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Kohler 15RYG, Installation Manual

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Commercial Generator Sets

Models:

15/30RYG

TP-6329 8/07c

Installation

Summary of Contents for 15RYG

Page 1: ...Commercial Generator Sets Models 15 30RYG TP 6329 8 07c 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: ...n optional 14 1 8 9 Automatic Transfer Switches 14 Section 2 Open Units 15 2 1 Introduction 15 2 2 Air and Cooling 16 2 2 1 Installation Considerations 16 2 2 2 Cooling Air Requirements 17 2 3 Exhaust...

Page 4: ...C 2100 35 5 2 Controller Automatic Power Down 35 5 3 Controller Configuration 35 5 4 Voltage Adjustments 39 Section 6 Generator Reconnection 43 6 1 Voltage Reconnection 43 6 2 Four Lead Single Phase G...

Page 5: ...ttery 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 aut...

Page 6: ...or 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 operatio...

Page 7: ...ectrocution 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: ...ere 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...

Page 9: ...al Keep this manual with the equipment for future reference List of Related Materials Figure 1 identifies related literature available for the generator sets covered in this manual Only trained and qu...

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: ...rations 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 t...

Page 12: ...ctions Rigid mount the piping but protect it from vibration Use flexible connections spanning a minimum of 152 mm 6 in between the stationary piping and the engine fuel inlet connection 1 8 Electrical...

Page 13: ...l and local codes when installing a wiring system Wire Size for Unit Connection Tightening Torque Nm in lb Slot Head 4 7 mm No 10 or Larger Hexagonal Head External Drive Socket Wrench AWG kcmil mm2 Sl...

Page 14: ...s usually sufficient to maintain a full charge on the batteries Select an automatic float equalize battery charger with a 3 amp or greater rating Use separate self contained battery chargers or units...

Page 15: ...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 16: ...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 17: ...rheating 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 noise...

Page 18: ...ss 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 compen...

Page 19: ...imbles 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 constructio...

Page 20: ...s 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 en...

Page 21: ...in 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...

Page 22: ...00005 0 00001 in Hg x 3 387 kPa in x 25 4 mm 10 33 5 15 1 04 0 52 0 09 0 05 0 01 0 005 0 001 0 0005 0 0001 1000 900 800 700 600 500 400 300 250 200 150 100 90 80 70 60 50 40 28 3 25 5 22 7 19 8 17 0 1...

Page 23: ...nstall carbon monoxide CO detector s on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Read and follow the safety precau...

Page 24: ...stallations Open Units Maintain a minimum of 457 mm 18 in between the generator set and any adjacent walls or obstructions to allow access for maintenance and service See Figure 2 1 for a typical open...

Page 25: ...Ground the generator set The grounding method must comply with NEC and local codes Connect the grounding strap to the generator set ground lug terminal GRD inside the controller compartment See Figur...

Page 26: ...tomer interface connector Optional Five Relay Interface Board RIB The optional relay interface board RIB has 5 relays and a customer connection harness The standard RIB has 3 relays with no customer c...

Page 27: ...negative battery terminal 8 Place the boots over the battery terminals 9 Plug the battery heater and battery charger if equipped into the 120 VAC power supply 3 8 Install and Connect Fuel Supply Explo...

Page 28: ...to within 10 inches of the generator set fuel inlet location See Figure 3 8 Maximum Pipe Length m ft Pipe Size 15RYG 30RYG 6 1 20 3 4 in NPT 1 1 4 in NPT 9 1 30 1 in NPT 1 1 4 in NPT 18 3 60 1 in NPT...

Page 29: ...To operate the generator set on natural gas install the spring and rotate the regulator to point up LP Fuel Conversion Procedure Use the following steps to set the fuel system for LP gas 1 Remove the...

Page 30: ...unning at rated load use a UEGO oxygen sensor to check and adjust the fuel mixture Follow the instructions in Section 3 8 2 3 8 2 Fuel System Adjustment Procedures Hot engine and exhaust system Can ca...

