Kohler 20-2800 kW Installation Manual Download Page 1

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Industrial/Commercial/Residential

Generator Sets

Models:

20--2800 kW

TP-5700 7/93d

Installation

Summary of Contents for 20-2800 kW

Page 1: ...Industrial Commercial Residential Generator Sets Models 20 2800 kW TP 5700 7 93d Installation ...

Page 2: ...ces 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 Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identificati...

Page 3: ... Vent 15 4 6 Liquid Cooled Models 16 4 7 Unit Mounted Radiator Cooling 16 4 8 Remote Radiator Cooling 17 4 9 City Water Cooling 18 4 10 Cooling Tower 18 4 11 Block Heaters 20 4 12 Recommended Coolant 20 Section 5 Exhaust System 21 5 1 Flexible Section 22 5 2 Condensation Trap 22 5 3 Piping 22 5 4 Double Sleeve Thimbles 23 Section 6 Fuel Systems 25 6 1 Diesel Fuel Systems 25 6 2 Main Fuel Tank 26 6...

Page 4: ...35 7 2 Electrical Connections 36 7 3 Load Lead Connections 36 7 4 Terminal Connector Torque 37 7 5 Automatic Transfer Switches 38 7 6 Control Connections 38 7 7 Remote Annunciator 38 7 8 Audiovisual Alarm 38 7 9 Remote Emergency Stop Switch 39 7 10 Dry Contact Kit 39 7 11 Wiring 39 Appendix A Abbreviations A 1 ...

Page 5: ...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 transfer switch remote start stop switch or engine start command from a remote computer Battery Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid m...

Page 6: ...tubing in diesel exhaust systems Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust leakage Generator set operation Carbon monoxide can cause severenausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathingexhaustfumeswhenworking on or near...

Page 7: ...nks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with th...

Page 8: ...rcuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outl...

Page 9: ...ol Then loosen the pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Checking the coolant level Hot coolant c...

Page 10: ...event rounding of the bolt heads and nuts NOTICE Hardware damage The transfer switch may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses...

Page 11: ...ellow Pages under the heading Generators Electric D Visit the Kohler Power Systems website at KohlerPowerSystems com D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product D Call toll free in the US and Canada 1 800 544 2444 D Outside the US and Canada call the nearest regional office Africa Europe Middle East London Reg...

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Page 13: ... Association NFPA and Underwriter s Laboratories Inc UL D NFPA 54 National Fuel Gas Code D NFPA 70 National Electrical Coder the National Electrical Code is a registered trademark of the NFPA D NFPA 99 Standard for Health Care Facilities D NFPA 101 Life Safety Code D NFPA 110 Emergency and Standby Power Systems D UL 486A The Standard for Wire Connectors and Soldering Lugs for Use with Copper Condu...

Page 14: ...all 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 Water trap with drain 10 Fresh air intake 1 2 3 4 5 6 7 8 9 10 Figure 1 1 Typical Stationary Duty Generator Set Installation ...

Page 15: ...the framework of these guidelines Obviously prepackaged crated sets may be exempt from certain aspects of this section Prepackaged generators generally are loaded in their containers with the aid of lift trucks 2 1 Lifting the Generator Set D Do not lift the generator set by the lifting eyes attached to the engine and or alternator These lifting eyes are only used during generator assembly and are...

Page 16: ... the bars See Figure 2 1 Be sure the bars are properly sized for the weight of the generator set Precautions must be taken to prevent the lifting hooks from sliding off the ends of the bars Spreader bars may be necessary with this arrangement if lifting cables are in contact with the set A specially designed lifting fixture is often used to lift the larger standby generators The fixture usually in...

Page 17: ...subbase fuel tank otherwise use chains or cables to lift the subbase fuel tank If using lifting straps protect the strap from sharp fuel tank edges Lift the generator set up to 400 kW and subbase fuel tank together provided the fuel tank is empty and the subbase fuel tank does not extend beyond the perimeter of the generator set skid In all other cases remove the mounting hardware and wiring betwe...

Page 18: ...TP 5700 7 93 6 Section 2 Load and Transport Notes ...

