Genset manual - Elmech Engineers
Contents
1. Corase wiremesh at end If horizontal exhaust outlet as recommended above is not possible provide a rain cap over exhaust pipe end as per the figure below The distance between exhaust pipe and rain cap should be higher than diameter of pipe minimum 2 5D with coarse wire mesh Rain Cap gt 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 Corase wiremesh at end KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BN Exhaust System a Exhaust Support Proper support is required for the extended exhaust pipe above Genset to ensure no self weight is transferred on to the Genset Type of Exhaust Pipe Use black MS ERW Electric Resistance Welded Class B Type pipes Galvanised Iron pipes should not be used Exhaust pipes should be joined through flanges Exhaust pipe through out should be cladded by mineral wool with aluminium sheet 0 8mm Minimum thickness of cladding should be 50 mm Bolted flange x GI Socket ERW GI KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support HE Cooling System Liquid Cooled Engine Kirloskar Liquid Cooled Engines use premixed coolant for removal of heat generated in the engine due to internal combustion and to maintain optimum operating temperature for efficient engine2. Fuel Filter Pre and Micro to be replaced alternatively after 250 hrs for 1 1 Ltr and 125 hrs for 0 5 Ltr Air filter change is based on Ideal site condition however extreme dusty condition change frequency is based on occurrence of red band in restriction indicator kk It is recommended to get the routine maintenance done through Kirloskar Authorized dealer KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support IBI Cleaning and Preservation of KGPI Genset BEEN 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 dustto deposit again on the cleaned parts gt Opentheairductwhilecleaning of Air Cooled Engine v Cleaning should be done from the opposite side of the system air flow When deposits are hard scrape and clean with a water jet Run the engine after such cleaning till all the water evaporates Do not clean electrical components like main alternator starter charging alternator control panel gauges wiring connections etc with water gt 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 Preservatives Manufacturer Engine lub oil and Engine cooling system Unpainted ferrous Fuel system for liquid cooled
3. Resistance between 2 earth pits should not be more than 5 O Typical Earth Pit diagram is as shown in figure GensetRating Recommended Earth Strip Cable 5 82 5kVA 8 SWG Copper 100 250kVA 25x3mmCU 25x6mm Gl 320 500kVA 50x6mm CU 50x6mm GI2 runs 625 750kVA 50x6mm CU 50x6mm GI2 runs TYPICAL EARTH PIT STATION ARRANGEMENT Chamber Cover Brick Work Ground Level Mud Soil ipe 1 Inch Dia Layers of Salt amp Charcoal Earth Pit GI Or Copper Plate KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BN Electrical System Power Cable Cabling from Alternator to Panel should be done with proper size of cable and lugs Typical cable sizes provided in the table are indicative Please refer to cable manufactures for details gt Ensure tight crimping terminations to avoid overheating and burning of the cable and terminals Ensure correct size of glands and gland plates are 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 withi
4. a Enriching Lives GENSET OWNER S MANUAL Call 1800 233 3344 020 6608 4608 Email koel helpdesk kirloskar com Customer assistance is also available from our help desk 24 hrs x 7 days a week for all after sales assistance Help Desk Power Performance Peace of Mind KIRLOSKAR OIL ENGINES LIMITED An L K Road Khadki Pune 411 003 INDIA KIRLOSKAR Tel 91 20 2581 0341 2581 5341 Fax 91 20 2581 3208 25810209 GREEN www kirloskar com POWER IDEAS GENSET OWNER S MANUAL Enriching Lives KIRLOSKAR OIL ENGINES LIMITED KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support Published on behalf of Customer Support Kirloskar Oil Engines Limited Khadki Pune 411 003 INDIA All rights reserved This Publication may not be produced in any form in whole or in part without our written permission In view of continuous product updating and design changes contents of this Manual are subject to change without prior notice Kirloskar Engines Prime Movers to the Indian Nation 1946 saw Kirloskar Oil Engines Limited KOEL taking shape A powerhouse today it easily stands out as India s leading manufacturer of engines giving its customers a wide choice ranging from 3 hp to 800 hp and 2400 hp to 11000 hp Manufactured in both air cooled and liquid cooled versions every detail in these engines is carefully perfected A variety so large also
