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installation guidelines & user mannual
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1. Do not drag the Genset on floor ground Use lift points on the acoustic enclosure Canopy which provides support to the equipment when it is moved This makes it easier to set them up on the foundation Exhaust System Genset Exhaust system directs the hot flue gases into the atmosphere harmlessly On KGPI Genset exhaust silencer and expansion bellow are the integral part of exhaust system At the time of Genset installation please ensure proper alignment of exhaust silencer with respect to expansion bellow If the canopy 15 required to dismantle then utmost 1s necessary at the time of re assembling Power Performance of Mind INSTALLATION GUIDELINES amp USER MANNUAL While taking exhaust gases away from Genset above stack height please refer table below for selecting the size of exhaust pipe As per Statutory regulations exhaust pipe has to be extended above the surrounding stack as below H h 0 2 x vKVA Where Minimum height of exhaust stack h height of building ENGINE MODEL MINIMUM PIPE MINIMUM PIPE WATER INSIDE DIAMETER gt INSIDE DIAMETER COOLED IN INCH AIR COOLED IN INCH EW SERIES EA 10 16 RB SERIES HA294 394 494 2R 3R 4R HA694 5 Note If the extension of exhaust pipe is more than 5 meters above Genset increase pipe dia by 0 5 for every 3 meters Exhaust bend Corase wiremesh at end m 0990 R 2 5d
2. M 5 Bends used in exhaust piping should have a long smooth bend as shown in figure to ensure smooth flow of exhaust gases Exhaust Outlet should have 3009 cut at the tail end with Coarse wire mesh Note If No of bends are more than 4 increase the diameter of Exhaust Pipe and Bend by 0 5 for addition of each bend The exhaust outlet should be in the direction of prevailing wind Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Rain Cap Corase wiremesh at end FIG RAIN CAP WITH RAIN CAP FIG CORASE WIREMESH If horizontal exhaust outlet as recommended above 18 not possible provide a rain cap over exhaust pipe end as per the figure The distance between exhaust pipe and rain cap should be higher than diameter of pipe minimum 2 5D with coarse wire mesh It is also recommended that horizontal run of exhaust piping should slope downwards away from engine to the condensate trap Silencer should be installed with drain plug at bottom Exhaust Support FIG EXHAUSE PIPE SUPPORT Proper support is required for the extended exhaust pipe above Genset to ensure no self weight 1s transferred on to the Genset Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Type of Exhaust Pipe Use black MS Pipe Galvanised Iron Pipes should not be used X Bolted flange Gl Socket ERW Gl FIG CORRECT amp INCORRECT EXHAUST PIPE Exhaust P
3. Cross ventilation and free flow of cool clean and fresh air should flow to the Genset The space should be open without any obstacles For room and basement installations supply of fresh air and removal of hot air should be done through forced ventilation with suitable air ducts Refer to table for values of air requirement for various Gensets rated at 1500 rpm Values mentioned in table are with lagged exhaust piping in the room and silencer fitted outside the room Maximum allowed temperature rise above ambient in Genset Enclosure at air intake of engine is 7 deg centigrade BARRELS CYL HEAD x HOTAIROVER _ ATMOSHPERIC AIR 5 FIG AIR COOLED GENSET FIG WATER COOLED GENSET Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Foundation Foundation 15 one of the important factor affecting the successful operation and life of a generating set Improper foundation may result in alignment and vibration problems which may subsequently lead to pre mature failure of Genset Components and Safety The basic functions of foundation are as below To provide leveled platform to seat and seal the Genset To support the weight of the entire generating set Support the dynamic load of Genset while in running Absorb the vibration produced by the rotating and reciprocating masses Isolate the surrounding st