Page 19: ...uel be available to sustain operation during emergencies 8 Will fuel tank location be within the vertical lift capabilities of the fuel pump The location of the generator set must D Meet applicable fire rating codes and standards D Position the generator set over a noncombustible surface If the mounting surface directly under or near the generator set is porous or deteriorates from exposure to eng...

Page 20: ...t shown in Figure 3 4 has the advantage of providing more working room under the engine without raising the engine or generator set off its mountings With either arrangement the mounting pad should extend six inches 15 cm beyond the mounting base dimensions When using the double pedestal arrangement the pedestals should extend at least six inches 15 cm back from the location of the front engine mo...

Page 21: ...solators between the engine generator and skid or spring type mounts between the skid and mounting pad An advantage of factory installed mounts between the engine generator and the skid is that engine generator alignment is not affected by stress induced in handling shipment or mounting on an uneven surface A less rigid skid may be used reducing weight and installation time All connections between...

Page 22: ...TP 5700 7 93 10 Section 3 Location Notes ...

Page 23: ...ngs In certain cold climate applications controlled recirculation may be used as a means of heat recovery however special equipment such as thermostatically activated louvers and fans are needed to prevent engine and engine room overheating The uncontrolled recirculation of heated air within an enclosure must be prevented Otherwise the temperature in the enclosure quickly rises to a point where ef...

Page 24: ...of the opening should be increased approximately 50 2 If window screening is used the opening should be increased approximately 80 3 If furnace filters are used the opening should be increased 120 4 2 Air Cooled Generators Air cooled generator sets are available with three basic types of air cooling systems that are discussed separately on the following pages For air cooled models 4 kW and smaller...

Page 25: ... 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 TP 5700 4 2 3 4 5 1 1 Air oulet 2 Air inlet opening 3 Blower housing 4 Cooling air inlet 5 Heated air outlet Figure 4 5 Standard Forced Air Coolin...

Page 26: ...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 The heated air is forced through ductwork to the outside of the building See Figure 4 6 Note Order Air Vac cooling systems factory installed since major components of the engine are affected making it difficult and uneconomical to install at a later ti...

Page 27: ...tional ductwork connects to the engine ductwork carrying the heated air outside For duct dimensions refer to the dimensional drawing for the particular unit This system is also efficient in maintaining consistent operating temperatures in confined areas See Figure 4 7 Note Air vent requires very little engine modification making it practical for field installation TP 5700 4 1 2 3 4 5 6 1 Ductwork ...

Page 28: ...ooling surface as shown in Figure 4 8 Cooling air flow can be reversed by using a suction fan but this is generally not recommended because it may interfere with generator cooling air flow which moves in the same direction as the engine s standard pusher fan Also a suction fan would result in higher temperature combustion air being drawn into the air cleaner reducing the maximum engine power avail...

Page 29: ...hat pressure inside the building is reduced Low pressure can cause pilot lights on gas fired appliances to be extinguished or problems with the building ventilation system Bringing large quantities of winter air into a building can waste building heat and even result in frozen water pipes in normally heated spaces An arrangement as shown in Figure 4 9 using thermostatic controls can eliminate such...

Page 30: ...ater Cooling These systems utilizes city water and heat exchangers for cooling and are similar to remote radiator systems in that they require less cooling air than unit mounted radiator systems Refer to Figure 4 11 for a view of some of the elements of a typical installation The heat exchanger the effects of city water lime deposits corrosion to one side of a heat exchanger which is relatively ea...

Page 31: ...r in 3 Flexible section 4 Manual shutoff valve 5 Heated water into drain 6 Solenoid valve 7 Heat Exchanger Figure 4 11 Installation Using City Water Cooling System with Heat Exchanger 1 2 3 4 5 6 1 Engine water pump 2 Surge tank 3 Cooling tower 4 Drain 5 Heat exchanger 6 Auxiliary water pump 4 Figure 4 12 Cooling Tower System ...

Page 32: ...eater failure will result Unplug block heater prior to draining cooling system 4 12 Recommended Coolant Antifreeze coolant protection will be required for most applications This must be performed prior to startup of generator set and energizing block heater s A solution of 50 ethylene glycol and 50 clean softened water is recommended to provide freezing protection to 34 F 37 C and boiling protecti...