5. 120 2 279 200 415 V 222 6 278 25 300 1 260 20 250 415V 278 25 347 81 185 2 360 21 275 415V 306 08 382 59 E 240 2 423 23 320 415 V 356 16 445 20 300 2 468 25 400 415 V 445 20 556 50 240 3 564 400 415V 445 2 556 50 150 4 560 26 500 415V 556 50 695 62 240 4 752 500 415 V 556 5 695 62 300 3 655 2 26 600 415 V 667 80 834 75 300 4 832 600 415 V 667 8 834 75 240 5 916 5 27 625 415 V 695 63 869 53 185 6 900 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support II Electrical System en Typical Cable Sizes for KGPI Genset Cable selection chart A Single Phase Generators Bi Current ford Ph Cable Size at 40 deg ambient for 2 core cable Alternator Sr Size of Rating of Size of kVA Volt No omage Copper Copper Aluminium Rating or 1 PF 0 8 PF Aluminium Cable Cable Cable Cable A Sqmm A Sqmm 1 10 230 34 43 6 45 10 56 2 15 230 52 65 16 78 16 71 3 20 230 69 86 25 105 25 93 4 25 230 86 108 25 105 35 110 5 30 230 104 130 35 125 50 130 Important Notes 1 Please use Comet make cable glands 2 Type of cable gland Single Compression Heavy Duty Cable Gland 3 Material of cable gland Brass 4 The amp rating of cable is considered as per duct laying method and 700 C operating Temperature mentioned in manufacturers catalogue Considered amb temp 400 C For grouping
6. At the time of Genset installation please ensure proper alignment of exhaust silencer with respect to expansion bellow While taking exhaust gases away from Genset above stack height please refer to the 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 2xvkVA Where H Minimum height of exhaust stack h height of building Engine Model Minimum pipe inside Engine Model Minimum pipe inside Liquid Cooled diameter in mm Air Cooled diameter in mm EW Series 63 EA10 EA16 50 2R 3R 4R 63 EA20 63 4RTA 6RT 75 HA2 HA3 HA4 63 4KTA 6RTA 6KTA 100 HA4 T HA6 HA6T 75 6SL Series 125 DV Series 125 Note gt Ifthe extension of exhaust pipe is more than 5 meters above Genset increase pipe diameter by 13 mm for every 3 meters Exhaust bend Bends used in exhaust piping should have a long smooth bend as shown in figure to ensure smooth flow of exhaust gases R 2 5d KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BN Exhaust System Ce Note gt If No of bends are more than 4 increase the diameter of exhaust pipe and bend by 13 mm for addition of each bend gt Theexhaust outlet should be in the direction of prevailing wind gt Exhaust outlet should have 30 cut at the tail end with Coarse wire mesh
7. KVA is applied on this Genset This voltage dip percentage is usually known to the customer based on equipment type to be powered Step 6 The previously obtained figures Running KVA Starting KVA Voltage Voltage Dip Loading sequence will decide Genset size For correct sizing of DG Set please consult seller or Kirloskar s area office KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support Bl Installing KGPI Genset PEEL Location A 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 is to be installed in Free field condition please ensure dust free location and clear space of 2 times the height of Genset 2 If KGPI Genset is to be installed in the room please ensure proper cross ventilation clear space of minimum 3 meters from all sides 3 If KGPI Genset is to be installed on a 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 is to be installed in the basement please ensure ventilation with respect to Air requirement and clear space for easy maintenance KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support HE Installing KGPI Genset PENES Layout Allow easy accessibility to Genset for easy opera
8. makes these engines the backbone in many industries including the role of prime movers for industrial agricultural construction power generation and marine applications On the other hand engines ranging from 2400 hp to 11000 hp are also used for marine propulsion and auxiliary power on naval and coast guard ships Such a wide acceptance has resulted in increase in demand for engines in all market segments Being a leader is also about being driven by technology And that means constant technology up gradation in house research investment in state of the art manufacturing facilities with thoroughly perfected processes All aimed at one goal Deliver well thoughtout quality products and services to the customers at competitive prices Of special mention are critical components like crankcases crankshafts camshafts and connecting rods that are manufactured in house KOEL also manufactures for its exclusive use special purpose machines to achieve critical degrees of precision that international specifications demand This practice towards achieving efficiency and performance is a mantra at all KOEL plants starting from the main engine manufacturing plant at Pune to all the other units at Nashik Ahmednagar Rajkot Indore and Kolhapur This rigorous internal quality pace easily makes sure that KOEL s processes meet all the standards that global specifications demand In 2007 ABS QE USA awarded KOEL Khadki plant the prestigious ISO TS 16949 2
