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TP-7045 3/18c

78 Appendix

Appendix B Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp

ampere

ABDC

after bottom dead center

AC

alternating current

A/D

analog to digital

ADC

analog to digital converter

adj.

adjust, adjustment

ADV

advertising dimensional

drawing

AHWT

anticipatory high water

temperature

AISI

American Iron and Steel

Institute

ALOP

anticipatory low oil pressure

alt.

alternator

Al

aluminum

ANSI

American National Standards

Institute

(formerly American Standards

Association, ASA)

AO

anticipatory only

API

American Petroleum Institute

approx.

approximate, approximately

AR

as required, as requested

AS

as supplied, as stated, as

suggested

ASE

American Society of Engineers

ASME

American Society of

Mechanical Engineers

assy.

assembly

ASTM

American Society for Testing

Materials

ATDC

after top dead center

ATS

automatic transfer switch

auto.

automatic

aux.

auxiliary

A / V

audiovisual

avg.

average

AVR

automatic voltage regulator

AWG

American Wire Gauge

AWM

appliance wiring material

bat.

battery

BBDC

before bottom dead center

BC

battery charger, battery

charging

BCA

battery charging alternator

BCI

Battery Council International

BDC

before dead center

BHP

brake horsepower

blk.

black (paint color), block

(engine)

blk. htr.

block heater

BMEP

brake mean effective pressure

bps

bits per second

br.

brass

BTDC

before top dead center

Btu

British thermal unit

Btu/min.

British thermal units per minute

C

Celsius, centigrade

cal.

calorie

CARB

California Air Resources Board

CB

circuit breaker

cc

cubic centimeter

CCA

cold cranking amps

ccw.

counterclockwise

CEC

Canadian Electrical Code

cfh

cubic feet per hour

cfm

cubic feet per minute

CG

center of gravity

CID

cubic inch displacement

CL

centerline

cm

centimeter

CMOS

complementary metal oxide

substrate (semiconductor)

cogen.

cogeneration

Com

communications (port)

conn.

connection

cont.

continued

CPVC

chlorinated polyvinyl chloride

crit.

critical

CRT

cathode ray tube

CSA

Canadian Standards

Association

CT

current transformer

Cu

copper

cu. in.

cubic inch

cw.

clockwise

CWC

city water-cooled

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 switch

DVR

digital voltage regulator

E, emer.

emergency (power source)

EDI

electronic data interchange

EFR

emergency frequency relay

e.g.

for example (

exempli gratia)

EG

electronic governor

EGSA

Electrical Generating Systems

Association

EIA

Electronic Industries

Association

EI/EO

end inlet/end outlet

EMI

electromagnetic interference

emiss.

emission

eng.

engine

EPA

Environmental Protection

Agency

EPS

emergency power system

ER

emergency relay

ES

engineering special,

engineered special

ESD

electrostatic discharge

est.

estimated

E-Stop

emergency stop

etc.

et cetera (and so forth)

exh.

exhaust

ext.

external

F

Fahrenheit, female

fglass.

fiberglass

FHM

flat head machine (screw)

fl. oz.

fluid ounce

flex.

flexible

freq.

frequency

FS

full scale

ft.

foot, feet

ft. lbs.

foot pounds (torque)

ft./min.

feet per minute

g

gram

ga.

gauge (meters, wire size)

gal.

gallon

gen.

generator

genset

generator set

GFI

ground fault interrupter

GND,

ground

gov.

governor

gph

gallons per hour

gpm

gallons per minute

gr.

grade, gross

GRD

equipment ground

gr. wt.

gross weight

H x W x D height by width by depth
HC

hex cap

HCHT

high cylinder head temperature

HD

heavy duty

HET

high exhaust temperature

hex

hexagon

Hg

mercury (element)

HH

hex head

HHC

hex head cap

HP

horsepower

hr.

hour

HS

heat shrink

hsg.

housing

HVAC

heating, ventilation, and air

conditioning

HWT

high water temperature

Hz

hertz (cycles per second)

