Home

15REYG 30REYG Installation

1. SSIIIYV QVil qvo UJNOISNI NOILYDOT NOILOJNNOQ JOV4AYSLNI YAWOLSNO 4444441444460 00L 0 JIVOS 1311N0 LSNYHX3 V Visa 1v201 AU3LLYE AVJYHL OS IXOIN XZ YS 40 JONVIS NOLLOG IINNOW LES 0 SEID Xv G 6ci 0 0GL Figure 7 3 Dimension Drawing ADV 7692 Sheet 2 Generator Set 53 Section 7 Dimension Drawings TP 6727 11 09 FLEXIBLE EXHAUST o S S mu Tii RADIATOR DUCT FLANGE MY S
2. Pressure cap engine coolant fill Coolant overflow tube Coolant overflow bottle Figure 3 12 Coolant Fill 3 8 Operation Tests A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 1 Check the items in the Prestart Checklist in the generator set Operation Manual TP 6727 11 09 2 Move the generator set master switch to the RUN position to start the generator set Use a digital voltmeter DVM to check the output voltage from the generator set If voltage adjustments are required refer to Section 5 5 for instructions to use the ADC 2100 voltage adjustment menu Perform voltage checks as described in the ATS Operation and Installation manual Close the main circuit breaker on the main distribution panel when instructed to connect power in the test procedure TP 6727 11 09 Test the system operation as described in the ATS Operation and Installation manual Set the exerciser on the transfer switch Refer to the instructions in the ATS Operation and Installation manual Verify that the generator set master switch is in the AUTO position Verify that all guards and enclosures are in place Section 3 Installation Instructions 33 Notes 34 Section 3 Installation Instructions TP 6727 11 09 4 1 Introduction Accessories a
3. 31 3 7 2 Add Coolant iseer neraca renna ier ccc ence cent neces 32 3 8 Operation Tests ulus usu nasa la in 32 TP 6727 11 09 Table of Contents Table of Contents continued Section A Accessories oso lola cue ean aa 35 4 1 Introduction corde akankunata dai puni bush 35 42 Common Fault and Run Relay Board 35 4 3 Remote Digital Gauge gt sr Me u shia d de eect A teens 36 44 Block Heaters imune m ae nn ene cee ie 36 45 Oli Makeup Kit u pa PEDE RUPEM RDUM UEM 36 4 6 OnCue Home Generator Management System 36 4 7 Dropover Sound Enclosures 37 Section 5 Controller 220 cen UU iui ie a nt iene a ape wih neg ann Sarees B R par REG 39 5 1 Advanced Digital Control ADC 2100 39 5 2 Controller Automatic Power Down 39 5 3 Controller Configuration 40 5 4 Voltage Adjustments a 43 Section 6 Generator Reconnection sseeeeeeeseee n nnn nnn 47 6 1 Voltage Reconnection rer rr rr rr rr aaa aaa 47 6 2 Four Lead Single Phase Generator Sets 48 6 3 12 Lead Three Phase Generator Sets 48 Section 7 Dimension Drawings usssussausanunannnnnnnnnnnnnnnnnnnnnnnnananna 51 Appendix A Abbrevi
4. 310N 338 S1108 YOHONY Xr QN3 3NI9N3 v3uv dh gnis 13nj 8521 01 Qvd 40 JOVJUNS dol YOLYNYJLIY v3uv dn anis 1v21u12313 I 8 X S Y 012 X SII ON I LNNOW ur ww Ul eje suoisueuuiq Z 133HS NO a3anT9N Q13IHS ANNOS G3LNNON QIMS doj 1IV13Q0 ONILNNON ONIM H9IH 3009 31VIS A8 O3NIW3S3130 YOLOW4 Al34JVS V ONIQODnIONI S3 VA 3S3H1 NO Q3SV8 S1108 HOHONV 371S 81 86 by 6LI 40 AYOT Nv3HS L Sd1 611 by 92 40 32404 1no T1nd 01 O3lodrans 38 11IM SL108 YOHONY AINO Q131HS GNNOS YJAO dOHQ SALON HLIM JSN 404 SSANWOIHL WOWINIW OG Lei 310N 339 W130 Qvd ONLLNNOW ONILNNOW 13SN39 Y03 S1108 YOHONY XF IS 621 310N 338 OSL 013IHS GNNOS 404 S1108 YOHINV XF r 910N QN3 3NI9N3 dh gnis 13nj Qvd 40 19Y4YNS dOL QN3 YOLYNY3LIV v3uv dh gnis 71991919373 EIS X S y ol2 X SII Figure 7 8 ADV 7695 Sheet 4 150 MPH High Wind Mounting Details TP 6727 11 09 imension Drawings 58 Section 7 D Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC
5. 1 With the generator set off connect a digital multimeter to the output leads or an electrical outlet on the load side of the generator set Set the meter to measure AC voltage 2 Start the generator set by moving the generator set master switch to the RUN position 3 Use the ADC controller to adjust the voltage parameter 1P until the output voltage reaches the desired value See Figure 5 5 for the approximate change in voltage per step in parameter 1P Voltage Change per Step VAC Coarse Adjust Fine Adjust 85 132 5 0 5 180 251 7 0 7 Measured Voltage VAC Figure 5 5 Voltage Adjustment approximate 4 Adjust the voltage stability gain parameter 2P to minimize light flicker 5 Readjust the voltage if necessary 6 Stop the generator set Section 5 Controller 43 Output Voltage Adjustment Mode Move the generator set master switch to the RUN position The generator set engine starts and the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode To raise or lower the voltage in large increments approximately 5 7 volts per step To enter fine voltage adjustment mode To raise or lower the volt
6. For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6727 11 09 1 1 Introd
7. Safety Precautions and Instructions 5 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Engine Backfire Flash Fire WARNING Gh r Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carbu
8. The generator set is equipped with neoprene vibration isolators Connections between the generator set or its mounting base and any conduits fuel lines or exhaust piping must include flexible sections to prevent breakage and to isolate vibration Section 1 General 11 1 6 Unit Mounted Radiator Cooling The generator set is equipped with a unit mounted radiator common cooling system 1 6 1 System Features The system s major components include an engine driven fan and circulating water pump a radiator and a thermostat The pump circulates water through the engine until it reaches operating temperature Then the engine thermostat opens allowing water circulation through the radiator The thermostat restricts water flow as necessary to prevent overcooling The fan blows air from the engine side of the radiator across the cooling surface 1 6 2 Recommended Coolant Add antifreeze before starting the generator set or energizing the block heater The generator set manufacturer recommends a solution of 50 ethylene glycol and 50 clean softened water to provide freezing protection to 37 C 34 F and boiling protection to 129 C 256 F A 50 50 solution also inhibits corrosion Consult the engine manufacturer s operation manual for engine coolant specifications 1 7 Fuel Supply Gas fuel systems operate on either LP liquefied petroleum or natural gas Refer to the the instructions in Section 3 7 for more detailed inf
9. Section 2 Open Units 17 2 2 Air and Cooling Combustion and heat dissipation require an ample flow of clean cool air To prevent accumulation of explosive gases ventilate compartments containing batteries 2 2 1 Installation Considerations Intake and outlet openings Provide air intake and air outlet openings for generator sets located in a building or enclosure Keep air inlets and outlets clean and unobstructed Position the air inlet into the prevailing wind and the air outlet in the opposite direction Ventilating fans Use ventilating fans and or ductwork to increase airflow if the generator set s cooling fan does not provide adequate cooling to prevent overheating See Figure 2 2 When using ductwork and ventilating fans check the exhaust fan capacity in m3 min cfm If using exhaust fans install fan operated louvers with exhaust fans to regulate airflow See Figure 2 5 Follow the fan manufacturer s recommendations to determine the size of the inlet and outlet openings Figure 2 2 Ventilating Fans Thermostatically controlled louvers The ventilation system must provide a temperature differential sufficient to prevent high engine temperature shutdown on even the hottest days In areas of great temperature variation install movable louvers to thermostatically regulate airflow and room temperature See Figure 2 3 and Figure 2 4 Refer to 2 2 2
10. To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 5 7 Output Voltage Adjustments Continued TP 6727 11 09 Section 5 Controller 45 Notes 46 Section 5 Controller TP 6727 11 09 Section 6 Generator Reconnection 6 1 Voltage Reconnection The reconnection procedure explains voltage reconnections only Do not attempt to change the frequency e g from 60 Hz to 50 Hz in the field The following instructions explain the reconnection of 12 lead generator sets In all cases follow the National Electrical Code NEC guidelines Reconnect the stator leads of the generator set if a different output phase or voltage is desired Refer to the following procedure and the connection schematics Refer to Section 5 for instructions to make adjustments though the ADC 2100 menus when instructed in the procedure Follow all safety precautions at the front of this manual and in the text while performing this procedure Note Order voltage reconnection decal 246242 from an authorized service distributor dealer and affix decal to generator set after reconnecting to a