9. of cables multiple runs the derating factors are considered as per ductlaying method of cable Du 7 The distance between two parallel cables is considered 30 mm for deration KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support IH Battery EEE Engine model Meu Battery Specification e T motent temp 42y Starting 24V Starting udi cias E Series System System gt 10 88 HA 204 394 20 to 10 193 gt 10 88 HA 494 494T M dg gt 10 100 E 1 35 sq mm HA 694 694T ae 150 gt 10 150 2R 1040 3R 1040 2009 120 MORE 410 88 7 PVC flexible 4R 1040 4R 1040T AN 135 Red and 10 135 Black colour MNT m 1 25 mts 4R 1040TA 4K1080 dc Copper gt 10 150 cable with 6K 1080 6R 10807 20 to 10 160 suitable lugs one side 6R 1080TA 410 150 battery lugs 1 50 sq Mm nd one sid NT 20 to 10 E 2x 12V 200 AH ane ae gt 10 A 2x 12V 180 AH mounds 20 to 10 i 2x12V 200AH 79 60 am DV sees gt 10 2x 12V 180 AH i 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 is insufficient to start the engine Get the battery charged or replaced and then try to start During installation and maintenance disconnect the battery For prolonged storage used static battery charger to keep battery f
10. 002 and ISO 14001 certification for its Quality Management Systems Similarly the belief that industry and environment can co exist led to in house development of the environmental friendly engines produced using environmental friendly manufacturing facilities Recognition for this came as an ISO 14001 certification for Environment Management Systems in 1999 Customer Support Assurance through adequate product support is derived out of clear thought processes coupled with the most extensive service network in the country Around 90 of Kirloskar engines are within 80 km of a Kirloskar Service Dealer 342 Service Dealership outlets are operating efficiently to provide relentless service to customers The dealership locations and infrastructure is continuously assessed based on the Kirloskar engine population build up in each territory and the customer s emerging service needs Out of these 210 Service Dealership locations provide 24 hour service as of December 2011 with the number growing steadily Add on Kirloskar Service Managers Service Engineers and Technicians have been stationed at 14 Kirloskar Area and Regional Offices A well spread out service network manned by about 3500 Kirloskar trained engineers and technicians ensure prompt service and easy availability of genuine consumable and spare parts making sure that there s always the highest uptime for Kirloskar engines KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued
11. 1080TA Sr 127 5 173 5 140 4040 x 1540 x 1900 3500 KG160WS2 6K1080TA 164 5 200 160 4040 x 1540 x 1900 3550 KG180WS 6SL1500TA Sri 165 224 180 4940 x 1700 x 2050 3870 KG200WS 6SL1500TA Srit 184 250 200 4940 x 1700 x 2050 3950 KG250WS1 6SL8800TA 228 310 250 4940 x 1700 x 2050 4660 KG320WS3 DV8 Sri 294 400 320 5700 x 2000 x 2555 5650 KG380WS DV8 Sru 346 471 380 5700 x 2000 x 2555 5850 KG400WS2 DV8 360 490 400 5700 x 2000 x 2555 6000 KG500WS3 DV10 448 608 500 6200 x 2000 x 2555 6655 KG600WS2 DV12 532 723 600 6660 x 2000 x 2705 7500 KG 625WS DV12 Sri 552 750 625 6660 x 2000 x 2705 7500 Note Genset ratings are as per ISO 8528 performance class G2 Prime Power Rating is the maximum power available continuously for a variable electrical load for unlimited number of hours per year under standard operating conditions Single phase genset option available up to 30 kVA For E Series fuel tank integral with base frame For site conditions other than standard operating conditions consult KOEL for available prime power Specific gravity of diesel is considered as 0 845 5 tolerance as per ISO 3046 All canopy dimensions have tolerance of 50 mm 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 Kirl
12. Check for leakages if any gt Topup the Fuel Tank gt Ensure proper closing of Genset Enclosure KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BE LOG Sheet LOG SHEEET Sample for use The user is requested to maintain a separate log book registering the following mentioned parameters in the table Following tables are meant for providing a reference to you Date Daily use in hrs Hour meter reading Cooling Water Temp C Pressure Kg cm Lub Oil Temp C Fuel added ltr Lub Oil added ml Engine rpm Current Amp 3 phase Voltage Frequency Hz PF amp kW if provided kWH meter reading if provided Remarks Record events of maintenance repairs KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BIN Maintenance Tips _ O First oil change 50 hrs or 7 days of commissioning Series Oil Change Oil Filter Fuel Filter Air Cleaner element V Belt Change hours Change hours Change hours change hours hours EW EA 500 500 500 1000 1000 1000 for dry type air 1000 HA 500 500 500 for HA4 HAG cleaner element 250 1 1 Ltr Oil change for Oil bath Air Cleaner RB RV 250 250 250 1000 1000 R1040 R1080 500 500 500 1000 1000 SL90 500 500 500 1000 1000 Dv Series 500 500 500 500 2000
13. Jaipur 21 Sudarshan Pura Industrial Area Bais Godwn Jaipur 302006 Phone 91 141 2210405 2214149 2214150 Fax 91 141 2214149 Kolkata 8th Floor Poonam Building Flat Nos 8A amp 8B 5 2 Russel Street Kolkata 700 071 Phone 91 33 2217 0858 2217 0860 2217 0861 Fax 91 33 2217 0859 Lucknow 498 143 KA Faizabad Road Near IT Collage Chauraha Upper Floor of State Bank of Indore Lucknow 226 007 Phone 91 522 2741440 42 43 Fax 91 522 2741441 Ludhiana Plot No 12 NPC Tempo Union Street Near Arjun Gas Godown Sherpur Chowk Ludhiana 141003 Phone 91 161 254 6667 2546669 Fax 91 161 2546753 New Delhi 404 4th Floor Surya Kiran Building 19 Kasturba Gandhi Marg New Delhi 110001 Phone 91 11 23711786 47195200 47195202 47195217 47195205 Fax 91 11 23710159 Secunderabad 5 2 220 to 222 2nd Floor Padmavathi Tower Hyder Basti Opp Andhra Bank Ranigunj Secunderabad 500003 Phone 91 40 27534197 27534176 Telefax 91 40 27534170 Y KIRLOSKAR OIL ENGINES LIMITED Laxmanrao Kirloskar Road Khadki Pune 411 003 INDIA Tel 91 20 2581 0341 Fax 91 20 2581 3208 25810209 www kirloskar com Enriching Lives J DV 10 FEB 2010 01 This Catalog is copyrighted and may not be reproduced in any form not even parts of it without previous written permission by copyright owners Kirloskar Oil Engines Ltd