Page 31: ...ain a no load oxygen sensor voltage reading of 2 5 0 10 VDC 15 Repeat steps 11 through 14 to verify the settings 16 Place the generator set master switch in the OFF position to stop generator set 17 D...

Page 32: ...TP 6329 8 07 32 Section 3 Installation Instructions Notes...

Page 33: ...4 304 8 1000 10 Figure 4 1 Wire Length and Size Lead N and 42B See Section 7 Diagrams and Drawings for more information regarding generator set electrical connections The following sections detail a f...

Page 34: ...er to TT 1285 Program Loader Instructions for instructions to load the latest version of the controller application code if necessary 1 2 3 1 SELECT button 2 UP arrow button 3 DOWN arrow button Figure...

Page 35: ...remote CAN gauge 5 3 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes The controller s configuration mode a...

Page 36: ...Three phase 4 Wire Wye Uu04 277 480 60 Three phase 4 Wire Wye Uu07 110 220 50 Single phase 3 Wire 1 PH Uu10 120 240 60 Three phase 4 Wire Delta Uu10 139 240 60 Three phase 4 Wire Wye Uu11 120 208 60...

Page 37: ...pe to Ec03 OR Ec06 if necessary See Figure 5 1 U u X X U c 0 1 U u 0 1 1 0 4 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 the...

Page 38: ...to the 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 ch...

Page 39: ...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 40: ...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 41: ...n 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 pres...

Page 42: ...TP 6329 8 07 42 Section 5 Controller Notes...

Page 43: ...ator 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...

Page 44: ...pment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage Reconnection Procedure 1 Place the generator set master...

Page 45: ...45 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 46: ...TP 6329 8 07 46 Section 6 Generator Reconnection Notes...

Page 47: ...rams refer to TP 6347 Wiring Diagram Manual Dimension Drawing Description Drawing Number Page Generator Set ADV 6916A E 48 Exhaust and Duct Flange ADV 6916B E 49 Weather Housing ADV 6916C E 50 Sound U...

Page 48: ...TP 6329 8 07 48 Section 7 Dimension Drawings ADV 6916A E Note Dimensions are in mm in Figure 7 2 Dimension Drawing ADV 6916A E Sheet 1 Generator Set...

Page 49: ...TP 6329 8 07 49 Section 7 Dimension Drawings ADV 6916B E Note Dimensions are in mm in Figure 7 3 Dimension Drawing ADV 6916B E Sheet 2 Exhaust Options and Duct Flange...

Page 50: ...TP 6329 8 07 50 Section 7 Dimension Drawings ADV 6916C E Note Dimensions are in mm in Figure 7 4 Dimension Drawing ADV 6916C E Sheet 3 Weather Housing...

Page 51: ...TP 6329 8 07 51 Section 7 Dimension Drawings ADV 6916D E Note Dimensions are in mm in Figure 7 5 Dimension Drawing ADV 6916D E Sheet 4 Weather Housing with Sound Upfit Kit...

Page 52: ...TP 6329 8 07 52 Section 7 Dimension Drawings ADV 6916E E Note Dimensions are in mm in Figure 7 6 Dimension Drawing ADV 6916E E Sheet 5 Sound Enclosure...

Page 53: ...TP 6329 8 07 53 Section 7 Dimension Drawings ADV 6916F E Note Dimensions are in mm in Figure 7 7 Dimension Drawing ADV 6916F E Sheet 6 Drop Over Sound Housing...

Page 54: ...TP 6329 8 07 54 Section 7 Dimension Drawings ADV 6916G E Note Dimensions are in mm in 150MPH HIGH WIND MOUNTING DETAIL Figure 7 8 Dimension Drawing ADV 6916G E Sheet 7 High Wind Mounting Detail...

Page 55: ...riter 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 deci...

Page 56: ...oversize 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 P...

Page 57: ...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 Btu...

Page 58: ...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 59: ...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 60: ...TPMPFP 6329 8 07 60 Notes...

Page 61: ...TPMPFP 6329 8 07 61 Notes...

Page 62: ...TPMPFP 6329 8 07 62 Notes...

Page 63: ......

Page 64: ...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 65 626...

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