11. Frequency Hz Phases Wires Connection 120 240 Unit s system voltage UUO1 60 Single phase 3 vvire 1 phase and frequency Uu04 277 480 60 Three phase 4 wire Wye Uu10 120 240 60 Three phase 4 wire Delta Uu10 139 240 60 Three phase 4 wire Wye Uu11 120 208 60 Three phase 4 wire Wye Uu16 127 220 60 Three phase 4 wire Wye Unit configuration UcO1 Standby Engine type Ec11 15REYG and 30REYG Engine data input types Edo1 15 30 kW factory setup Battery voltage Bt12 12 VDC Communications Cn00 No CAN communications Cn01 J1939 use for Remote Digital Gauge for either Cn06 Enables J1939 communications and 1 hour ADC power down after engine stop a Remote start stop switch b Automatic transfer switch c Remote Digital Gauge with remote start stop switch and replacement harness ADC application program version 3 25 or higher is required Figure 5 1 Configuration Parameters 40 Section 5 Controller TP 6727 11 09 Controller Configuration Mode Hold the Select button Display Move the generator set master switch to the RUN position The generator set engine will not start Wait about 5 seconds until the display shows the program version number The number may be different than the one shown here Press the down arrow key and then the up arrow key 3 times t
12. hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6727 11 09 Accidental Starting A WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fu
13. power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element
14. the information in Sections 1 and 2 before beginning the installation procedure See Figure 2 1 for a typical open unit installation Note Indoor Installations For the protection of generator set service technicians and any other people that may enter the building install carbon monoxide CO detector s on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Read and follow the safety precautions in this manual and observe the decals on the equipment Refer to the diagrams and drawings in Section 7 for dimensions and electrical connections during the installation procedure Read the entire installation procedure and obtain the accessories and tools needed before beginning installation Perform the steps in the order shown TP 6727 11 09 Section 3 Installation Instructions To install optional accessories follow the instructions provided with each kit A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically grou
15. 1 Note For wiring diagrams refer to TP 6719 Wiring Diagram Manual Drawing Dimension Drawing Description Number Generator Set Sheet 1 ADV 7692 Sheet 2 ADV 7692 Accessories ADV 7693 Enclosures Sheet 1 Weather Housing and Sound Upfit Kit ADV 7695 Sheet 2 Sound Enclosure ADV 7695 Sheet 3 Dropover Sound Enclosure loose kit ADV 7695 Sheet 4 High Wind Mounting Details ADV 7695 Figure 7 1 Dimension Drawings TP 6727 11 09 Section 7 Dimension Drawings 51 Z69L NAV ui ww ur eje suoisueuiig 8 0N LO NOILYIOT 3SOH NOISN31X3 NIVYG 110 31VN33 131N1I 13f NOILVJOT ONILNNON YINVIY 1105815 YITIOYLNOI dvd ONILNAOW NI SANIS OIN XF LINA N3dO 404 1YDIdAL IV130a Qyd NILNNOW 066 v3uv dN ANLS 1304 L9L el 0 0L Yd 9NILNNON NIN SSINYJIHI O F col i 3NI 1100 AVd F ee S QIXS 13SN35 VIYV dh anis 1V21812313 LI 19 dvd ON LNNOW GOLI Figure 7 2 Dimension Dravving ADV 7692 Sheet 1 Generator Set TP 6727 11 09 52 Section 7 Dimension Drawings ui ww ul eje SUOISUBWIG 8 0N V vlad 33s 131100 dl
16. 10 in minimum 25 mm 1 in minimum Exhaust pipe Ventilation holes at both ends 254 mm 10 in minimum 25 mm 1 in minimum Flashing Inner sleeve Outer sleeve Thimble outer diameter 254 mm 10 in minimum outside 254 mm 10 in minimum inside Exhaust pipe diameter O OO I O QI KON Figure 2 11 Double Sleeved Thimbles and Rain Cap 22 Section 2 Open Units 2 3 6 Exhaust System Backpressure Exhaust backpressure limits engine power and excessive backpressure causes serious engine damage Excessive backpressure usually results from one or more of the following reasons e The exhaust pipe diameter is too small e The exhaust pipe is too long e The exhaust system has too many sharp bends e The exhaust silencer is too small e The exhaust silencer is not the correct design for the application The engine s maximum exhaust backpressure limit is 10 2 kPa 3 0 in Hg Use the following procedure to verify that the installed exhaust system does not exceed the maximum exhaust backpressure limit Exhaust System Backpressure Calculation Procedure Determine the total backpressure by calculating the effects of the individual exhaust system components and adding the results Make calculations using either English or metric units Exhaust pipe references are nominal pipe NPT in sizes The procedure shows an example with italic text 1 Identify the type of silencer used in the
17. 15 8 ft total Refer to Figure 2 13 Place a straight edge across the chart with the edge in line with the pipe size in inches D on the right column from step 4 and the engine exhaust flow Q from step 2 on the left column Read backpressure kPa m or in of Hg ft AP from the center column Calculate the total piping system backpressure by multiplying the total equivalent straight pipe in m ft from step 6 by the kPa m or in of Hg ft of pipe from this step Example 4 76 equiv m x 0 5 kPa m 2 4 total system backpressure in kPa 15 8 equiv ft x 0 048 in Hg ft 0 76 total system backpressure in inches of Hg Add the backpressure of the piping determined in step 7 to the backpressure of the silencer and exhaust pipe determined in steps 1 and 2 The total should not exceed the engine manufacturer s maximum allowable system backpressure determined in step 2 or on the generator set s specification sheet If the total exceeds the maximum use a larger pipe size or silencer or both Repeat the calculation if new components are selected to verify that the system backpressure would not exceed the limit using the larger component s Example 2 44 1 7 5 45 kPa 9 55 kPa Maximum allowable backpressure 10 2 kPa 9 55 10 2 backpressure drop is acceptable 0 76 10 5 1 6 in Hg 2 86 in Hg Maximum allowable backpressure 2 88 in of Hg 2 86 8 in Hg backpressure drop is acceptable Section 2 Ope
18. 16 Section 1 General TP 6727 11 09 Section 2 Open Units 2 1 Introduction This section contains installation information specific to open unhoused commercial generator sets Review the precautions in the Safety Precautions section and the information in Section 1 General Open unhoused commercial generator sets may be installed inside an unoccupied building if the exhaust gas is piped safely outside and adequate air flow is provided for cooling and combustion The generator set location must be safe secure locked and well ventilated Figure 2 1 illustrates a typical open unit installation For the protection of the building s occupants install carbon monoxide CO detectors on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Note Do not install open unenclosed commercial generator sets in residential applications Note Do not install enclosed units inside a building Note Do not install open commercial generator sets in residential applications Supports Exhaust thimble for wall or ceiling Silencer Water trap with drain Flexible sections Duct work for cooling air outlet Mounting base Controller Electrical conduit Fresh air intake Figure 2 1 Typical Open Commercial Generator Set Installation TP 6727 11 09
19. BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources
20. Figure 3 3 Natural Gas Flow Rate Section 3 Installation Instructions 29 Fuel Supply Specifications Fuel type LP Gas or Natural Gas Fuel supply inlet 3 4 14 NPT Fuel supply pressure oz in 2 in H2O 4 6 7 11 Nominal Fuel Rating Btu ft Natural gas 1000 LP vapor 2500 Figure 3 4 Fuel Requirements Fuel Consumption 15 kW 30 kW Natural Gas m hr cfh at load 5 7 200 12 7 450 4 5 160 10 6 375 3 5 125 8 5 300 2 5 90 6 4 225 LP Gas m3 hr cfh at 96 load 5 1 180 4 2 150 3 4 120 2 5 90 Figure 3 5 Generator Set Fuel Consumption 2 Measure the pipe length from the primary gas pressure regulator to the pipe connection on the installation shown generator set fuel inlet Add 2 4 m 8 ft to the 3 Connect the fuel supply measured length for each 90 degree elbow Use the pipe size indicated in Figure 3 6 for the total a Apply pipe sealant that is approved for fuel length of pipe connections to the threaded fuel connections Have your fuel supplier install a manual fuel b Usea section of flexible fuel line to connect the shut off valve and rigid gas piping Bring the pipe to fuel supply to the fuel inlet connection on the within 10 inches of the generator set fuel inlet generator set See Figure 3 8 and Figure 3 9 location See Figure 3 7 for the fuel inlet connection location Pipe Size c Open the manual fuel valves and leak