14. 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 consultSeller or Kirloskar s Area Office KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support EN Sizing of KGPI Genset General Guidelines PIE 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 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 kVA of each equipment is based on type of starting method For e g In case of motors gt Starting by DOL will pull up to 6 to 7 times the rated full load kW ofa motor gt Star Delta will pull up to 2 to 3 times the full load kW of the motor gt SoftStart will pull up to 1 2 to 1 5 times the full load kW of the motor Rectifier loads may also pull up to 50 above their rated kVA Step 4 Sum up all the steady state running loads in kVA and sum up all the starting kVA 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
15. alls provide extensive after sales support including operational maintenance amp repair contract m Single window service for Genset amp Customised AMC W 24 7 help line service for all our customers offering timely customer support to deal with inquiries W Fully implemented CRM module to provide proactive amp quick service response W Trained amp experienced service team to provide value added support to the highest standards ensuring customer satisfaction at all times W Support systems like Mean Time to Restore Engine Down Order First Pick Availability for maximum uptime of Gensets E K oil K cool super plus for product life extension W Excellent product support through easy availability of spare parts product training Re conditioning and warranty administration W Easy and Quick delivery anywhere anytime KOEL Sales Offices Service Network across the Nation Where your business operations are far reaching across the country amp moreover when they are located in absolute remote places your business counts on reliability amp availability ensuring minimum downtime Key to the quality of our after sales service is our strong service force which are always ready to attend your calls anywhere anytime Jammu amp Kashmir North Zone 44 Factory Training amp Service Centre A Srinagar 7 x S East Zone amp Area Office 13 A Rajouri aa We
16. ble prime power Specific gravity of diesel is considered as 0 845 5 96 tolerance as per ISO 3046 All canopy dimensions have tolerance of 50 mm In view of continuous product updating and design changes all above specifications and dimensions are subjectto 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 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support 3 IN Sizing of KGPI Genset General Guidelines SSS Sizing of KGPI Genset To select the right Genset under a given set of circumstances knowledge of Genset 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 having a margin available it is 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 kVA The relation between kW and kVA rati
17. by Customer Support Enriching Lives All pervasive IT in Operations Having forethought and foreseen the power of Information Technology IT to transform businesses Kirloskar installed Oracle s Enterprise solutions in 1998 The company has also launched Oracle CRM Oracle Customer Relationship Management module in 2006 to serve customers pro actively This exercise by itself is noted to be one of the most extensive installations of Oracle in the manufacturing industry The installation of ERP was followed by net enabled business processes in 2000 This networked Kirloskar Service Dealers AGOEMs Area Sales Offices Suppliers and the Logistic Providers into a closely knit digital community Such a high internet led IT focus has helped Kirloskar service its customers with a new found efficiency 365 days a year 24 hours a day So whether it s the latest service information or parts availability expect complete information access at the touch ofa button DG Genset the Specific Anecdote We are recognized as one of the world s leading generating set manufacturers Kirloskar Green Genset is a major player globally specialized in manufacturing of both air cooled amp water cooled Engines Diesel Gensets with power output covering from 5 kVA to 625kVA amp 1800kVA to 6300 kVA We have been instrumental in developing the latest technology driven products to suffice power requirements of every individual custome
