Kohler 20--2800 kW - Manuals

TP-5700 7/93 II Safety Precautions and Instructions Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injuryand/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove wristwatch, rings, and other jewelry ...

TP-5700 7/93 III Safety Precautions and Instructions The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe r...

TP-5700 7/93 V Safety Precautions and Instructions Servicing the transfer switch controls and accessories within theenclosure. Hazardous voltage cancause severe injury or death. Disconnect the transfer switch controlsat the inline connector to deenergizethe circuit boards and logic circuitry butallo...

TP-5700 7/93 VI Safety Precautions and Instructions Notice NOTICE This generator set has been rewired from its nameplate voltageto 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Order voltage ...

TP-5700 7/93 i Introduction Introduction This manual provides installation instructions for20--2800 kW generator sets. Operation manuals andwiring diagram manuals are available separately. x:in:001:001 Information in this publication represents data availableat the time of print. Kohler Co. reserves...

TP-5700 7/93 1 Section 1 General Section 1 General Industrial power systems give years of dependableservice if installed using the guidelines provided in thismanual and in applicable codes. Incorrect installationcan cause continuing problems. Figure 1-1 illustrates atypical installation. Your author...

TP-5700 7/93 3 Section 2 Load and Transport Section 2 Load and Transport To ensure personal safety while preventing damage tothe product, we strongly recommend the followingguidelines be observed when loading and transportingstandby generator sets. Due to the different designs,dimensions and weights...

TP-5700 7/93 5 Section 2 Load and Transport D Do not attach lifting hooks to outside reinforcing plate on skid. Attach lifting hooks to skid exactly as shown in Figure 2-4. This method utilizes thestrongest portion of the mounting skid and alsoprevents the lifting hooks from slipping. Generatorswith...

TP-5700 7/93 7 Section 3 Location Section 3 Location 3.1 Location Factors Location is the key to a proper installation. The followingsections will deal with the factors to consider in a properinstallation. Before final plans are made for locating agenerator set, the following questions should be rai...

TP-5700 7/93 9 Section 3 Location The composition of the mounting pad should followstandard practice for the required loading. Commonspecifications call for 2500-3000 psi (176-211 kg/cm 2 ) concrete reinforced with eight-gauge wire mesh ornumber 6 reinforcing bars on 12-inch (30-cm) centers.The tota...

TP-5700 7/93 11 Section 4 Air Requirements Section 4 Air Requirements 4.1 General An ample flow of clean, cool air is required to supportcombustion and dissipate heat. Approximately 70% ofthe heat value of fuel consumed by an engine will berejected to the cooling system and exhaust. Battery compartm...

TP-5700 7/93 14 Section 4 Air Requirements 4.4 Air-Vac  Cooling System The air flow direction with the Air-Vac  system is the opposite of the conventional forced air cooling system.Use the Air-Vac  system in confined areas since it includes a blower scroll which easily connects to theductwork. Fo...

TP-5700 7/93 17 Section 4 Air Requirements The connection from the radiator duct flange to theductwork should be heavy canvas, silicone or similarflexible material to prevent noise and vibrationtransmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should havean un...

TP-5700 7/93 18 Section 4 Air Requirements The engine water pump can be used to circulate waterthrough the remote radiator providing that the verticaldistance from the engine water pump does not exceed theengine manufacturer’s recommendations. The allowablestatic head may range from 17-50 feet (5.2-...

TP-5700 7/93 20 Section 4 Air Requirements 4.11 Block Heaters Block heaters are recommended on all standbyapplications where the generator is subject to temperatures below 60 ° F (16 ° C) and are available as installed accessories on all generator sets. The blockheater should be connected to a sourc...

TP-5700 7/93 21 Section 5 Exhaust System Section 5 Exhaust System Proper installation of the exhaust system is essential toobtain satisfactory performance from a generator set.The most important factor is that the installed systemmust not exceed the engine manufacturer’s maximumexhaust back pressure...

TP-5700 7/93 25 Section 6 Fuel Systems Section 6 Fuel Systems When planning an installation, check state and localregulations regarding fuel storage and handling. Piping andfuel system components must conform to these regulations. 6.1 Diesel Fuel Systems Since diesel fuel is less volatile than gas o...

TP-5700 7/93 28 Section 6 Fuel Systems 6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop amaximum of 7 psi (48 kPa) pressure and have a liftcapacity of 4-6 feet (1.2-1.8 m). Even if the engine pumpcan draw fuel a greater distance, a more reliable systemresults if a transfer ...