21. application and refer to Figure 2 12 for the silencer back pressure Example Determine the silencer backpressure for the recommended critical silencer on a model 30kW generator set Silencer backpressure 5 5 kPa 1 6 in Hg 2 Refer to Figure 2 12 for the backpressure from the J shaped engine mounted exhaust pipe Example Determine the exhaust pipe backpressure for a model 30kW generator set Exhaust pipe backpressure 1 7 kPa 0 5 in Hg Backpressure kPa in Hg Silencer Type 15kW 30kW Residential SIEO 2 in NPT Critical SIEO 2 in NPT Exhaust J tube 1 5 0 47 1 7 0 51 0 3 0 1 4 7 1 4 5 5 1 6 1 7 0 5 Figure 2 12 Silencer and Engine Exhaust Pipe Back Pressures TP 6727 11 09 3 Refer to the generator set specification sheet for a Engine exhaust flow at rated kW in m min cfm Example 8 35 m3 min 295 cfm b Maximum allowable backpressure in kPa in of Hg Example 10 2 kPa 3 0 in Hg 4 Refer to the submittal catalog for a The flexible exhaust adapter part number Example 324089 b Flexible exhaust adapter flexible section length Example 432 mm 17 in 5 Countthe number of elbows and flexible sections in the exhaust system between the engine and the exhaust system outlet Compare the radius of the bend R to the pipe diameter D Diameter is the nominal pipe diameter in inches Determine the equivalent length in m ft of straight pipe f
22. for a CAN gauge communications parameter setting CnO1 the controller will not power down The ADC 2100 controller remains powered at all times to allow remote start commands from the remote CAN gauge 1 hour power down Setting the communications parameter to Cno6 will cause the controller to power down after 1 hour of no activity In this mode a remote start stop switch or the generator set master switch must be used to activate the controller after it has powered down Controller application code version 1 21 or higher is required for the 1 hour power down option Section 5 Controller 39 5 4 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes The controller s configuration mode allows adjustment of the system parameters listed in this section If necessary use the instructions in this section to check the configuration after installation and change the parameters to match the settings shown in Figure 5 1 The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved Follow the instructions in Figure 5 2 to enter the configuration mode while the engine is not running and then step through the following parameters Use
23. hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with Sl units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 22 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 60 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA oz p Pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straig
24. not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater 4 5 Oil Makeup Kit The optional oil makeup kit available for 30 kW generator sets provides an additional 2 quarts of oil for extended run time Follow the instructions provided with the kitto add oil if necessary and to check the height of the oil level sight gauge during generator set installation 4 6 OnCue Home Generator Management System The OnCue Home Generator Management System allows monitoring and control of your generator set from a personal computer located in your home or at other remote locations OnCue can also be configured to send email or text message notifications in the event of a generator set fault The OnCue systemis available as aloose kit Followthe instructions provided with the OnCue kit to install the network bridge inside the generator set junction box connect to your ethernet router and cable or DSL modem and configure the system for monitoring and notification TP 6727 11 09 4 7 Dropover Sound Enclosures The dropover sound enclosure is available as a loose kit for field installation The enclosure kit includes the assembled enclosure radiator duct flanges and exhaust system components Refer to the assembly drawing included with the kit for installation details Connect the exhaust
25. stud and isolated if the installation requires an ungrounded neutral connection at the generator The generator set will operate properly with the neutral either bonded to ground or isolated from ground at the generator Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding of the neutral atthe generator NEC 2002 Section 250 20 is one example that has a very good explanation of the neutral grounding requirements for generators Neutral LO connection Ground GRD connection Relay interface board RIB standard 3 relay board shown Line circuit breaker location Load lead access opening Customer interface connector location Figure 3 1 Generator Set Electrical Connections 3 5 Generator Set Electrical Connections Note Have a licensed electrician make the following electrical connections All connections must comply with state and local codes Section 3 Installation Instructions 27 Size the wire according to the length of run and 115 of the circuit current amperage as directed by the National Electrical Code NEC in ANSI NFPA 70 See Figure 3 1 and refer to the wiring diagrams in Section 7 Diagrams and Drawings Load Lead and Engine Start Connections 1 Install a 120 VAC receptacle for the generator set battery charger and block heater if equipped Supply power to the recep
26. test all fuel connections using soapy water If a leak is 15 kW Feng T S NB SUEN detected close the fuel valves disconnect the 61m 20ft gt in NPT 11 4 2 NPT lines at the location of the leak clean the 9 1m 30ft tin NPT 1 1 4 in NPT fittings and apply fresh pipe sealant 18 3 m 60 ft tin NPT 1 1 2 in NPT Reconnect the lines and recheck for leaks 30 5m 100 ft 1 1 4 in NPT 1 1 2 in NPT 157 TT Ain NET NPT Note After the system installation is complete 57m 150 ft ule ae check for fuel leaks with the generator 61 0m 200 ft 1 1 4 in NPT 2in NPT setrunning See Section 3 8 Operation Tests Maximum Pipe Figure 3 6 Fuel Pipe Sizes 30 Section 3 Installation Instructions TP 6727 11 09 4 Check that the fuel system is set up for the fuel being used natural gas or LP See Section 3 7 1 ADV 7692 1 2 Note UL 2200 listed units include a second fuel valve See Figure 3 9 1 Fuel supply connection 3 4 NPT 2 Fuel solenoid valve Figure 3 8 Fuel Supply Connection Location Generator set enclosure not shown SI men 1 Fuel solenoid valves qty 2 2 Fuel supply connection 3 4 NPT Figure 3 9 Fuel Supply Connection with Two Fuel Valves 3 7 4 Fuel Conversion Procedures Note Th
27. the up and down v arrow buttons to select the appropriate setting for the application Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 5 1 Note This parameter sets the nominal system voltage and frequency To adjust the output measured voltage see Section 5 1 Unit configuration Uc This parameter sets the generator set type Select UcO1 standby Engine configuration Ec The engine configuration must match the generator set engine type Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine data input types Ed This setting defines the type of senders used on the generator set engine Battery voltage Bt This setting toggles between 12 and 24 VDC for the engine starting battery voltage Communications setting Cn This setting allows the user to set the controller for communication with optional meters The factory setting is Cn00 no CAN communications Change this setting if the optional Remote Digital Gauge is used See Figure 5 1 Description Parameter Setting Voltage VAC
28. uuu sos vara salen nia t r a ia e a NA BLINKA SR a edere Selah r 10 Section 1 General dina de dd alec ied a a ee IV t ae BAe ee 11 1 CIDUOd CUQO s s art a beta Sete eshte due ted 11 1 2 Enclosed and Open Generator Sets 11 1 3 Location Factors Lulus orb Y sk ee hades eee hed eg 11 1 4 Mounting Surface sz ur ada S ccc eh 11 155 Vibration Isolation x n or Baka dh Goodale a eA teh ie d 11 1 6 Unit Mounted Radiator Cooling 12 1 6 1 System Features sa seb u nee Ha an 12 1 6 2 Recommended Coolant 12 1 77 F el S pply viu sot t opto Ape bI aterert erbe Ege e diee e 12 1 7 1 Fuel ING Sa x gets alerts Denis ataqu 12 1 7 2 Gas Regulators epe epe Ra a ahnen 12 1 8 Electrical System ye ra sense area nett en 12 1 8 1 Line Circuit Breakers 12 1 8 2 Electrical Connections ulus sassa h sls ala e 13 1 8 3 Ground and Neutral Connections 13 1 8 4 Load Lead Connections 13 1 8 5 Terminal Connector Torque 13 1 8 6 Batteries uod b d uy E e tte a 14 1 8 7 Battery Chargers aa 14 1 8 8 Remote Start Connection optional 15 1 89 Automatic Transfer Switches 15 Se
29. voltage different than the nameplate A WARNING D AS te Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery TP 6727 11 09 Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources bef