18. iaywada wy Karnataka Goe A Oni Cuddapah Dna e ANallore A Ananthapur AKumpol Hasan uua G Tinpatia Mangalore es agha Andaman Bangalor A CHENNAI sande Pon Br Kerala MEO OSS an P S A Dindigul Calicut s Tichu A Erode A Karur Ernakulam A Amps Korda o Kochi Coimbatore A Thanjavur A p Temilridu Idukki A Trichy Lakshadweep Palaked Md onya A Sakasti Madra Tivandrunt p Ailicorn Micobar cud Islands Ahmedabad Ground Floor D Block Pruthvi Tower Jodhpur Char Rasta Ahmedabad 380015 Phone 91 79 2692 9687 2692 9689 Bangalore 3rd Floor Shri Lakshmi Complex 15 St Marks Road Bangalore 560 001 Phone 91 80 2558 7562 30578164 30578165 Fax 91 80 2558 7559 e Bhubaneswar 178A Zone B Mancheswar Industrial Estate Bhubaneswar 751010 Orissa Phone 91 674 2585064 2586059 2588047 Telefax 91 674 2588021 Chennai Nelson Tower 1st Floor 2nd Wing 51 Nelson Manickam Road Chennai 600 029 Phone 91 44 23744661 23744624 Cochin No 39 2694 A1 Anugraha Panthiyil Lane Warriam Road Cochin 682016 Phone 91 484 2385757 2385758 Fax 91 484 2385756 e Guwahati 29 G amp B Road Pan Bazzar Guwahati 781 001 Phone 91 361 2736016 2736017 Telefax 91 361 2736015 Indore 203 Goldstar Complex Opp Treasure Island 576 MG Road Indore 452001 Phone 91 731 3913108 3913109 3913110 3913111 Telefax 91 731 3913112
19. 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 is 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 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support HB Unloading and Positioning gt Allthe Gensets are provided with suitable lifting arrangements Unload the Genset by lifting with proper lifting tackle nylon sling soft sling with spreader bar spacer plate of suitable capacity to avoid any damage gt Donotdrag the Genset on floor ground gt 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 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support EN 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 parts of the exhaust system
20. l at site of installation should be determined The table below gives approximate safe bearing capacity of various soils for ref Nature ofthe load bearing material Safe bearing capacity kg sq meter Hard Rock Granite 2 44 100 9 76 400 Medium Rock Shell 97 600 1 46 400 Hard Pan 78 100 97 600 SoftRock 48 800 58 600 Hard Clay 39 000 48 800 Gravel and Coarse Sand 39 000 48 800 Loose Medium Coarse and Compact Fine Sand 29 300 39 000 Medium Clay 19 500 39 000 Loose Fine Sand 9 750 39 500 SoftClay 9 750 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BI Foundation N gt The length and width of foundation should be atleast 300 mm more on each side than acoustic enclosure length and width respectively gt It is recommended to have foundation height of 150 to 200 mm above ground level to maintain cleanliness and avoid flooding gt Check the foundation level diagonally as well as across the length and width for even flatness and same should be within 50 mm in horizontal plane in any one direction only gt Ensure that the concrete is completely cured before positioning the enclosure gt 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 installation gt For rooftop installations it
21. metal parts Bharat petroleum Bharat Preserve oil 30 Bharat Sherol B Emulsion Bharat Rustrol 152 with water ratio 1 20 Hindustan petroleum Autoprun T120 Koolkit40 5 Emulsion with water Rustop 274 SES Servo Preserve30 OR Servo Cut S 20 Indianollcorporation So e RN OIS Ermulsionwith water cone Castrol India Russtilo DW 904 OR DW901 Veedol tide wateroilco Veedol 30 40 Neos OTe UIA GEILE Veedol Rustop IT with water in ratio 1 15 Alternatively Surprabha VCL 302 of Suprabha products can be used in engine cooling System For preservation and recommissioning please consult KOEL Area Office KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support ME KGPI Customer Support Network oe e gt The after sales service to KGPI Genset is provided through KOEL country wide network of authorized spare and service dealers Service dealers are equipped with all necessary tools and tackles to take care of every need ofservice gt Weunderstand how important after sales support is to your business Where your business operations are far reaching across the country amp moreover when they are located in absolute remote places your business counts on reliability amp availability of prompt service to ensure minimum downtime gt We are committed to provide adequate after sales service support amp believe in creating an enduring relationship with every individual customer we
22. n 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 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support IE Electrical System HEEL Typical Cable Sizes for KGPI Genset Cable selection chart A Three Phase Generators pa Pod id 3 Cable Size at 40 deg ambient for 3 5 core cable kVA Voltage ed n eM ies umm A 1 PF 0 8 PF Copper Copper No of Cable Cable Cable Cable size multiple AYFY A Sqmm A in Sqmm rine 1 10 415V 11 13 13 91 2 5 24 2 15 415V 16 70 20 87 4 30 3 20 415 V 22 26 27 82 4 30 For Lower pcd Cables are 4 25 415 V 27 83 34 78 6 39 5 30 415 V 33 39 41 74 10 52 6 35 415 V 38 96 48 69 10 52 25 1 63 7 40 415V 44 52 55 65 16 66 25 1 63 8 45 415 V 50 09 62 61 16 66 35 1 77 9 50 415 V 55 65 69 56 25 90 35 1 77 10 62 5 415V 69 23 86 54 35 90 50 1 95 11 70 415 V 77 91 97 39 35 110 70 1 115 12 75 415V 83 48 104 34 50 110 70 1 115 13 82 5 415V 91 83 114 78 50 135 70 1 115 14 100 415V 111 30 139 12 95 1 140 15 125 415V 139 13 173 91 150 1 175 16 140 415 V 155 82 194 77 185 1 200 17 160 415 V 178 08 222 60 240 1 235 18 180 415V 200 34 250 42 120 2 279 180 415V 200 34 250 42 300 1 260 19 200 415V 222 60 278 25