4. Polarity Check Battery cables are correctly connected and secured Check all other electrical connections and intactness Ensure Emergency Push Button in released condition Ensure Load Change over Switch Breaker in off condition Starting and Stopping of KGPI Genset Procedure Starting KGPI Genset Before Starting Clean the Genset with dry cloth Check the lub oil coolant and fuel levels Top up if required as per recommendation given Check for V belt Hoses and external leakage if any Ensure Load change over switch Breaker in Off condition Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Starting For Key Starting Do not crank engine for more than 5 second As soon as engine fires release the start key Leave ignition switch in position For Push Button Starting Gently press starts button once and release If engine fails to start wait for a minute and try again Check for leakages if any Allow the engine to idle for 3 minutes and then start loading the Genset gradually in steps Check for Engine parameters like Oil Pressure Coolant Temp and Battery charging rate at regular intervals while the Genset in operation and maintain log book Check for Exhaust Smoke Check for Abnormal Noise if any Check for A C Alternator parameters like Voltage Ampere KW PF on all phases Ensure load is balanced in all phases as per recomme
5. used to avoid tension on alternator terminal terminal box and control panel terminations Ensure phase colour coding is adopted while terminating cables at both the ends of Alternator and Control Panel Ensure proper Bending radius is given to the cable to avoid excessive tension on cable termination For extended control cabling use 10 12 core 2 5 sq mm of armoured copper cable Any type of control and monitoring cables should be sheathed and should be within 5 meters length for accurate performance Ensure that the weight of cables does not rest on alternator terminations Proper support to be provided from the ground separately through cable tray Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Typical cable sizes for KGPI Genset 3 Phase Genset 1 Phase Genset CABLE SIZES IN SQMM CABLE SIZES IN SQMM COPPER COPPER MULTISTR MULTISTR ina AND AND 5 2083 6 10 4 10 4166 10 16 2 15 625 16 25 28 8333 35 50 5 25 10416 35 50 42 2030 125 50 70 _ 56 16666 70 95 6 20833 95 150 _ 7 K ON 16 LA UJ P ec eoe os 5 B 445 T 240 185 556 150 150 3004 300 695 62 185 x 240 x 3 869 52 300 x 3 Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL BATTERY WATER COOLED GENSET SL BA
6. INSTALLATION GUIDELINES amp USER MANNUAL OVERALL SPECIFICATIONS OF KIRLOSKAR GREEN SILENT GENSETS Liquid Cooled KGPI Genset KG30WS 5 25 30 2355 X1090 X 1915 1260 6511500 1 KG40WS2 49 570x220x345 600 _ DVI 69 6660X2120X3598 7580 Air cooled KGPI Genset SEKG6AS7 SEKGIOASS SEKGIOAS KGISASI C KG25AS C KG35AS 3 KG3sAS 2NXIUSXIM _ KG40AS KG50AS KGT0AS 0 5 5 0 5 5 5 0 Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Note In view of continuous product updating and design changes all above specifications and dimensions are subject to change without prior notice Also refer to latest product catalogue for updates For the site conditions other than standard operating conditions consult Seller or Kirloskar s Area Office Sizing of KGPI Genset To select the right generating set under a given set of circumstances knowledge of generating set and its performance under various conditions is necessary It is also equally necessary to understand load characteristics and to make a load analysis Beyond that the effect of the voltage regulation systems plays an important role It is better to select a slightly larger generator capacity than the available load the reason is that additional uses are invariably observed after it has been installed These are usually not predictable By havi
7. TTERY RATING IN NO KVA RATING ENGINE MODEL AMPS EAIO 75 10 16 i AIR COOLED GENSET SL BATTERY RATING IN KVA RATING ENGINE MODEL AMPS T T 5355 6 HAOMC Ensure that the polarity of the battery connections are correct before switching on the DC controls Never attempt to start the Genset if battery charge 1s insufficient to start the engine Get the battery charged or replaced and then try to start During installation and maintenance disconnect the battery Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL For prolonged storage used static battery charger to keep battery fully charged Before Starting the New KGPI Genset Ensure intactness of all external fasteners hose clamps V belt tension as per specifications Ensure Cleanliness of the Genset Lubrication Check Lub oil level with help of Dipstick and if require Topup up to H Mark with K Oil Super Fuel Ensure fuel tank 1s clean from inside Hill fuel tank with clean High Speed Diesel Bleed the fuel system as shown in maintenance manual Cooling Liquid cooled engine Check Coolant level inside Radiator and Compensatory tank If required Topup with Super Plus Air Cooled Enignes Check Blower Fan belt tension Check hot air exhaust fan 1s working properly Electrical Check Battery