30. 0 Ib Use equipment that is rated for the generator set s weight to lift the unit into place Follow these general precautions when lifting all generator sets When lifting housed units lift the weather enclosure and generator set together as one unit e Do not lift the generator set using the lifting eyes attached to the engine and or alternator These eyes cannot support the generator set s weight Instead insert lifting hooks or lifting bars through the four holes in the mounting skid The placement of the holes prevents the lifting cables from damaging the generator set components and maintains balance during lifting e Ifthe lifting cables contact the air cleaner guards or other protruding components use spreader bars on the cables If the cables still do not clear the protruding component s temporarily remove the component s 3 4 Mount and Ground Generator Set 1 Place the generator set on the concrete mounting pad Secure the generator set with mounting bolts anchored in the concrete pad TP 6727 11 09 2 Ground the generator set The grounding method must comply with NEC and local codes Connect the grounding strap to the generator set ground lug terminal GRD inside the controller compartment See Figure 3 1 Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box At installation the neutral can be grounded at the generator set or lifted from the ground
31. 1 09 1 8 8 Remote Start Connection optional Connect leads 3 and 4 from the ADC 2100 controller to the automatic transfer switch s engine start terminals or to an optional remote start stop switch 1 8 9 Automatic Transfer Switches A typical standby system has at least one automatic transfer switch connected to the generator set output to automatically transfer the electrical load to the generator set if the normal source fails When normal power returns the switch transfers the load back to the normal power source and then signals the generator set to stop The transfer switch uses a set of contacts to signal the engine generator to start When the normal source fails TP 6727 11 09 and the generator set master switch is in the AUTO position the transfer switch contacts close to start the generator set The engine start terminals are usually located near the transfer switch contactor with an engine start decal identifying the terminals Use the transfer switch wiring diagrams to identify the engine start terminals prior to making connections Use 14 gauge wire run through conduit to connect the transfer switch engine start contacts or a remote manual engine start switch to the engine start connectors on the generator set Connect to leads 3 and 4 from the ADC 2100 generator set controller Use separate conduits for engine start leads generator set load cables and battery charger leads Section 1 General 15 Notes
32. 12 4 110 3 26 7 4 0 85 5 6 50 81 1 16 9 150 2 33 6 4 5 40 5 6 50 31 1 16 9 150 1 42 4 5 6 50 31 1 16 9 150 1 0 2 0 53 5 67 4 5 6 50 43 5 20 3 180 3 0 4 0 85 0 107 2 5 6 50 56 5 28 2 250 250 350 127 177 5 6 50 73 4 36 7 325 400 203 5 6 50 93 2 36 7 325 93 2 42 4 375 600 750 304 380 5 6 50 113 0 1000 42 4 375 800 1000 406 508 5 6 50 124 3 1100 56 5 500 1250 2000 635 1016 124 3 1100 67 8 600 For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Note If a connector has a clamp screw such as a slotted hexagonal head screw with more than one means of tightening test the connector using both applicable torque values 500 253 5 6 50 Figure 1 2 Tightening Torque for Screw Type Pressure Wire Connectors ADC 2100 uses three 15 second crank cycles separated by 15 second rests for larger models Refer to the generator set specification sheet for the required battery cold cranking ampere CCA rating Socket Size Across Tightening Torque Flats mm in Nm in Ib 3 2 5 1 4 0 11 4 4 8 13 8 5 6 17 0 1 87 Battery Charger
33. 420 177 850 357 675 Heating value Btu gal net LHV 94670 102032 3264 83340 91500 2516 gal gross ft gas 63310 1000 116400 124600 6390 130300 139000 Density Ft of gas gal 31 26 36 39 57 75 19 5 Wt gal liquid Ib 4 81 4 24 2 65 6 16 Octane Number Research 94 110 Motor 90 97 110 80 100 75 90 Lower Heating Value Figure 1 Engine Fuels Physical Properties Characteristic LP Gas Formula Butane C4H10 Propane CaHg Boiling point C F 0 82 42 44 Specific gravity of gas air 1 00 2 00 1 53 Specific gravity of liquid water 1 00 0 58 0 51 Btu lb of gas 21221 21591 Ft of vapor at 16 C 60 F Ib of liquid at 16 C 60 F 6 506 8 547 Latent heat of vaporization at boiling point Btu gal 808 0 785 0 Combustion Data Ft air required to burn 1 ft of gas Flash point C F Ignition temperature in air C F Max flame temperature in air C F 31 02 N A 482 538 900 1000 1991 3615 23 86 104 156 493 549 920 1020 1979 8595 Limits of inflammability percentage of gas in air mixture At lower limit At upper limit 1 9 8 6 2 4 9 6 Octane Number ISO Octane 100 92 Over 100 Commercial quality Figures shown in this chart represent average values F
34. Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6727 11 09 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department Design Failure Mode and Effects Analysis diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency
35. Cooling Air Requirements Louvers for further information 18 Section 2 Open Units Figure 2 5 Exhaust Fan Operated Louvers TP 6727 11 09 In cold climate interior installations using controlled recirculation to recover heat install thermostatically activated louvers and fans to prevent the generator set and engine room from overheating Electric louvers are usually connected to the optional generator set run relay Typically the louvers are energized to open when the generator set is operating However some louvers are energized to close and when deenergized are spring actuated to open when the generator set is operating Filters Install a furnace type or similar filter in the inlet opening if the generator set operates in an atmosphere highly contaminated with impurities such as dust and chaff Air restrictions When using a filter screen or other air restriction increase the inlet opening size by the following amounts to compensate for diminished airflow e Louvers Enlarge the opening 50 e Window screening Enlarge the opening 80 e Furnace type filters Enlarge the opening 120 2 2 Cooling Air Requirements The generator set is equipped with a unit moun
36. I b Ob MY 0 E SY 199 7 8 30 KW 177 t1 01 15 il Figure 7 4 Dimension Drawing ADV 7693 Accessories 54 Section 7 Dimension Drawings SILENCER FLEXIBLE EXHAUST amp RADIATOR DUCT FLANGE o o C2 mm TG BLOCK HEATER ENGINE MOUNTED SILENCER amp BLOCK HEATER Dimensions are in mm in Note TP 6727 11 09 O WT WT WT WT LUCE ee Ka gi IL IL IL IL IL IL IL IL IL IL IL IL IL IL Je IL IL IL IL IL IL IL IL IL IL IL IL IL IL I L Jf jJ jJ jJ jJ jJ j j J j J WEATHER HOUSING WEATHER HOUSING W SOUND UPFIT LID Ck AMN IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL IL L J j jJ jJ jJ j I jJ j j j Note Dime
37. Installation Commercial Generator Sets Models 15REYG 30REYG NATIONALLY REGISTERED KOHLER PLANER SYSTEMS sens California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description ADC 2100 Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information 2sannnnsuunannnnnnnnnnnnnnnnnnnnnnnnnna nnn 1 Safety Precautions and Instructions 2l ssssssaaanaaaaaaanaannnannnannnnnanna 5 Introduction n s n an D Emi E saywa were Ra use 9 Service Assistance
38. SNILNNON 13SN39 404 sanis OIN XF SNILNNON Q131HS ANNOS voj SONLS OIW XF AINO Q13IHS ANNOS YJAO dota HLIM ISN YOd SSINYOIHL WAWINIW O Y 201 vlad QVd SNILNNOW ur ww Ul eje suoisueuuiq SiQvuo9dn 07314 404 LIM 3S001 V SV 318VlIVAV AINO H LS 62 H OSL QN3 INIONI dh gnis 1303 Qvd 40 JOVJUNS dOl QN3 NOLVNU31 TV GIS ANNOS Y3AO dona O S681 Ly Se F 9NI x 006 u JAIS 40 NOLIOG NI SA 10H INNOW S 0 S EIB XY ADV 7695 Sheet 3 Dropover Sound Enclosure ing imension Drawi Figure 7 7 D 57 Section 7 Dimension Drawings TP 6727 11 09 S 69 AQV SI009 J1VLS A8 Q3NIWU313Q YOLOW4 Al3dVS V ONIGNIONI SINIYA 3S3H1 NO Q3SV8 Sl1108 YOH NY IZIS S81 GLE by OLI 40 QVO uv3HS S81 Fyll BM LEE jO 39404 LNO 11Nd ol a3ldarans 38 11IM S1108 HOHONV S310N 114 LIddh GNNOS HLIM ONISNOH YIHLVIM ONISNOH YIHLVIM LINN N3dO HOJ WOIdAL SSINXOIHI NONININ O G Lel W130 GVd SNILNNOW
39. T USED OPTIONAL DROOP 12 COMP CT vo 9Q1 1 38 ht 9 uy 8 3 aS 8 12 CT2 2 7 10 6 L2 Nm LO METER SCALE LAMP JUMPER 12 LEAD ALTERNATOR 4 WIRE DELTA 60 HZ 120 240V 50 HZ 110 220V L2 4 8 Lo I n 2 x OPTIONAL 7 crz DROOP CTI COMP CT 6 3 012 T dica L1 5 9 9 5 1 METER SCALE V LAMP JUMPER 12 LEAD ALTERNATOR 4 WIRE LOW WYE 60 HZ 120 208V 50 HZ 110 190V 60 HZ 127 220V 50 HZ 115 200V 60 HZ 139 240V 50 HZ 120 208V OPTIONAL DROOP COMP CT VO a i LO 1 V7 L1 7 O 1 UNA 12 4 511 2 8 METER SCALE Lo LAMP JUMPER 12 LEAD ALTERNATOR 4 WIRE HI WYE 60 HZ 220 380V 50 HZ 220 380V 60 HZ 240 416V 50 HZ 230 400V 60 HZ 277 480V 50 HZ 240 416V L1 Oj 5 e O C CT1 4 5 sy aa v8 2 v7 vo 10 11 p i v9 9 o 6 3 OPTIONAL DROOP e COMP CT 3 6 METER SCALE v7 to LAMP JUMPER PHASE ROTATION Note The current transformers CTs shown are not used on generator A B C sets equipped with the Advanced Digital Control ADC 2100 L1 L2 L3 Figure 6 2 12 Lead Generator Reconnection TP 6727 11 09 ADV 5875B J Section 6 Generator Reconnection 49 Notes 50 Section6 Generator Reconnection TP 6727 11 09 Section 7 Dimension Drawings This section contains the dimension drawings listed in Figure 7