IC

integrated circuit

ID

inside diameter, identification

IEC

International Electrotechnical

Commission

IEEE

Institute of Electrical and

Electronics Engineers

IMS

improved motor starting

in.

inch

in. H

2

O

inches of water

in. Hg

inches of mercury

in. lbs.

inch pounds

Inc.

incorporated

ind.

industrial

int.

internal

int./ext.

internal/external

I/O

input/output

IP

iron pipe

ISO

International Organization for

Standardization

J

joule

JIS

Japanese Industry Standard

k

kilo (1000)

K

kelvin

kA

kiloampere

KB

kilobyte (2

10

bytes)

Содержание 12EFKOZD

Страница 1: ...Marine Generator Sets TP 7045 3 18c Installation Models 14 16 21 24 32 40EKOZD 12 13 5 17 18 20 5 28 35EFKOZD Controller Decision Makerr 3500...

Страница 2: ...TP 7045 3 18c 2...

Страница 3: ...ing and Installation 18 4 3 1 Above Waterline Installation 19 4 3 2 Mid Below Waterline Installation 20 Section 5 Fuel System 25 5 1 Fuel Tank 25 5 2 Fuel Lines 26 5 2 1 Fuel Line Selection and Applic...

Страница 4: ...reaker Does Not Close to Bus 63 9 4 1 Faults Not Shown 63 9 4 2 Faults Shown 64 9 5 Troubleshooting When Breaker Does Close to Bus 66 9 5 1 Faults Shown 66 9 6 Troubleshooting When Running in AUTO 70...

Страница 5: ...ath Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect th...

Страница 6: ...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 equip...

Страница 7: ...h to prevent interconnection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current will cause severe injury or death Have trained and qualified perso...

Страница 8: ...TP 7045 3 18c 8 Safety Precautions and Instructions Notes...

Страница 9: ...anning your installation Use current dimension drawings and wiring diagrams 1 2 5 6 3 7 8 9 11 12 14 10 15 16 17 18 ADV8558 1 Exhaust mixer elbow exhaust water outlet non service side 2 Heat exchanger...

Страница 10: ...p Note If the personality disk is NOT available request a replacement from Kohler Co using the generator set serial number or order number D User parameters unique to an installation include timer val...

Страница 11: ...ent is often the ideal location for the generator set if the propulsion engine s does not obstruct access to the generator set and controller Allow clearance for vibration and cooling during operation...

Страница 12: ...TP 7045 3 18c 12 Section 2 Location Lifting and Mounting Notes...

Страница 13: ...or allowable intake restriction Note ISO 3046 derates apply See Appendix C Model Allowable Intake Restriction kPa in H2O 14EKOZD 1 and 3 Phase 16EKOZD 1 and 3 Phase 2 4 9 6 12EFKOZD 1 and 3 Phase 13 5...

Страница 14: ...tconfigurationappliespositivepressuresimilar to a scoop type through hull strainer 3 2 2 Seacock Mount the seacock to the hull assemble it to the intake and ensure that it is accessible for operation...

Страница 15: ...of its connection to the flexible section Keep the seawater hose as straight and short as possible If the hose is too long usually over 4 6 m 15 ft water suction problems may occur See Section 7 for t...

Страница 16: ...water Freshwater Coolant Antifreeze 1 2 8 10 9 11 12 7 6 5 4 3 1 Engine block 2 Thermostat 3 Engine driven water pump 4 Engine driven seawater pump 5 Seawater strainer customer supplied 6 Seacock cust...

Страница 17: ...carbon monoxide detector Inspect the detector before each generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating th...

Страница 18: ...rd A lift in the exhaust piping before the piping exits the craft prevents backwash See Figure 4 3 item 1 Support the exhaust lines to prevent the formation of water pockets Exhaust system installatio...

Страница 19: ...anger locations vary by model 6 Coolant recovery tank located on the unit on some models 7 Maximum seawater pump lift of 1 m 3 ft 8 Seawater strainer 9 Seacock 10 Intake strainer 11 Engine driven seaw...