23. nd tables Adequate information is compiled together keeping in mind to make this manual crisp handy and user friendly We are sure this manual will be useful for installation to the end user to achieve desired performance of the KGPI Genset KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BE Technical Specifications General Guidelines MEMME Overall Specifications of Kirloskar Green Silent Gensets Liquid Radiator cooled Silent Gensets F Engine Power Prime Power Genset Overall Canopy Dimensions Approx weight Genset Model Engine Model 2 1500 rom kW hp rating at 0 8 pf kVA LxWxH mm with canopy kg KG7 5WS EW14 10 3 14 1 5 1725 x 845 x 1155 KG10WS EW14 10 3 14 10 1725 x 845 x 1155 755 KG15WS4 2R1040 20 6 28 15 2050 x 950 x 1220 915 KG20WS4 2R1040 20 6 28 20 2050 x 950 x 1220 925 KG25WS5 3R1040 30 9 42 25 2380 x 950 x 1230 1020 KG30WS 3R1040 30 9 42 30 2380 x 950 x 1230 1050 KG40WS 4R1040 41 2 56 1 40 2650 x 1050 x 1605 1520 KG50WS 4R1190 45 6 62 50 3350 x 1190 x 1650 1500 KG62 5WS2 4R1040T 61 83 62 5 3240 x 1140 x 1585 1900 KG82 5WS2 4R1040TA 77 2 105 82 5 3240 x 1140 x 1585 1950 KG100WS 4K1080TA 92 125 100 3200 x 1300 x 1805 1950 KG100WS2 6R1080T 93 3 127 100 3450 x 1300 x 1900 2500 KG125WS2 6R1080TA 113 2 154 125 3450 x 1300 x 1900 2700 KG140WS2 6K
24. ng is kW kVA x Power Factor kW 1 732 x V x Ax Power Factor for 3 phase alternator 1000 Load variation between phases should not be kW VxAx Power Factor fora single phase alternator more than 10 1000 Where V Line voltage A Line current 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 is 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 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BN Sizing of KGPI Genset General Guidelines EE 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 AC Motor DC Generator 0 80 0 90 Transformers 0 80 0 95 Block Loading For Naturally aspirated engines 10096 of rated power For Turbocharged and Turbo after cooled engines Please consult Seller or Kirloskar s Area Office for load pattern and sequencing Deration Factor The engine s horse power as mentioned on its name plate is the HP which an engine can deliver at
25. ong grade of oil could lead to x Overheating of the engine x Sluggish performance x Excessive fuel consumption Increased wear of bearings and other moving components 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 is accessible and clean all the time Ensure all fuel piping is leak free Avoid fuel spillage Ensure fuel dilution does not occur VV VV ON Care should be taken while filling of tank to prevent ingress of dust amp moisture inside diesel tank gt It is recommended to fill fuel after stopping of the Genset to avoid condensation A It is recommended not to fill fuel during running of Genset KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support IE Electrical System a Earthing Any leakages in current will be earthed through the shortest route in the link KGPI Genset should be connected to earth in accordance with local regulations The size of the link used for the main earth connection should be of adequate size as shown in table below The generating set and all associated equipment must be earthed before the set is put into operation 4 numbers of earth pits are required as per Indian Electricity rules local electricity regulations gt earthing pits for Genset control panel body gt earthing pits for neutral
26. operation KGPI Genset Liquid Cooled are delivered with initial fill of Premixed Coolant K Cool Super Plus gt Ensure NO addition of water in coolant gt Ensure Top Up only with K Cool Super Plus coolant gt 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 gt Ensure cleanliness of cooling air passages KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BN Lub Oil System a 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 gt Check the Lub Oil level with the help of Dipstick to H Mark and top up if required with K Oil Super only K Oil Super SAE 15W 40 is a specially blended engine oil which ensures Y Increased change intervals Y Better oxidation stability and hence less top ups Y Reduced frictional wear Y Increased internal cooling Y Protection against rust and corrosion Y Reduced carbon deposits A Use of the wr