8. atives Fuel system system for liquid metal parts Manufacturer cooled Bharat petroleum Bharat Preserve 01 30 Bharat Sherol Bharat Rustrol 152 Emulsion with water ratio 1 20 Hindustan petroleum Autoprun T120 Koolkit Rustop 274 40 5 Emulsion with water Indian oil corporation Servo Servo Cut S 2096 Servo RP 125 Preserve 30 OR Emulsion with water Servo Run N Oil 30 Castrol India Russtilo DW 904 OR DW90 Veedol tide water oil Veedol 30 40 Veedol Amulkut 4 Veedol Rustop IT CO Emulsion with water in ratio 1 15 Alternatively Surprabha VCL 302 of Suprabha products can be used in engine cooling System For preservation and re commissioning contact seller After Sales Service Guidelines The after sales service to KGPI Genset is provided through KOEL s Country wide network of authorized spare and service dealers For information about KOEL s Authorized Dealers please contact either the supplier of KGPI Genset or nearest KOEL Area office Before commissioning the KGPI Genset please go through the contents of the warranty booklet YOU ARE ENTITLED TO RECEIVE THE FOLLOWING ENGINE RELATED DOCUMENTS FROM KGPI GENSET SUPPLIER Warranty Booklet User manual Hard copy Soft copy Maintenance manual Hard copy Soft copy Power Performance Peace of Mind
9. elp of Dipstick to H Mark and top up if required with K Oil Super Plus only K Oil Super SAE 15W 40 1s a specially blended engine oil which ensures Increased change intervals Better oxidation stability and hence less top ups Reduced Frictional wear Increased internal cooling Protection against Rust and Corrosion Reduced carbon deposits Use of the wrong grade of oil could lead to Overheating of the engine Sluggish performance Excessive Fuel Consumption Increase Wear of Bearings and Other moving components Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Fuel System The fuel High Speed Diesel should comply with the following International Standards DIN 51601 IS 1460 1995 ASTM D 975 81 ID amp 2D Ensure fuel filling point 18 accessible and clean all the time Ensure all fuel piping 1s leak free Avoid fuel spillage Ensure fuel dilution does not occur Care should be taken while filling of tank to prevent ingress of dust amp moisture inside diesel tank t is recommended to fill fuel after stopping of the Genset to avoid condensation 3 It is recommended not to fill Fuel during running of Genset Electrical System Earthing Any leakages in current will be earthed through the shortest route in the link KGPI Genset should be connected to earth in accordance
10. ipes should be joined through flanges Exhaust pipe throughout should be cladded by mineral wool with aluminium sheet Minimum thickness of cladding should be 50 mm Cooling System Liquid Cooled Engine Kirloskar Liquid Cooled Engines use solid cooling system for removal of heat generated in the engine due to internal combustion and to maintain optimum operating temperature for efficient engine operation KGPI Genset Liquid Cooled are delivered with initial fill of Pre mixed Coolant K Cool Super Plus Power Performance of Mind INSTALLATION GUIDELINES amp USER MANNUAL Ensure NO addition of Water in Coolant Ensure only with K Cool Super Plus coolant Ensure coolant level in Compensation Tank between Min and Max Level Air Cooled Engine Kirloskar Air Cooled Engines use Air as a cooling media for removal of heat generated in the engine through cooling passages and to maintain optimum operating temperature for efficient engine operation Ensure cleanliness of cooling air passages Lub Oil System Kirloskar engines utilize the pressure lubrication system with the lub oil filter adequately designed to handle the flow of lubricating oil at the designed pressure and temperature for Lubrication Cooling and Cleaning of internal components KGPI Gensets are delivered with initial fill of Lub Oil K Oil Super Plus Check the Lub Oil level with the h
11. n 10 e KVA x 1 39 per Phase for III phase gen set amp KVA X 1 39 x 3 AMP for I phase gen set at 10096 load Minimum 50 of AMPs per phase is required at the time of commissioning Deration Factor The engine s horse power as mentioned on its name plate 18 the HP which an engine can deliver in MSL at NTP conditions HP delivered at site will vary depending on site conditions deration due to altitude temperature and humidity For details of site derations please consult Seller or Kirloskar s Area Office Input HP Metric kW 0 736 x Alternator Efficiency Load Calculation Steps to be followed while sizing the Genset Step 1 Collect all necessary basic data of load Tabulate the details such as lighting load motor load A C load Heaters load etc with quantity and name plate details For motor loads mention starting method also 1 6 of starter used Step 2 Applicable For Three Phase Genset Convert all single phase loads to three phase loads by distributing equally on three phases Step 3 Starting power of each equipment is based on type of starting method For eg In case of motors Starting by DOL will pull up to 6 to 7 times the rated full load kW of a motor Star Delta will pull up to 2 to 3 times the full load kW of the motor Soft Start will pull up to 1 2 to 1 5 times the full load kW of the motor Rectifier loads may also pull up to 5090 above their rated Step 4 Sum