Страница 20: ...the siphon break s cap is tight before operating the generator set 1 Heat exchanger located inside the manifold 2 Exhaust mixer 3 Cut hose and connect siphon break and hardware rotate the fitting on...

Страница 21: ...of 1 3 cm per 30 5 cm 0 5 in per ft 16 Maximum distance between silencer and exhaust mixer elbow of 3 m 10 ft 17 Maximum distance between silencer and exhaust outlet of 1 5 m 5 ft 18 Silencer custome...

Страница 22: ...tween silencer and exhaust mixer elbow of 3 m 10 ft 17 Maximum distance between silencer and exhaust outlet of 1 5 m 5 ft 18 Silencer customer supplied 19 Minimum exhaust hose pitch of 1 3 cm per 30 5...

Страница 23: ...in outlet from silencer must be equal to or greater than water drain item 17 to be greater than 30 5 cm 1 ft 20 Exhaust outlet to be diameter appropriate so exhaust back pressure does not exceed limit...

Страница 24: ...TP 7045 3 18c 24 Section 4 Exhaust System Notes...

Страница 25: ...rine generator sets drawfuel fromthe same fuel tank as the craft s propulsion engine s If the tank s fuel pickup opening allows a multiple dip tube use a multiple dip tube arrangement See Figure 5 1 T...

Страница 26: ...failure or hard starting of the generator set The dip tube depth should be at least as deep as the main engine fuel pick up dip tube Under no circumstances should the propulsion engine and generator s...

Страница 27: ...ilure Use of such materials may affect fuel system warranty Note The KDI TCR engines require that the above metals are not present in the fuel system components 5 3 Fuel Filters Conform to USCG Regula...

Страница 28: ...TP 7045 3 18c 28 Section 5 Fuel System Notes...

Страница 29: ...r at sea The wiring then connects to a main circuit breaker box panel board that distributes branch circuits throughout the craft See Section 8 for reconnection of the generator set 6 2 Circuit Protec...

Страница 30: ...ct electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can...

Страница 31: ...able ties as necessary to protect and secure wiring from sharp objects the exhaust system and any moving parts 8 Attach the new panel to the junction box using the original six screws 9 Check that the...

Страница 32: ...ore information The scope of these topics is too extensive to be fully discussed here Consult your local marine authority for more information Before installing the generator set check the available w...

Страница 33: ...he spec requires to start the generator See Figure 6 4 for minimum cold cranking amps CCA recommendations 12 Volt Starting Battery Size CCA at 15 C 5 F or 100 Amp Hr Models CCA 14EKOZD 12EFKOZD 1 and...

Страница 34: ...TP 7045 3 18c 34 Section 6 Electrical System Notes...

Страница 35: ...gure 7 1 for installation drawing identification Model No Drawing Page 14EKOZD 12EFKOZD 16EKOZD 13 5EFKOZD 1 and 3 phase ADV 8880A ADV 8880B 36 37 with sound shield ADV 8881A A ADV 8881B A 40 41 acces...

Страница 36: ...TP 7045 3 18c 36 Section 7 Installation Drawings ADV 8880A NOTE Dimensions are shown in mm in Figure 7 2 Dimension Drawing 14 16EKOZD and 12 13 5EFKOZD Sheet 1 of 2...

Страница 37: ...TP 7045 3 18c 37 Section 7 Installation Drawings ADV 8880B NOTE Dimensions are shown in mm in Figure 7 3 Dimension Drawing 14 16EKOZD and 12 13 5EFKOZD Sheet 2 of 2...

Страница 38: ...TP 7045 3 18c 38 Section 7 Installation Drawings ADV 8883A NOTE Dimensions are shown in mm in Figure 7 4 Dimension Drawing 21 24EKOZD and 17 20 5EFKOZD Sheet 1 of 2...

Страница 39: ...TP 7045 3 18c 39 Section 7 Installation Drawings ADV 8883B NOTE Dimensions are shown in mm in Figure 7 5 Dimension Drawing 21 24EKOZD and 17 20 5EFKOZD Sheet 2 of 2...