40. age in smaller increments approximately 0 5 0 7 volts per step Continued on Figure 5 7 Display X X X X X Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 5 6 Output Voltage Adjustments 44 Section 5 Controller TP6196 TP 6727 11 09 Continued from Figure 5 6 Display To enter coarse voltage stability gain adjustment mode 2 P x x To raise or lower the voltage stability gain in large increments B To enter fine voltage stability gain adjustment mode To raise or lower the voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high To enter SAVE mode A SA AI Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position There are 3 options when the display says SAVE SA Press To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 5 6
41. ainer contains less liquid the vaporization rate of the container is a lower value Maximum Continuous Draw In Btu Hour At Various Temperatures In C F Lb of Propane 18 C 7 C 4C 16 C 21 C in Cyl OPF 20 F 40 F 60 F 70 F 113000 167000 214000 277000 300000 104000 152000 200000 247000 277000 94000 137000 180000 214000 236000 83000 122000 160000 199000 214000 75000 109000 140000 176000 192000 64000 94000 125000 154000 167000 55000 79000 105000 131000 141000 45000 66000 85000 107000 118000 36000 51000 68000 83000 92000 28000 38000 49000 60000 66000 Figure 1 Vaporization Rate 100 Ib Propane Cylinders Approximate TP 6727 11 09 Determining Propane Vaporization Capacity Guide for ASME LP Gas Storage Containers of Propane Vaporization Container Capacity at 18 C 0 F in Filled Btu Hr 60 DxLx 100 50 90 DxLx90 40 80 DxLx80 30 70 DxLx70 20 60 DxLx60 10 45 DxLx45 These formulae allow for the temperature of the liquid to refrigerate to 29 C 20 F producing a temperature differential of 7 C 20 F for the transfer of heat from the air to the container s wetted surface and then into the liquid The vapor space area of the vessel is not considered since its effect is negligible Dzoutside diameter in inches L overall length i
42. ate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment The controller s adjustment mode allows adjustment of the output voltage if necessary Have adjustments performed by an authorized distributor dealer or service technician Note A digital voltmeter is required for these adjustments Use a voltmeter to check the output voltage If the output voltage is not within specifications use the ADC controller to adjust the output voltage while the generator set is running The flowcharts in Figure 5 6 and Figure 5 7 outline the adjustment procedures Note Be sure to save your settings before exiting the configuration mode Voltage changes are lost if they are not saved before the generator set shuts down Ifthe changes are not saved the generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup TP 6727 11 09 Pressing the Select button when SAVE is displayed returns to the first parameter voltage adjust 1P Voltage Adjustment Procedure Note Refer to the flowcharts in Figure 5 6 and Figure 5 7 during the voltage adjustment procedure
43. ations 006 es nere 59 Appendix B Fuel Physical Properties e e 61 Appendix C Gas Fuel Vapor Pressures kakak e 62 Appendix D Gas Fuel System Installation Planning 63 Table of Contents TP 6727 11 09 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential
44. battery voltage selection mode To toggle between 12 and 24 VDC Set this parameter to 12 VDC To enter communications selection mode To set the communications parameter See Figure 5 1 Q lt To enter SAVE mode Go to Figure 5 4 SIAVE Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 5 3 Advanced Configuration Mode engine data input types battery voltage and engine communications There are 3 options when the display says SAVE Press To return to the first parameter system voltage frequency Uu to check or change settings before saving See Figure 5 2 or To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET X in the runtime hours display above denotes any number from 0 to 9 Figure 5 4 Save Mode after configuring generator set parameters 42 Section 5 Controller TP 6727 11 09 5 5 Voltage Adjustments A WARNING Hazardous voltage Moving parts Can cause severe injury or death Oper
45. circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a_ utility electrical system can cause severe injury or death to utility personnel working on power lines Safety Precautions and Instructions 7 A WARNING Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Heavy Equipment A WARNING Unbalanced weight Improp
46. ct the exhaust outlet away from the air inlet to prevent exhaust gases from entering the air inlet and clogging the dry type air filter elements Hot exhaust drawn through the radiator adversely affects engine cooling Locate the exhaust outlet to prevent exhaust fumes from entering a building or enclosure Noise reduction The exhaust outlet configuration affects the apparent noise level for people or animals in the vicinity An upward directed outlet seems quieter than one directed downward or horizontally Additionally a 30 to 45 degree angled cut at the end of a horizontal exhaust outlet pipe reduces turbulence at the outlet thereby reducing the noise level Section 2 Open Units 21 Rain cap To prevent precipitation from entering the exhaust pipe install a rain cap on vertical outlets See Figure 2 11 In aclimate where freezing is common do not use arain cap Instead extend the exhaust piping at least 610 mm 24 in beyond the roof line and create a gradual U bend at the end to direct the exhaust outlet downward Keep the pipe outlet at least 457 mm 18 in from the roof to prevent hot exhaust from igniting the roof material Note Avoid using a rain cap in areas subject to freezing temperatures Rain cap or gradual U bend Rain shield 254 mm
47. ction 2 Open Units 1712 ss ee ewe d 17 2212 gt Introduction aus nuqan a Siew soe ee eal aa pec d 17 2 2 Airand Cooling 1 tasya cette eee tenet eee RE 18 2 2 1 Installation Considerations 18 2 2 2 Cooling Air Requirements 19 2 39 ExhaustSystem va EVER Rund E pasi a salida 19 2 3 1 Flexible Exhaust Line ore ccc cece IIR 20 2 3 2 Condensation Trap uu sn ua lisasta shu teen eens 20 2 3 3 PIPINO ss k sakta 21 2 3 4 Double Sleeved Thimbles 21 2 3 5 EXhaust Outlet icen kec nn dhi nd dt s aaa ab oa ne 21 2 3 6 Exhaust System Backpressure 22 Section 3 Installation Instructions i aaa aa aa 6c cece RAKA RAR RR ees 25 3 1 ntrod ction sie se nre ERR ae ig he des 25 3 2 Prepare Site e TURPE EUR Mq re 26 3 2 1 Indoor Installations Open Units 26 3 2 2 Outdoor Installations Enclosed Units 26 3 3 Lifting Generator Set aa 27 3 4 Mount and Ground Generator Set 27 3 5 Generator Set Electrical Connections 27 3 6 Install Engine Starting Battery 11 1 22222 eee eee 29 3 7 Install and Connect Fuel Supply 29 3 7 1 Fuel Conversion Procedures
48. ctions inside the building Low building pressure can extinguish pilot lights on gas fired appliances or cause problems with the building ventilation system Additionally bringing large quantities of winter air into a building wastes building heat and risks frozen water pipes in normally heated spaces Use dampers and controlled air outlet louvers as shown in Figure 2 6 to eliminate these problems and allow recovery of engine heat to reduce building heat loss Close the louvers to the exterior and open the interior louvers when the outdoor temperature is below 18 21 C 65 70 F Reverse the louver settings when the outdoor temperature is above 21 24 C 70 75 F Exterior Interior Air outlet duct Generator set Dampers Controlled air outlet louvers Figure 2 6 Air Control Louvers 2 3 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Section 2 Open Units 19 Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could ac
49. cumulate and seep back inside a potentially occupied building Satisfactory generator set performance requires proper exhaust system installation The following sections detail exhaust system components 2 3 1 Flexible Exhaust Line For units without enclosures or with separately mounted exhaust systems install the flexible exhaust kit onto the engine exhaust outlet See Figure 2 7 and Figure 2 8 The flexible line limits stress on the engine exhaust manifold or turbocharger Never allow the engine manifold or turbocharger to support the silencer or exhausting piping Note Do not bend the flexible section or use it to compensate for misalignment between the engine exhaust and the exhaust piping g 3 tp6329 1 Flexible exhaust line 2 Clamp 3 Exhaust pipe 4 Gasket Figure 2 7 Flexible Exhaust Kit 20 Section 2 Open Units Cy SA S S SA gt A 3 gt 3 C SA Exhaust wall thimble Muffler 45 Y fitting Water trap Drain petcock Outer diameter adapter and clamp Flexible section Manifold 45 elbow tO O l O O gt G N Figure 2 8 Exhaust System Side Inlet Silencer 2 3 2 Condensation Trap Some silencers are equipped with a drain pipe plug for draining condensation see Figure 2 9 Othe