12. ndation and within rated output of Genset Check for all gauges and meters provided in Control Panel are working Procedure Stopping KGPI Genset Before Stopping Remove the load from Genset and let it run for about 3 minutes For Key Start Put Ignition key in condition For Push Button Start Push Stop button gently once and release After Stopping Put Load Change Over Switch in OFF position Check for leakages if any Top Up the Fuel Tank Ensure Proper closing of Genset Enclosure Maintenance Tips First oil change 50 hrs or 3 months of commissioning For details refer user manual Cleaning and Preservation of KGPI Genset Remove dust deposit from the Cylinder heads Liners fins lub oil cooler fins Radiator and A C Alternator with compressed air Cleaning with diesel fuel or kerosene may cause dust to deposit again on the cleaned parts Open the Air duct while cleaning of Air Cooled Engine Cleaning should be done from the opposite side of the system air flow Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL When deposits are hard scrape and clean with a water jet Run the engine after such cleaning till all the water evaporates When the Genset is kept idle for more than 6 months it is advisable to protect it from atmospheric moisture condensates internal corrosions and rodents Recommended Engine lub oil and Engine cooling Unpainted ferrous Preserv
13. ng a margin available it 1s possible to power some loads which may have been overlooked during Genset selection or which may be added after the installation of the Genset Ratings The rating of an alternator is expressed either in kilowatt kW or The relation between kW and kVA rating is KW x Power Factor Load variation between phases kW 1 732 x V x A x Power Factor for 3 phase alternator 1000 should not be more than 1096 kW V x Ax Power Factor for a single phase alternator 1000 and min 5096 load should be available at the time of Where V Line voltage Line current commissioning Power Factor The power factor of electrical system depends upon the nature of characteristics of load e g Induction motors Furnaces thyristor power electronics etc Power Factor 18 lagging for inductive load Power Factor is leading for capacitive load Power factor is unity for purely resistive loads Normally a generator is designed for a power factor of 0 8 The table below gives power factors of non motor loads Type of load Power Factor Incandescent lights 1 00 Heating elements ovens 1 00 Fluorescent lights 0 90 Induction furnaces 0 60 0 70 Arc furnaces 0 80 0 90 Welding Set Transformer 0 60 Welding Set Motor DC 0 80 0 90 Generator Transformers Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL e Load variation between phases should not be more tha
14. ructures by absorbing the vibration of generating set while in running 11 _ FIG FOUNDATION GENSET DG FOUNDATION RCC BLOCK 100 MIM ING COMPACTED FIG CORRECT amp INCORRECT FOUNDATION While casting the concrete foundation the bearing strength of the soil at site of installation should be determined The Table below gives the approximate safe bearing capacity of various soil Nature of the load bearing material Hard Rock Granite Medium Rock Shell Hard Pan Soft Rock Hard Clay Gravel and Corse Sand Loose Medium coarse and Compact fine sand Medium Clay Loose Fine Sand Soft Clay Safe bearing capacity kg sq meter 2 44 100 9 76 400 97 600 1 46 400 78 100 97 600 48 800 58 600 39 000 48 800 39 000 48 800 29 300 39 000 19 500 39 000 9 750 39 500 9 750 The length and width of foundation should be at least 300 mm more on each side than acoustic enclosure length and width respectively t is recommended to have foundation height of 150 to 200 mm above ground level to maintain cleanliness and avoid flooding Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Check the foundation level diagonally as well as across the length and width for even flatness and same should be within 0 50 in horizontal plane in any one direction only Ensure that