27. oskar s Area Office KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BIN Technical Specifications General Guidelines RTT Overall Specifications of Kirloskar Green Silent Gensets Air cooled Silent Gensets G Mode Enaine Model Engine Power Prime Power Genset Overall Canopy Dimensions Approx weight enset Model Engine Model 4500 rpm KW hp rating at 0 8 pf kVA LxWxH mm with canopy kg SEKG5AS7 EA10 74 10 5 1600 x 820 x 1320 650 SEKG7 5AS5 EA16 11 7 16 7 5 2070 x 820 x 1320 850 SEKG10AS5 EA16 11 7 16 10 2070 x 820 x 1540 850 KG15AS4 HA294 SrIII 15 1 20 5 15 1770 x 1050 x 1400 1220 KG25AS C HA394 23 5 32 25 2030 x 1050 x 1400 1350 KG30AS HA494 31 6 43 30 3130 x 1100 x 1680 1440 KG40AS HA494T 41 2 56 40 3220 x 1100 x 1680 1580 KG45AS HA494T 41 2 56 45 3220 x 1100 x 1680 1580 KG50AS HA694 47 8 65 50 3980 x 1240 x 1680 1870 KG70AS HA694T 61 83 70 3980 x 1240 x 1680 1920 Note Genset ratings are as per ISO 8528 performance class G2 Prime Power Rating is the maximum power available continuously for a variable electrical load for unlimited number of hours per year under standard operating conditions Single phase genset option available up to 30 kVA For ESeries fuel tank integral with base frame Forsite conditions other than standard operating conditions consult KOEL for availa
28. ould 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 Maximum allowed temperature rise above ambient in Genset Enclosure at air intake of engine is 7 9 deg centigrade HOT AIR OVER x x BARRELS CYL HEAD ATMOSHPERIC AIR ATMOSPHERIC C wee e 4 TP RON om D eo 4d ooo KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BI Foundation LB i Foundation is one of the important factors 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 given below gt 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 running Absorb the vibration produced by the rotating and reciprocating masses VV V WV Isolate the surrounding structures by absorbing the vibration of generating set while running UT B KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BI Foundation DE While casting the concrete foundation the bearing strength of the soi
29. r from different market segments We provide reliable amp high quality products at competitive cost We also provide variety of alternative fuel gensets which efficiently run on Bio Diesel Bio Gas SVO Straight Vegetable Oil and Natural Gas as per customer requirement KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support IIl Contents E Topic Introduction Technical Specifications Liquid cooled m Air cooled m Sizing and load calculation Installing KGPI Genset for the best performance Location and Room Layout Location Layout Ventilation m Foundation a Unloading and Positioning m Exhaust System Cooling System a Lub Oil System m Fuel System m Electrical System m Battery Starting and Stopping a New KGPI Genset 24 271 m Before Starting a Starting and Stopping KGPI Genset a Log Book m Maintenance Tips KGPI Genset Cleaning and Preservation 28 KGPI Customer Support Network 29 KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BI Introduction Se Welcome to the family of Kirloskar Oil Engines Ltd You are a proud owner of The Best amp Preferred Nation s own Kirloskar Green Power Ideas Genset KGPI Genset This product is designed to deliver full rated output with high degree of reliability Utmost care is taken while manufacturing the generating set to ensure to deliver the best perfo
30. rmance to the end user To get the best performance from the generating set the installation and continuous maintenance of the set are the important factors This booklet describes simple procedures that should be followed to get the best output from the generating set If the installation and maintenance procedures are followed the generating set will deliver the output for prolonged time and will also ensure gt Better reliability gt Highest uptime gt Improved aesthetic gt Better working conditions Our Area offices and Service Dealer network will be pleased to provide you the necessary support and guidance The details of this network are provided at the end of this booklet Before operating the KGPI Genset read the User Manual to become familiar with your generating set Safe and optimum operation can only be possible if the generating set is properly operated and maintained Once again thank you for showing your trust by selecting KGPI Genset About this manual This manual provides installations and commissioning general guidelines and recommendations for KGPI Genset In this manual different types of installations Free field Roof top Basement and Structural etc have been considered while preparing the guidelines and recommendations However in case of a customized or critical installation need kindly consult Seller or Kirloskar Area Office The information is supported by different photographs diagrams a
31. serve Our service team is always round the corner to provide onsite assistance and comprehensive Service supportensuring your power needs are fulfilled Before commissioning the KGPI Genset please go through the contents of the warranty document For any of your service requirements please contact nearest service dealer or KOEL Help Desk Help Desk Call 1800 233 3344 Email koel helpdesk kirloskar com Customer Assistance is available from our 24 x 7 Help desk for Sales after Sales and Service assistance KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support Notes KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support After Sales Service Support Customer Care Round the clock at your service whenever amp wherever you need After sales service is the key to the long term viability of any business We are committed to provide adequate after sales service support amp believe in creating enduring relationship with every individual customer we serve Kirloskar believes in the wise saying think global amp act local with full dedication which have helped us successfully achieve 100 years of great service Service Offerings W Free service checks W Authorized Kirloskar Service Dealers in your neigh borhood to promptly respond to your service c