Page 33: ...orrect silencer design Figure 5 1 and Figure 5 2 show the general arrangement of recommended exhaust systems 1 3 2 4 5 6 7 8 TP 5700 5 1 Supports 2 Pitch line downward 3 Muffler 4 Water trap 5 Drain petcock 6 Flexible section 7 Solid section 6 8 in 152 203 mm 8 Manifold Figure 5 1 Exhaust System End Inlet Silencer Exhaust lines should be as short and straight as possible Schedule 40 black iron pip...

Page 34: ...and exhaust silencer as shown in Figure 5 3 This will prevent condensed moisture in the engine exhaust from draining into the engine when it is shut down The trap should be drained of collected moisture periodically 1 TP 5700 5 1 Condensation trap Figure 5 3 Condensation Trap 5 3 Piping Exhaust piping should conform to all applicable codes In general exhaust temperatures will be less than 1000 F 5...

Page 35: ...enough so that it doesn t impair air circulation through the thimble If the exhaust pipe must exit through a roof a rain shield must be included above the thimble as shown in Figure 5 4 The rain cap as shown on the end of the exhaust pipe is recommended only in areas not subject to freezing temperatures In an area where freezing is common extend the exhaust piping well beyond the roof and use a gr...

Page 36: ...TP 5700 7 93 24 Section 5 Exhaust System Notes ...

Page 37: ...ounted 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 Fuel filters and sediment drains must be easily accessible for regular and frequent service Cleanliness of the fuel is especially important on diesel engines which have easily clogged precision fuel injectors and pumps Black iron pipe or steel tubing must be used for...

Page 38: ...equirements a tank sized for eight hours operation at rated load is suggested Refer to the specification sheet for fuel consumption data Most diesel engines will operate satisfactorily on 2 domestic burner oil as furnished in most parts of the United States The engine can be supplied from the same tank used for heating oil if both use the same fuel This is desirable both because of the cost saving...

Page 39: ...failure by means of a quantity of fuel stored in a tank adjacent to the engine This allows the engine fuel transfer pump to easily draw fuel when starting and provides a convenient location to connect injector return lines Standard tanks are available in sizes from 5 275 gallons 19 1040 L with or without integral electric fuel transfer pumps They can also be provided with fuel level gauges manual ...

Page 40: ... driven positive displacement pump should be used with a transfer tank and float switch The power supply for the pump should always be from the load side of the transfer switch for maximum reliability Such pumps typically are capable of lifting fuel 18 feet 5 5 m or drawing it horizontally up to 200 feet 61 m Where vertical or horizontal runs exceed these limits the pump should be remote mounted a...

Page 41: ... be Schedule 40 black iron pipe steel tubing or copper tubing Galvanized pipe and fittings are not recommended Line size should be kept to the minimum necessary for the required flow TP 5700 6 1 Fuel tank 2 Fuel pump 3 Gasoline shutoff 4 Gasoline carburetor 1 2 3 4 Figure 6 4 Gasoline Fuel System Flexible connections at least six inches 15 3 cm in length should be used between stationary piping an...

Page 42: ...oline Figure 6 11 The engine mounted components of all these systems are similar and usually include a carburetor secondary gas regulator electric gas fuel solenoid shutoff valve and flexible fuel connector 1 2 3 4 5 1 Primary regulator supplied by gas supplier or customer 2 Pressure gauge 3 Solenoid valve 4 Secondary regulator 5 Carburetor Figure 6 5 LP Gas Vapor Fuel System 1 2 3 4 5 1 Carbureto...

Page 43: ... 5 TP 5700 6 1 Carburetor 2 Load adjustment valve 3 Secondary regulator 4 Solenoid valve 5 LP gas supply 6 Natural gas supply 7 Low pressure switch Figure 6 9 Natural Gas and LP Gas System Vapor Withdrawal 1 2 3 4 5 TP 5700 6 1 Primary regulator supplied by gas supplier or installer 2 Pressure gauge 3 Solenoid valve 4 Secondary regulator 5 Carburetor Figure 6 10 Natural Gas Fuel System 8 1 2 3 4 T...