15. sibility to Genset for easy operation and maintenance Locate the Genset considering the prevailing wind direction Genset installation should be as close as possible to the load However in some cases like stone crusher plant garment plant cement factory paint factory chemical factory etc the Genset should be isolated from the dust hazardous and chemical fumes contained in the surrounding air In case Genset is to be installed in heavy dusty conditions it is recommended to use heavy duty air cleaners Please contact Seller or KOEL Area office for further guidelines For fuel supply and fuel storage arrangement for Genset follow the local rules and regulations o The environment protections Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL o The fire protection In case of high humid atmospheric conditions an anti condensation heaters should be used for the alternator A rooftop installation requires proper planning and the structural design considerations for dynamic loading Proper consideration should be given to take exhaust gases away from Genset location and shielded for hot surface Noise o There should be sufficient space around the Genset to avoid resonance and echo effect which contributes to abnormal sound from Genset o The space should be open without any obstacles Ventilation
16. the concrete 1s completely cured before positioning the enclosure Ensure that the foundation to support 1 5 times of the total wet weight of the single generating set installation and 2 times of the total wet weight for the multiple generating set installations For Rooftop installations it is necessary to have planning and structural design approval Do not install acoustic enclosure on loose sand or clay Avoid hard sharp projections such as stone or steel parts on foundation surface which may damage fuel tank at the bottom Avoid uneven foundation which may lead to improper resting of Genset on foundation there by leading to leakage of sound and vibration on Genset If Genset to be mounted on foundation having uneven surface under unavoidable circumstances use appropriate thickness of Rubber Matting above foundation for positive sealing of Genset with base Use a spreader of sufficient width for fixing the Rope Belt slings 0 gt Wi dth of G only in the eyeholes provided on the base amp Spreader E TN KS wg v ET dap 115 1 ft n gt gt lt NOOK E 3 5 J NET Unload the Genset only by crane by lifting with proper lifting tackle nylon sling soft sling with spreader bar spacer plate of suitable capacity to avoid any damage of the D G set
17. to local regulations The size of the link used for the main earth connection should be of adequate size as shown below table The generating set and all associated equipment must be earthed before the set 1s put into operation 4 numbers of earth pits are required as per Indian Electricity rules local electricity regulations 2 earthing pits for Genset control panel body 2 earthing pits for neutral Resistance between 2 earth pits should be more than 5 EARTHING WIRE amp Recommended Earth STRIP SIZE KVA Strip Cable 5 82 5 KVA SSWG COPPER 25 x 3nm GI 100 250 KVA 25 X 3mm COPPER 25 X 6mm GI 320 625 KVA 50 X 6mm COPPER Power Performance Peace of Mind TYPICAL EARTH PIT STATION ARRANGEMENT Chamber Cover Brick Work extemal Earth Connection J y L Ground Level T Mud Soi 4 Inch Dia Layers of salt amp Charcoal Gi Or Copper Plate FIG EARTH PIT Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL FIG 4 NOS EARTHING ARRANGEMENT Power Cable Cabling from Alternator to Panel should be done with proper size of cable and lugs Typical cable sizes are provided in the tables which are indicative Please refer to cable manufactures for details Ensure tight crimping terminations to avoid overheating and burning of the cable and terminals Ensure correct size of glands and gland plates are
18. up all the steady state running loads in and sum up all the starting kV A s These two figures will be used to size up the Genset and sequence of loading Step 5 Determine the maximum allowable voltage dip which the Genset should experience when the total starting KVA 16 applied on this Genset This voltage dip percentage 1s usually known to the customer based on equipment type to be powered Step 6 The previously obtained figures Running Starting Voltage Voltage Dip Loading sequence will decide Genset size Power Performance Peace of Mind INSTALLATION GUIDELINES amp USER MANNUAL Installing Genset Location Dust and Fumes are the greatest danger to generating set as they could lead to clogging of cooling and air system which may affect Genset performance 1 If KGPI Genset to be installed in free field condition please ensure dust free location and clear space of 2 times of height of Genset 2 If KGPI Genset to be installed in the room please ensure proper cross ventilation clear space of minimum 3 meters from all sides 3 If KGPI Genset to be installed on Roof Top please ensure Structural clearance proper cross ventilation with respect to wind direction clear space of minimum 3 meters from all sides 4 If KGPI Genset to be installed in basement ensure ventilation with respect to Air requirement and clear space for easy maintenance Layout Allow easy acces
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