Page 45: ...e 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 t...

Page 46: ...rs and other accessories match the selected line voltage Reconnection Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect engine starting battery negative lead fir...

Page 47: ...47 Section 6 Generator Reconnection ADV 5875B J Note The current transformers CTs shown are not used on generator sets equipped with the Advanced Digital Control ADC 2100 Figure 6 2 12 Lead Generator...

Page 48: ...TP 6727 10 11 48 Section 6 Generator Reconnection Notes...

Page 49: ...ng diagrams refer to TP 6719 Wiring Diagram Manual Dimension Drawing Description Drawing Number Page Generator Set without Customer Connection Box Sheet 1 ADV 7692 50 Sheet 2 ADV 7692 51 Generator Set...

Page 50: ...TP 6727 10 11 50 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 2 Dimension Drawing ADV 7692 Sheet 1 Generator Set...

Page 51: ...TP 6727 10 11 51 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 3 Dimension Drawing ADV 7692 Sheet 2 Generator Set...

Page 52: ...TP 6727 10 11 52 Section 7 Dimension Drawings Note Dimensions are in mm in 05 14 2010 Controlled Document Figure 7 4 Dimension Drawing ADV 7693 Accessories...

Page 53: ...TP 6727 10 11 53 Section 7 Dimension Drawings ADV 7695 Note Dimensions are in mm in Figure 7 5 Dimension Drawing ADV 7695 Sheet 1 Weather Enclosure and Weather Enclosure with Sound Kit...

Page 54: ...TP 6727 10 11 54 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 6 Dimension Drawing ADV 7695 Sheet 2 Sound Enclosure...

Page 55: ...TP 6727 10 11 55 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 7 Dimension Drawing ADV 7695 Sheet 3 Dropover Sound Enclosure...

Page 56: ...TP 6727 10 11 56 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 8 ADV 7695 Sheet 4 150 MPH High Wind Mounting Details...

Page 57: ...TP 6727 10 11 57 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 9 Dimension Drawing ADV 8159 Sheet 1 Generator Set with Customer Connection Box...

Page 58: ...TP 6727 10 11 58 Section 7 Dimension Drawings Note Dimensions are in mm in Figure 7 10 Dimension Drawing ADV 8159 Sheet 2 Generator Set with Customer Connection Box...

Page 59: ...ies 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 decibel A weighted DC direct current DCR direct current resis...

Page 60: ...C Phillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per millio...

Page 61: ...s Physical Properties Characteristic LP Gas Butane Propane Formula C4H10 C3H8 Boiling point C F 0 32 42 44 Specific gravity of gas air 1 00 2 00 1 53 Specific gravity of liquid water 1 00 0 58 0 51 Bt...

Page 62: ...1 41 kg cm2 20 psi 0 kg cm2 0 psi 40 C 40 F 28 C 20 F 18 C 0 F 7 C 20 F 4 C 40 F 15 C 60 F 27 C 80 F 38 C 100 F Figure 1 Heat Rejection to Ambient Air Temperature C F Approximate Pressure PSIG Propan...

Page 63: ...141000 30 45000 66000 85000 107000 118000 20 36000 51000 68000 83000 92000 10 28000 38000 49000 60000 66000 Figure 1 Vaporization Rate 100 lb Propane Cylinders Approximate Determining Propane Vaporiz...

Page 64: ...TP 6727 10 11 64 Notes...

Page 65: ...TP 6727 10 11 65 Notes...

Page 66: ...TP 6727 10 11 66 Notes...

Page 67: ......

Page 68: ...he 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 6...

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