Страница 40: ...TP 7045 3 18c 40 Section 7 Installation Drawings ADV 8881A A NOTE Dimensions are shown in mm in Figure 7 6 Dimension Drawing Sound Shield 14 24EKOZD and 12 20 5EFKOZD Sheet 1 of 2...

Страница 41: ...TP 7045 3 18c 41 Section 7 Installation Drawings ADV 8881B A NOTE Dimensions are shown in mm in Figure 7 7 Dimension Drawing Sound Shield 14 24EKOZD and 12 20 5EFKOZD Sheet 2 of 2...

Страница 42: ...TP 7045 3 18c 42 Section 7 Installation Drawings ADV 8882A NOTE Dimensions are shown in mm in Figure 7 8 Dimension Drawing Accessories 14 24EKOZD and 12 20 5EFKOZD Sheet 1 of 2...

Страница 43: ...TP 7045 3 18c 43 Section 7 Installation Drawings ADV 8882B NOTE Dimensions are shown in mm in Figure 7 9 Dimension Drawing Accessories 14 24EKOZD and 12 20 5EFKOZD Sheet 2 of 2...

Страница 44: ...TP 7045 3 18c 44 Section 7 Installation Drawings ADV 8857A B NOTE Dimensions are shown in mm in Figure 7 10 Dimension Drawing 32 40EKOZD and 28 35EFKOZD Sheet 1 of 2...

Страница 45: ...TP 7045 3 18c 45 Section 7 Installation Drawings ADV 8857B B NOTE Dimensions are shown in mm in Figure 7 11 Dimension Drawing 32 40EKOZD and 28 35EFKOZD Sheet 2 of 2...

Страница 46: ...TP 7045 3 18c 46 Section 7 Installation Drawings ADV 8858 B NOTE Dimensions are shown in mm in Figure 7 12 Dimension Drawing Sound Shield 32 40EKOZD and 28 35EFKOZD Sheet 1 of 2...

Страница 47: ...TP 7045 3 18c 47 Section 7 Installation Drawings ADV 8858 B NOTE Dimensions are shown in mm in Figure 7 13 Dimension Drawing Sound Shield 32 40EKOZD and 28 35EFKOZD Sheet 2 of 2...

Страница 48: ...TP 7045 3 18c 48 Section 7 Installation Drawings ADV 8859A A NOTE Dimensions are shown in mm in Figure 7 14 Accessory Drawing Keel Cooling with Dry Exhaust 32 40EKOZD and 28 35EFKOZD Sheet 1 of 2...

Страница 49: ...TP 7045 3 18c 49 Section 7 Installation Drawings ADV 8859B A NOTE Dimensions are shown in mm in Figure 7 15 Accessory Drawing Siphon Break Connection 32 40EKOZD and 28 35EFKOZD Sheet 2 of 2...

Страница 50: ...TP 7045 3 18c 50 Section 7 Installation Drawings Notes...

Страница 51: ...injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 D...

Страница 52: ...rican Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets 2 1...

Страница 53: ...ow allsafety precautions at the front of this manual and in the text during the reconnection procedure NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a v...

Страница 54: ...TP 7045 3 18c 54 Section 8 Reconnection Figure 8 3 Generator Reconnection ADV 5875F U...

Страница 55: ...luded in this manual Pay attention to the decals on the equipment and follow the instructions below D All personnel involved in handling site preparation installation testing operation and maintenance...

Страница 56: ...prime power applications 9 1 2 Paralleling Functions There are two methods of paralleling 1 PGEN The Decision Makerr 3500 is a full featured paralleling controller It offers integrated control for sy...

Страница 57: ...nerator Info Paralleling Operation Sharing Setup Menus Note Non ECM engines will require an electronic governor Woodward APECs and an appropriate Kohler governor calibration in order to permit speed a...

Страница 58: ...rotation ofthe busdoesn tmatch thatof the generator set For PGEN paralleling the synchronizing is handled within the Decision Makerr 3500 controller For Remote Speed and Voltage Bias paralleling the s...