32. st Zone Service Dealer 105 Katia A Himachal Pradesh South Zone A Service Dealer Branch 332 Damtaly Kuly punis Manda AUna Nr rar A Baddi alandnar Ferozpdlk udhani Shia sir Ag Chandigath Bhatindaa Sangtury Yamuna Dehradun PalasO O erasa mA Hara Kamaf A Sdharanpur nod Sri gfnganegar EE Panis A Hildvani 9 ART A Bipot r rey els M4 Jhunjunu Gowns t os S M j BikanerA i Gurgaon Noida Mets rates dine a Rajasthan Ep Kaui CA O POA i Bareily A Slapur o gt pm A Jaisalmer vines a A Hardoi A Gonda Cem Poemi A f land mer A Shahj hanpur Lucknow M Sligui T amp ces Nagalan totoro V e DS ACER en ane VA femmes e Assam TAA alova A 5 kenpur sutanpur Maua 5 Patna Hajipur f oo AN A ABhiwara A Rajsamand Allahabad 3 thar Y Meghalaya 2 5 Manipur Barmer A Varanasi Bihar 4 T T QUsir y Kota A Lo N a Bado Bhagalpur J 4f A Dungarpurp La Same i X a A Imphal X d Dhe C Oy a k A arnan OE 4 z Rancha e b Va Ail eles X Bur y A Pakur a ot Mizordm Ca Jamsnedgur West Bengal Rourkela ORs Aem KOLKATTA Apap Jp Orissa A Raygada n A Bhubaneshwar b Avharsugude A passers Braid i AvsipurRoad 7 MUMBAI jare abs Som gi Ph Ac mee Pune e Vichokhapattanam Raigad A 9 Solapur De _ Warangal pi Asma p secundrabad a ABafemundri Ratnagiri Kohapu i e Hyderabad Chipp 4 Ee Kage Gulbarga a s Kan Belgaum V
33. tion 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 m The environment protections m The fire protection In case of high humid atmospheric conditions an anti condensation heater 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 m There should be sufficient space around the Genset to avoid resonance and echo effect which contributes to abnormal sound from Genset m Thespace should be open without any obstacles KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support Bl Installing KGPI Genset PEEL Ventilation gt Crossventilation and free flow of cool clean and fresh air gt The space sh
34. ully charged Specific Gravity of Lead Acid in the Battery at various stages 100 Charge 1 27 to 1 24 gm cc Yellow 70 Charged 1 24 to 1 20 gm cc Blue Needs Recharge Below 1 20 gm cc Red KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BE Starting and Stopping A New KGPI Genset MEMME Ensure tightness of all external fasteners hose clamps V belt tension as per specifications Ensure Cleanliness of the Genset Lubrication gt Check Lub oil level with help of Dipstick and if required top up to H Mark with K Oil Super Fuel gt Ensure fuel tank is clean from inside gt Fill fuel tank with clean High Speed Diesel gt Bleed the fuel system as shown in maintenance manual Cooling Liquid Cooled Engines gt Check Coolant level inside Radiator and Compensatory tank If required Top up with K Cool Super Plus Air Cooled Engines gt Check Blower Fan belt tension Electrical gt Check Battery Polarity Check Battery cables are correctly connected and secured Check all other electrical connections and tightness Ensure Emergency Push Button is in released condition Ensure Load Change Over Switch Breaker is in Off condition KIRLOSKAR OIL ENGINES LIMITED First Edition April 2012 Issued by Customer Support BE Starting and Stopping A New KGPI Genset EEE Procedure Starting KGPI Genset Before Starting gt Clean the Genset
35. with dry cloth gt Check the lub oil coolant and fuel levels top up if required as per recommendation given gt Check for V belt Hoses and external leakage if any gt Ensure Load Change Over Switch Breaker is in Off condition On Starting For Key Starting gt Donotcrank engine for more than 5 seconds gt As soon as engine fires release the start key Leave ignition switch in ON position For Push Button Starting gt Gently press Start button once and release gt Ifengine fails to start wait for a minute and try again gt Check for leakages if any gt Allow the engine to idle for 3 minutes and then start loading the Genset gradually in steps gt Check for Engine parameters like Oil Pressure Coolant Temp and Battery charging rate at regular intervals while the Genset is in operation and maintain log book gt Check for exhaust smoke gt Check forabnormal noise if any gt Check for A C Alternator parameters like Voltage Ampere KW PF on all phases gt Ensure load is balanced in all phases as per recommendation and within rated output of Genset gt Checkallgauges and meters provided in Control Panel are working Procedure Stopping KGPI Genset Before stopping gt Remove the load from Genset and let it run for about 3 minutes gt ForKeyStart put Ignition key in Off condition gt For Push Button Start push Stop button gently once and release After Stopping gt
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