Page 44: ...g upward for use with natural gas only Two regulators are used in the typical gaseous fuel system D Primary Regulator This regulator provides initial control of the gas from the fuel supply The primary regulator reduces line pressures to allowable inlet pressures for the secondary regulators on the system This regulator would drop high pressure from a tank or transmission line to a low pressure ty...

Page 45: ...ximately 18 psi 124 kPa Some primary regulators will not operate if tank pressure drops below 30 psi 207 kPa while others operate at incoming pressures as low as to 3 5 psi 20 7 34 5 kPa The fuel mixture and its vaporization pressure at the anticipated temperatures influence the selection of regulatory equipment The components of the vapor withdrawal system used in a typical stationary application...

Page 46: ...se only fuel line approved for gas fuels See Figure 6 10 6 16 Combination Gas Gasoline Most engines especially the smaller models will operate successfully on gas or gasoline without extensive modification or complicated mechanical changeover With a combination gas gasoline fuel system changeover involves only a few simple steps These systems normally utilize a gaseous fuel as the primary fuel wit...

Page 47: ...ecial charging requirements Conventional lead acid batteries have proven satisfactory for the majority of generator set applications Batteries are charged by engine driven battery charging alternators whenever the generator set operates These systems are normally capable of charge rates of 30 amperes or more and can restore the charge used in a normal cranking cycle within a short period of operat...

Page 48: ...G 4 90_C 194_F Use No AWG 90_C wire Use 90_C wire either No AWG Cu or No AWG Al Use 90_C wire No AWG The wire size for 60_C 140_F wire is not required to be included in the marking If included the wire size is based on ampacities for the wire given in Table 310 16 of the National Electrical Coder in ANSI NFPA 70 and on 115 of the maximum current that the circuit carries under rated conditions The ...

Page 49: ...0 31 1 275 16 9 150 1 0 2 0 53 5 67 4 5 6 50 43 5 385 20 3 180 3 0 4 0 85 0 107 2 5 6 50 56 5 500 28 2 250 250 350 127 177 5 6 50 73 4 650 36 7 325 400 203 5 6 50 93 2 825 36 7 325 500 253 5 6 50 93 2 825 42 4 375 600 750 304 380 5 6 50 113 0 1000 42 4 375 800 1000 406 508 5 6 50 124 3 1100 56 5 500 1250 2000 635 1016 124 3 1100 67 8 600 For values of slot width or length not corresponding to thos...

Page 50: ...quipment that will have to be connected to other components in the system These accessories will enable the generator set to meet standards for local and national codes or specific requirements of the customer s installation A few of the more common accessories and their functions are listed on the following pages 7 7 Remote Annunciator The remote annunciator allows monitoring of the standby power...

Page 51: ...Kit The dry contact kit allows monitoring of the standby system and or the ability to activate accessories from a remote location Customer provided warning devices lamps horns etc can be connected to any of the generator controller s alarm indication outputs allowing the user to customize an alarm system to their needs 7 11 Wiring Connections between the components of a standby generator system di...

Page 52: ...ERY POSITIVE ENGINE CONNECTION OPTIONAL EQUIPMENT CUSTOMER ACCESSORIES 3 WIRES MAX 18 20 GA MUST BE MOUNTED AT GENERATOR 3 WIRES 18 20 GA 200 FT MAX 3 WIRES 18 20 GA GENERATOR BATTERY NEGATIVE POSITIVE CONNECTION 2 WIRES 14 GA SEE NOTE 2 1 WIRE 18 20 GA 2 WIRES 18 20 GA CUSTOMER ACCESSORIES 30 WIRES MAX 18 GA GENERATOR BATTERY NEGATIVE CONNEC TION GENERATOR BATTERY POSITIVE CONNECTION SEE NOTE 1 A...

Page 53: ...ooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double pole double throw DPST double pole single throw DS disconnect ...

Page 54: ...nal OS 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 Phillips head crimptite screw PHH Phillips hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per milli...

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Page 56: ...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 Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455 ...

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