50. customer connections required See Figure 3 1 for the RIB location The common fault relay is energized on a fault The auxiliary run relay is energized when the generator setis running When a relay is energized the normally open contacts close and the normally closed contacts open Connect customer equipment to connector P24 on the optional relay board harness Use 16 gauge or larger leads for the relay connections Connect to each relay s normally open or normally closed contacts depending on the requirements for the connected equipment See Figure 3 2 and the manufacturer s instructions for the connected equipment Lead P24 Pin Number Number Connection Common fault relay normally open Common fault relay common Common fault relay normally closed Run relay normally open Run relay common Run relay normally closed Figure 3 2 Optional Relay Connections TP 6727 11 09 3 6 Install Engine Starting Battery A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could caus
51. e Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Moving Parts A DANGER kaS Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 6727 11 09 A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply A CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances w
52. e Integrated Electronic Pressure Regulator IEPR and air fuel mixer are specially calibrated emission control devices Do not adjust the IEPR or the air fuel mixer Check the connections to the fuel solenoid valve to verify that the fuel system is set up for the type of fuel that will be used See Figure 3 8 for the location of the fuel solenoid valve TP 6727 11 09 To change the fuel type change the connection to the fuel solenoid valve as described below and shown in Figure 3 10 Natural Gas Connections e Disconnect lead 65 from N3 e Disconnect lead 73B from the fuel valve e Connect lead 73A to the fuel valve LP Connections e Disconnect lead 73A from the fuel valve e Connect lead 73B to the fuel valve e Connect lead 65 to lead N3 ground FUEL SYSTEMS NATURAL GAS FV1 QCON4 AN QCON7 R TO ECM INTERFACE LIQUID QCON10 QCONS N3 QCON4 NOT QCON11 USED TOE FV1 QCONS AN QCON6 pa NS TO ECM INTERFACE LP1 ADV 7602 Figure 3 10 Fuel Type Connections Section 3 Installation Instructions 31 3 7 2 Add Coolant Follow the instructions below to fill the cooling system 1 Close the radiator s coolant drain valve and tighten the hose clamps Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled 2 Fill the radiator with the reco
53. e an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases 1 Verify that the generator set master switch is in the OFF RESET position 2 Ensure that the starting battery is fully charged before placing the battery in service 3 Clean the battery posts and or adapters if necessary 4 Install battery post adapters if needed 5 Place the battery on the battery rack on the skid See dimension drawing ADV 6916A in Section 7 for the battery location 6 Connect the red battery cable to the positive battery terminal 7 Connect the black battery cable to the negative battery terminal 8 Place the boots over the battery terminals 9 Plug the battery heater and battery charger if equipped into the 120 VAC power supply TP 6727 11 09 3 7 Install and Connect Fuel Supply A WARNING E gt b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel syste
54. e between the generator set and other components of the system for proper operation Most field installed accessory kits include installation instructions Comply with applicable national and local codes when installing a wiring system Size the wire according to the length of run and 11596 of the circuit current amperage as directed by the National Electrical Code NEC in ANSI NFPA 70 The National Electrical Code is a registered trademark of the National Fire Protection Association Inc 1 8 3 Ground and Neutral Connections Ground the generator set The grounding method must comply with NEC and local codes Connect the grounding strap to the generator set ground lug terminal GND inside the junction box See Section 3 4 for the ground lug location Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding of the neutral at the generator NEC 2002 Section 250 20 is one example that has a very good explanation of the neutral grounding requirements for generators Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box At installation the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the generator The generator set will operate properly with the neu
55. e controller configuration mode See Figure 5 2 5 3 Controller Automatic Power Down With the generator set master switch in the AUTO position there are three possible controller power modes 48 hour power down Ifthe ADC 2100 controller is not configured for a CAN gauge communications parameter setting CnOO see Section 5 4 the controller will power down after 48 hours of no activity If the generator set has been started the controller will power down 48 hours after the generator stops A remote start signal from atransfer switch or remote switch connected to engine start leads 3 and 4 will signal the controller to power up and the generator set to start If the ADC 2100 is not configured for a CAN gauge communications parameter setting Cn00 see Section 5 4 the controller will power down after 48 TP 6727 11 09 Section 5 Controller hours of no activity If the generator set has been started the controller will power down 48 hours after the generator stops A remote start signal from a transfer Switch or remote switch connected to engine start leads 3 and 4 will signal the controller to power up and the generator set to start If the ADC 2100 is configured for a CAN gauge communications parameter setting CnO1 or Cn02 the controller will not power down The ADC 2100 remains powered at all times to allow remote start commands from the remote CAN gauge Continuous power mode If the ADC 2100 controller is configured
56. ealant provided by fuel supplier e Carbon monoxide CO detector s e Exhaust piping open units Required Accessories for Open Units e Silencer Critical SIEO or engine mounted e Flex exhaust e Radiator duct flange Available Accessories Air cleaner restriction indicator Battery charger Battery heater Block heater Flexible fuel lines Rain cap Relay kit includes common fault and auxiliary run relays Remote digital gauge e Rodent guards e Skid end caps 26 Section 3 Installation Instructions 3 2 Prepare Site See Section 1 3 for important factors to consider in choosing the generator set location 3 2 1 Indoor Installations Open Units Maintain a minimum of 457 mm 18 in between the generator set and any adjacent walls or obstructions to allow access for maintenance and service See Figure 2 1 for a typical open unit installation Prepare an area for mounting the generator set 1 Clear all combustible materials from the generator set location 2 Refer to the applicable dimension drawing in Section 7 to find the minimum mounting pad dimensions Lay a concrete pad including mounting bolts and stub ups for the fuel supply and electrical conduit as shown 3 Provide air intake and outlet openings as described in Section 2 2 3 2 2 Outdoor Installations Enclosed Units Choose a location that is at least 0 9 m 3 ft from any building or structure and near the incoming gas service Allow a minimu
57. elbow after installing the enclosure Install the exhaust pipe with the opening pointed down and angled toward the center of the generator set at a 45 degree angle See Figure 4 6 TP 6727 11 09 Vv GM36247 1 Exhaust elbow Orient at 45 degree angle as shown Figure 4 6 Exhaust Elbow Orientation Section 4 Accessories 37 Notes 38 Section 4 Accessories TP 6727 11 09 5 1 Advanced Digital Control ADC 2100 The generator sets use the Advanced Digital Control ADC 2100 The ADC 2100 uses password protected menus for generator output adjustments and controller configuration This section contains instructions for using the controller s password protected menus to check and adjust the generator output and controller configuration The controller configuration and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the configuration and or output in the following cases e Check and adjust the controller configuration and generator output after generator set reconnection toa different voltage e Check the controller configuration when troubleshooting generator set problems e Check and adjust the generator set output after installation if the voltage requires adjustment for a particular application 5 2 Code Version These models require ADC 2100 application code version 3 25 or later The code version is displayed as you enter th