Страница 59: ...olts 5 values supplied outside of this range will default the setting to nominal Note Some engines may limit this speed adjust to no more than approx 3 5 Voltage Regulator The voltage regulator is int...

Страница 60: ...d pair communication cable Connect the shield to ground at one end only Tighten the connections to 0 5 Nm 4 4 in lbs The PGEN connection between the generator sets is always required when the generato...

Страница 61: ...llers are shown in SiteTecht under the Manage Parallel Devices mode located at the top of the SiteTecht screen Note For more information on SiteTecht see TP 6701 SiteTecht Software Operation Manual If...

Страница 62: ...output leads to the paralleling bus Consult the wiring diagrams provided in the operation manual Connect PGEN communication wiring See Section 9 3 1 in this manual If the engine does not start consult...

Страница 63: ...that there are no unintentional or loose connections 4 Baud rate misconfigured One of the controllers on the network is attempting to communicate at a different baud rate than the other controllers Th...

Страница 64: ...generator Fault Close Attempt Fault Fail to Close 1 Breaker is unable to close The controller is attempting to close the circuit breaker but the breaker is not closing Watch the ready flag on the moto...

Страница 65: ...ing is not connected correctly on any generators on the network Verify the wiring on the circuit breaker to ensure that it is connected correctly Verify bus wiring for all nodes Verify the generator o...

Страница 66: ...sed when it was triggered to close but it did not indicate that it was open when the breaker opened This fault will only occur if the bus sensing is connected correctly the controller sees the voltage...

Страница 67: ...not connected to the output of the generator Verify the generator metering is sensed at the output of the generators A common mistake is to connect the metering to the center tap voltages V7 V8 V9 Fa...

Страница 68: ...and bus rotation is backwards Verify metering connections on the generator L1 should connect to the phase A output lead L2 to phase B L3 to phase C L0 to neutral Fault Bus Sensing Phases C and A are...

Страница 69: ...when the breaker contacts indicate that the breaker is open Verify the paralleling breaker control wiring is connected correctly and the status feedback is connected to an A contact Fault Failure to...

Страница 70: ...generator should be started and closed to a dead bus again to validate the changes Fault Dead Bus Sensed When Live Bus Expected 1 The wiring was not connected between the load side of the paralleling...

Страница 71: ...ect calibration it may see this voltage as a much higher level than the other generators resulting in a protective relay trip Verify the controller is measuring voltage accurately If not re calibrate...

Страница 72: ...ll trip to protect the generator from damage due to excessive loads Ensure that the load is low enough for a single generator to support it Fault Generator Total Real Power Low Warning 1 Loss of fuel...

Страница 73: ...ating on the network have different Order Selection modes Generator management will not operate if any generators on the PGEN network have different Order Selection modes Adjust the Order Selection mo...

Страница 74: ...remain essentially identical D Prime power applications where the generators are all of similar size Typical Applications for Fuel Level Order Selection Mode D Prime power applications where the gene...

Страница 75: ...tor Start Percentage The Generator Start Percentage is the percent load on the running generators above which this generator will begin timing for the Generator Start Delay The default setting is 80 t...

Страница 76: ...ies are events which can be assigned to programmable IO Priorities 1 and 2 are defaulted to RDO outputs 3 and 4 The priorities can be configured to outputs on the 14 relay dry contact kit or each cont...

Страница 77: ...requirements than a 10 000 Btu unit of another variety When using only one unit there is usually no starting problem provided the lighting and appliance load is not too high when starting the unit Si...

Страница 78: ...oled 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...

Страница 79: ...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 P...

Страница 80: ...F 1 175 29 2 Dry Barometer in Hg 1 Temperature _F 460 537 75 175 x Alternator Efficiency Reference Alternator Efficiency Observed 2 For turbocharged compression ignition engines C F 1 175 29 2 Baromet...

Страница 81: ...TP 7045 3 18c 81...

Страница 82: ...TP 7045 3 18c 82...

Страница 83: ...TP 7045 3 18c 83...

Страница 84: ...Co All rights reserved TP 7045 3 18c Original Instructions English 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...

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