TP-5700 7/93 29 Section 6 Fuel Systems 6.6 Gasoline Fuel Systems Due to code restrictions which do not allow storage ofmore than one gallon (3.8 L) of gasoline inside abuilding, gasoline fuel systems are usually limited tohoused generator sets installed outdoors or portabletrailer-mounted units. Gas...

TP-5700 7/93 30 Section 6 Fuel Systems 6.7 Natural or LP Gas Fuel Systems Natural and LP (liquified petroleum) gas fuel systemsshould be designed and installed in accordance with therequirements of NFPA 54, National Fuel Gas Code, andall applicable local codes. Various types of gas fuelsystems are a...

TP-5700 7/93 32 Section 6 Fuel Systems 6.8 Flexible Connector An approved flexible connector should always be usedbetween stationary gas piping and the engine-mountedfuel system components. It should be at least six inches(15.3 cm) long or as recommended by the generatorsupplier based upon engine sp...

TP-5700 7/93 33 Section 6 Fuel Systems 6.11 LP Gas Fuel Characteristics LP gas is supplied as a liquid in pressure tanks. It iseasily adaptable to stationary applications wherecomplete independence of an outside fuel supply isrequired. Since LP gas does not deteriorate in longperiods of storage as g...

TP-5700 7/93 36 Section 7 Electrical Requirements 7.2 Electrical Connections Several electrical connections must be made betweenthe generator set and other components of the systemfor proper operation. Because of the large number ofaccessories and possible combinations, this manualdoes not address s...

TP-5700 7/93 37 Section 7 Electrical Requirements 7.4 Terminal Connector Torque Use the torque values shown in Figure 7-4 or Figure 7-5for terminal connectors. Refer to UL-486A, UL-486B,and UL-486E for information on terminal connectors foraluminum and/or copper conductors. See Section 7.2,Electrica...

TP-5700 7/93 38 Section 7 Electrical Requirements 7.5 Automatic Transfer Switches A typical standby system has at least one automatictransfer switch connected to the generator set output toautomatically transfer the electrical load to thegenerator set if the normal source fails. When normalpower ret...

TP-5700 7/93 39 Section 7 Electrical Requirements 7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdownof the generator from a remote location. If theemergency stop switch is activated, the emergency stoplamp on the generator controller lights and the unit shutsdown im...

TP-5700 7/93 Appendix A-1 Appendix A 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 dimension...

TP-5700 7/93 II Safety Precautions and Instructions Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injuryand/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove wristwatch, rings, and other jewelry ...

TP-5700 7/93 III Safety Precautions and Instructions The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe r...

TP-5700 7/93 V Safety Precautions and Instructions Servicing the transfer switch controls and accessories within theenclosure. Hazardous voltage cancause severe injury or death. Disconnect the transfer switch controlsat the inline connector to deenergizethe circuit boards and logic circuitry butallo...

TP-5700 7/93 VI Safety Precautions and Instructions Notice NOTICE This generator set has been rewired from its nameplate voltageto 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Order voltage ...

TP-5700 7/93 i Introduction Introduction This manual provides installation instructions for20--2800 kW generator sets. Operation manuals andwiring diagram manuals are available separately. x:in:001:001 Information in this publication represents data availableat the time of print. Kohler Co. reserves...

TP-5700 7/93 1 Section 1 General Section 1 General Industrial power systems give years of dependableservice if installed using the guidelines provided in thismanual and in applicable codes. Incorrect installationcan cause continuing problems. Figure 1-1 illustrates atypical installation. Your author...

TP-5700 7/93 3 Section 2 Load and Transport Section 2 Load and Transport To ensure personal safety while preventing damage tothe product, we strongly recommend the followingguidelines be observed when loading and transportingstandby generator sets. Due to the different designs,dimensions and weights...

TP-5700 7/93 5 Section 2 Load and Transport D Do not attach lifting hooks to outside reinforcing plate on skid. Attach lifting hooks to skid exactly as shown in Figure 2-4. This method utilizes thestrongest portion of the mounting skid and alsoprevents the lifting hooks from slipping. Generatorswith...

TP-5700 7/93 7 Section 3 Location Section 3 Location 3.1 Location Factors Location is the key to a proper installation. The followingsections will deal with the factors to consider in a properinstallation. Before final plans are made for locating agenerator set, the following questions should be rai...

TP-5700 7/93 9 Section 3 Location The composition of the mounting pad should followstandard practice for the required loading. Commonspecifications call for 2500-3000 psi (176-211 kg/cm 2 ) concrete reinforced with eight-gauge wire mesh ornumber 6 reinforcing bars on 12-inch (30-cm) centers.The tota...