58. er lifting can cause severe injury or death and equipment damage Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid 8 Safety Precautions and Instructions Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6727 11 09 This manual provides installation instructions for 15 and 30 kW commercial generator set equipped with ADC 2100 controls Applicable models are listed o
59. f combustible materials If the proximity of the exhaust system to the combustible materials cannot be avoided follow a regular maintenance schedule to ensure that combustible materials are kept away from the exhaust pipes after installation Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a safe distance from the exhaust system 2 3 4 Double Sleeved Thimbles If the exhaust pipe passes through a wall or roof use a double sleeved exhaust thimble to prevent the transmission of exhaust pipe heat to the combustible material Figure 2 11 shows construction details of a typical double sleeved thimble in which exhaust piping passes through a combustible structure Sheet metal shops usually fabricate thimbles using installation engineer s specifications and drawings Construct the thimble so it extends at least 254 mm 10 in both inside and outside the structure s surface Openings at both ends of the thimble allow cooling air to circulate through the thimble If screening is used on the outer end to keep birds and animals from entering the thimble use a mesh large enough to allow unrestricted air circulation through the thimble See Section 2 3 5 for additional exhaust outlet location and protection considerations 2 3 5 Exhaust Outlet Outlet location Engine performance and efficiency depend on the location of the exhaust outlet Dire
60. he building engineer must determine whether the structure can support the weight of the generator set TP 6727 11 09 Section 1 General The location of the generator set must e Support the weight of the generator set and related equipment such as batteries radiators and mounting pad s Keep in mind that the mounting pad weight may exceed the weight of the generator set e Meet applicable fire rating codes and standards e Position the generator set over a noncombustible surface Do not allow accumulation of combustible materials under the generator set e Permit vibration isolation to reduce noise and prevent damage e Beclean dry open units and not subject to flooding e Allow ventilation with a minimum amount of ductwork open units e Provide clearance for cooling air flow and access for service See Section 3 2 for required clearances around the generator set e Allow safe expulsion of exhaust e Minimize the risk of public or unauthorized access 1 4 Mounting Surface The manufacturer recommends a single level concrete mounting pad This method provides maximum stability for the generator set The recommended mounting pad dimensions for open and enclosed units are shown in the dimension drawings in Section 7 Refer to the generator set dimension drawings for conduit and fuel line placement The drawings give dimensions for electrical and fuel connection roughins and stubups 1 5 Vibration Isolation
61. hen standing in water or on wet ground because these conditions increase the risk of electrocution Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short
62. hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 59 k K kA KB KBus kg kg cm kgm kg m kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW kWh kWm kWth L LAN LxWxH Ib Ibm ft LCB LCD Id shd LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m hr m min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilo 1000 kelvin kiloampere kilobyte 219 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per
63. ht National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR s sec SI SI EO sil SNMP SPDT SPST spec specs sq Sq cm sq in ss std stl tach root mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectif
64. ier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6727 11 09 Physical Property 15 C 60 F Normal atmospheric state Butane Propane Natural Gas Appendix B Fuel Physical Properties Manufactured or Sewage Gas Gasoline Diesel Fuel Liquid Liquid Boiling point Initial C F End C F 0 82 42 44 162 259 36 97 216
65. igure 2 Additional LP Gas Characteristics TP 6727 11 09 Appendix 61 Appendix C Gas Fuel Vapor Pressures 14 06 kg cm 200 psi 12 65 kg cm 180 psi 11 25 kg cm 160 psi 9 84 kg cm 140 psi 3 a 8 44 kg cm 120 psi 7 03 kg cm 100 psi 5 62 kg cm 80 psi 4 22 kg cm 60 psi 2 81 kg cm 40 psi 1 41 kg cm 20 psi 0 kg cm 0 psi VAPOR PRESSURE APPROXIMATE VALUES s ERE Rae Re ES usu r 4 mm w Ul esee J RR fees aaa Rae NEN o 7 F 40 F 80 F 100 F 20 Temperature 9 Figure 1 Heat Rejection to Ambient Air Temperature Approximate Pressure PSIG Propane Butane Figure 2 Vapor Pressures of LP Gases 62 Appendix TP 6727 11 09 Appendix D Gas Fuel System Installation Planning Determining Propane Cylinder Quantity Guide for Installing 100 Ib Cylinders For continuous draws where temperatures may reach 18 C 0 F Assume the vaporization rate of 100 Ib cylinder as approximately 50000 Btu hr Number of cylinders side Total load in Btu 50000 Example Assume total load 200 000 Btu hour Cylinders side 200000 4 cylinders side 50000 The chart in Figure 1 shows the vaporization rate of containers in terms of the temperature of the liquid and the wet surface area of the container When the temperature is lower or if the cont
66. lier is also responsible for providing sufficient gas pressure to operate the primary regulator Secondary gas regulator The secondary regulator is factory installed on the generator set engine and controls the inlet pressure to the engine The models covered by this manual use an electronic pressure regulator See Section 3 7 1 Note The Integrated Electronic Pressure Regulator IEPR and air fuel mixer are specially calibrated emission control devices Do not adjust the IEPR or the air fuel mixer 1 8 Electrical System Before installing the generator set provide for electrical connections through conduit to the transfer switch and other accessories for the generator set Route DC leads in separate conduit from AC conductors Carefully install the selected generator set accessories Route wiring to the generator set through flexible connections Comply with all applicable codes when installing a wiring system 1 8 1 Line Circuit Breakers AC circuit protection All AC circuits must include circuit breaker or fuse protection If the generator set is not equipped with a factory installed circuit breaker select a circuit breaker for up to 125 of the rated generator set output current The circuit breaker must open all ungrounded connectors The circuit breaker or fuse must be mounted within 7 6 m 25 ft of the alternator output terminals TP 6727 11 09 1 8 2 Electrical Connections Several electrical connections must be mad
67. m Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels ina well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do notreplace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Note Have the fuel piping and regulator installed by the fuel supplier The fuel supply installation must comply with NFPA and local codes 1 See Figure 3 3 Figure 3 4 and Figure 3 5 for the fuel supply requirements Add up the fuel requirements for the generator set plus all other gas fired equipment fueled by the same supply Check that the primary regulator and gas meter have sufficient capacity for the fuel requirements for the generator set plus all other gas fired equipment Have the fuel supplier install a larger gas meter if necessary Gas Flow Rate Btu hr Natural Gas LP 205 000 548 000 212 500 547 500
68. m of 2 4 m 8 ft clearance beyond the exhaust end ofthe generator set Planthe installation so that the exhaust end of the generator set is not directed toward the building or any openings where exhaust gas could be drawn into the building 1 Obtain a building permit and contact your local utility companies to mark the locations of underground pipes and cables 2 Prepare an area for mounting the generator set a Clear all combustible materials including plants and shrubs building materials and lawn furniture from an area at least 2 4 m 8 ft beyond the exhaust end of the generator set b Spread a 76 mm 3 in thick layer of gravel to support the concrete mounting pad For the mounting pad dimensions see the corresponding dimension drawing in Section 7 for weather or sound enclosures TP 6727 11 09 c Laya100 mm 4 in thick concrete pad on the gravel layer Include mounting bolts and stub ups for the fuel supply and electrical conduit See the corresponding dimension drawing in Section 7 for the mounting pad dimensions mounting bolts and stub up locations 3 3 Lifting Generator Set A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Open generator sets weigh approximately 325 kg 720 Ib Enclosed units weigh approximately 500 kg 110