TP-5700 7/93 11 Section 4 Air Requirements Section 4 Air Requirements 4.1 General An ample flow of clean, cool air is required to supportcombustion and dissipate heat. Approximately 70% ofthe heat value of fuel consumed by an engine will berejected to the cooling system and exhaust. Battery compartm...

TP-5700 7/93 14 Section 4 Air Requirements 4.4 Air-Vac  Cooling System The air flow direction with the Air-Vac  system is the opposite of the conventional forced air cooling system.Use the Air-Vac  system in confined areas since it includes a blower scroll which easily connects to theductwork. Fo...

TP-5700 7/93 17 Section 4 Air Requirements The connection from the radiator duct flange to theductwork should be heavy canvas, silicone or similarflexible material to prevent noise and vibrationtransmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should havean un...

TP-5700 7/93 18 Section 4 Air Requirements The engine water pump can be used to circulate waterthrough the remote radiator providing that the verticaldistance from the engine water pump does not exceed theengine manufacturer’s recommendations. The allowablestatic head may range from 17-50 feet (5.2-...

TP-5700 7/93 20 Section 4 Air Requirements 4.11 Block Heaters Block heaters are recommended on all standbyapplications where the generator is subject to temperatures below 60 ° F (16 ° C) and are available as installed accessories on all generator sets. The blockheater should be connected to a sourc...

TP-5700 7/93 21 Section 5 Exhaust System Section 5 Exhaust System Proper installation of the exhaust system is essential toobtain satisfactory performance from a generator set.The most important factor is that the installed systemmust not exceed the engine manufacturer’s maximumexhaust back pressure...

TP-5700 7/93 25 Section 6 Fuel Systems Section 6 Fuel Systems When planning an installation, check state and localregulations regarding fuel storage and handling. Piping andfuel system components must conform to these regulations. 6.1 Diesel Fuel Systems Since diesel fuel is less volatile than gas o...

TP-5700 7/93 28 Section 6 Fuel Systems 6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop amaximum of 7 psi (48 kPa) pressure and have a liftcapacity of 4-6 feet (1.2-1.8 m). Even if the engine pumpcan draw fuel a greater distance, a more reliable systemresults if a transfer ...

TP-5700 7/93 29 Section 6 Fuel Systems 6.6 Gasoline Fuel Systems Due to code restrictions which do not allow storage ofmore than one gallon (3.8 L) of gasoline inside abuilding, gasoline fuel systems are usually limited tohoused generator sets installed outdoors or portabletrailer-mounted units. Gas...

TP-5700 7/93 30 Section 6 Fuel Systems 6.7 Natural or LP Gas Fuel Systems Natural and LP (liquified petroleum) gas fuel systemsshould be designed and installed in accordance with therequirements of NFPA 54, National Fuel Gas Code, andall applicable local codes. Various types of gas fuelsystems are a...

TP-5700 7/93 32 Section 6 Fuel Systems 6.8 Flexible Connector An approved flexible connector should always be usedbetween stationary gas piping and the engine-mountedfuel system components. It should be at least six inches(15.3 cm) long or as recommended by the generatorsupplier based upon engine sp...

TP-5700 7/93 33 Section 6 Fuel Systems 6.11 LP Gas Fuel Characteristics LP gas is supplied as a liquid in pressure tanks. It iseasily adaptable to stationary applications wherecomplete independence of an outside fuel supply isrequired. Since LP gas does not deteriorate in longperiods of storage as g...

TP-5700 7/93 36 Section 7 Electrical Requirements 7.2 Electrical Connections Several electrical connections must be made betweenthe generator set and other components of the systemfor proper operation. Because of the large number ofaccessories and possible combinations, this manualdoes not address s...

TP-5700 7/93 37 Section 7 Electrical Requirements 7.4 Terminal Connector Torque Use the torque values shown in Figure 7-4 or Figure 7-5for terminal connectors. Refer to UL-486A, UL-486B,and UL-486E for information on terminal connectors foraluminum and/or copper conductors. See Section 7.2,Electrica...

TP-5700 7/93 38 Section 7 Electrical Requirements 7.5 Automatic Transfer Switches A typical standby system has at least one automatictransfer switch connected to the generator set output toautomatically transfer the electrical load to thegenerator set if the normal source fails. When normalpower ret...

TP-5700 7/93 39 Section 7 Electrical Requirements 7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdownof the generator from a remote location. If theemergency stop switch is activated, the emergency stoplamp on the generator controller lights and the unit shutsdown im...

TP-5700 7/93 Appendix A-1 Appendix A 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 dimension...