69. mes Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid
70. mmended coolant mixture of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing See Figure 3 11 for coolant capacity Do not replace the pressure cap at this time Note A coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Coolant Capacity L Gal 11 5 3 0 11 5 3 0 Figure 3 11 Coolant Capacity 32 Section 3 Installation Instructions 4 N 1 2 3 Check the oil level before operating the engine Operate the engine with the radiator s pressure cap removed until the thermostat opens and the radiator upper hose becomes hot Stop the engine and allow it to cool Add coolant to the radiator to just below the overflow tube on the filler neck See Figure 3 12 for the overflow tube location Replace the radiator s pressure cap Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Figure 3 12 for the coolant overflow bottle location c BE c pS J lo N Ue o m JEEE NS Ss x Affe I S3 I aa
71. monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive 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 equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or pe
72. n Units 23 Q Engine Exhaust Flow m3 min cfm 28 3 1000 25 5 900 d Pipe Diameter mm inches 25 4 1 0 22 7 800 19 8 700 17 0 600 A P Backpressure 500 kPa per m in Hg per foot 10 33 1 0 5 15 0 5 0 0001 0 00005 aB 0 0001 0 00001 PERE 2 cfm x 0 02832 m3 min in Hg x 3 387 kPa 127 0 5 0 in x 25 4 mm Figure 2 13 Backpressure using Pipe Size 4 in 152 m or Less 24 Section 2 Open Units TP 6727 11 09 3 1 Introduction Have the generator set installed by a trained authorized Kohler distributor dealer or authorized representative Note These instructions outline one procedure for installing the generator set Local codes may require different procedures Install the equipment in compliance with the National Electrical Code NEC and local codes Enclosed units must be installed outside The exhaust systems on enclosed units are designed for outdoor installations Review the information in Section 1 General before beginning the installation procedure Note Do not install enclosed units inside a building Note Outdoor Installations Install carbon monoxide CO detector s on each level of any building adjacent to a generator set Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Open units may be installed inside a building The exhaust must be piped safely outside and adequate air for combustion and cooling must be provided Review
73. n inches K constant for percent volume of liquid in container Figure2 Propane Vaporization Capacity Vaporizing Capacities for Other Air Temperatures Multiply the results obtained with the formulae in Figure 2 by one of the factors in the following table for the prevailing air temperature Prevailing Air Temperature 26 C 15 F 23 C 10 F 21 C 5 F Multiplier 18 C 0 F 15 C 5 F 12 C 10 F 26 C 15 F 7 C 20 P Figure 3 Propane Vaporization Temperature Appendix 63 64 Notes TP 6727 11 09 TP 6727 11 09 Notes 65 66 Notes TP 6727 11 09 TP 6727 11 09 2009 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
74. n the front cover Operation manuals are available separately Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference TP 6727 11 09 Introduction List of Related Materials Figure 1 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Part Number TP 6728 TP 6319 TP 6724 TP 6198 TP 6719 One Parts Catalog combines generator and engine information Literature Type Operation Manual 15 30REYG Parts Catalog Service Manual Engine Service Manual Generator Set Wiring Diagram Manual Generator Set Figure 1 Related Literature Warranty Registration Complete the startup and installation checklists supplied with the startup notification form Complete and sign the startup notification form and return copies to Kohler Co and the distributor dealer as instructed on the form Introduction 9 Service Assistance
75. nd the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electricalleads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Section 3 Installation Instructions 25 Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operational at alltimes Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Tools Required e Multimeter for measuring voltage and current e Frequency meter may be part of multimeter e Torque wrench e Wrenches e Screwdrivers e Socket wrenches or nut drivers e Pliers e Safety glasses or goggles e Drill with bits and hole saw outdoor installations Installer Customer Supplied Items e One 12 volt battery with a minimum rating of 525 cold cranking amps CCA at O F Gravel or crushed stone outdoor installations Concrete mounting pad Cables and conduit Fuel supply line with shutoff valve and pipe s
76. nsions are in mm in Figure 7 5 Dimension Drawing ADV 7695 Sheet 1 Weather Enclosure and Weather Enclosure with Sound Kit TP 6727 11 09 Section 7 Dimension Drawings 55 S 69 AQV AINO Q13IHS ANNOS Q31NDnON QIMS HLIM ISA 403 SSINMOIHL NONININ O G Lal IV13q Gvd ONILNNOW ur ww Ul eje suoisueuuiq G Hs ANNOS 8211 0581 6 Sp Soll QIMS 40 TIVY NOLLOG NI 310H ONILNNOW S 0 S EID XY LIM ONIM HOIH HLIM 3SN 404 HdW OGI OL HdW OI 3AO8V SONILVY ONIM 404 34V SHINHOJ ly SGNLS ONILNAOW 1VNOILIQQV S0 1S OIN XF QN3 3NI9N3 v3uv dh anis 1303 L d Io o S Qyd 40 19YjYNS dOl QN3 YOLYNGILIV Y ONILNMOW 13SN39 404 SQnlS OIN XF L Syl Soll 0 658 6512 VIYV dn anis 1v21u12313 6 v X 6 v1 S2 X Sel ADV 7695 Sheet 2 Sound Enclosure imension Drawing Figure 7 6 D TP 6727 11 09 56 Section 7 Dimension Drawings S 69 AQV
77. o enter the configuration mode This is the controller password Now release the Select button To set the voltage frequency setting See Figure 5 1 D To step to the next parameter unit configuration Uc To set the unit configuration setting to Uc01 if necessary B To step to the next parameter engine type Ec To set the engine type to Ec03 OR Eco6 if necessary See Figure 5 1 B To step to the next parameter advanced configuration mode or save mode selection e Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press To enter advanced configuration mode Go to Figure 5 3 To proceed to the save mode without AIV entering the advanced configuration mode Go to Figure 5 4 Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed Figure 5 2 Configuration Mode system voltage frequency unit configuration and engine type parameters TP 6727 11 09 Section 5 Controller 41 Pressing the up arrow key at the Adnc display See Figure 5 2 puts you into the Advanced Configuration Mode Press To set the engine data input type to Ed01 To enter
78. or the elbows and flexible sections from the following Bend Equivalent Elbow Type Radius Length ft 90 Close R D 32 x D 12 90 Medium R 2D 10xD 12 90 Sweep R 4D 8xD 12 45 Close R D 15 x D 12 45 Sweep R 4D 9xD 12 2 x Lengtht 12 Use the diameter of the silencer inlet in inches from step 4 for the initial calculation If the results from step 8 indicate excessive backpressure drop then recalculate using the larger diameter pipe size selected Use the flexible exhaust adapter length from step 4 and add any additional flex sections in the exhaust System expressed in inches Flex Sections Convert the equivalent pipe length calculated in feet to meters using ft x 0 305 m as needed Examples For two 45 sweep elbows 9x 2 0 in 12 1 5 equiv ft or 0 46 equiv m Multiply by 2 for 2 elbows 2 x 1 5 ft 3 0 equivalent ft or 2 x 0 46 m 0 92 equiv m Flexible sections 2x17 in 12 2 8 equiv ft or 0 86 equiv m TP 6727 11 09 Equivalent of straight pipe 3 0 2 8 5 8 equiv straight ft 0 9 0 86 1 76 equiv straight m Determine the total length of straight pipe used in the exhaust system Add this calculation to the equivalent length for elbows and flexible sections obtained in step 5 Example Straight pipe 3 0 m 10 ft Equivalent straight pipe from step 5 1 76 m 5 8 ft 3 0 m 1 76 m 4 76 m or 10 ft 5 8 ft
79. ore servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Section 6 Generator Reconnection 47 6 2 Four Lead Single Phase Generator Sets Figure 6 1 shows the factory connection for the single phase 120 240 V 60 Hz generator set Single phase models are not reconnectable 100 120 200 240V 60HZ i A LO NEUTRAL GRD L1 j L2 O H V L GROUND LOAD SIDE FACTORY 2 TWO POLE CIRCUIT BREAKER 3 2 4 1 STATOR LEADS 100 120 200 240 VOLT 3 WIRE ADV 5857 A Figure 6 1 Single Phase Factory Connection 120 240 V 60 Hz 48 Section 6 Generator Reconnection 6 3 12 Lead Three Phase Generator Sets Note The current transformers CTs shown on the following diagrams are not used on generator sets equipped with the Advanced Digital Control ADC 2100 Three phase 12 lead generator sets are reconnectable to the voltages and phases shown in Figure 6 2 Use the following procedure to reconnect the generator to the desired voltage configura
80. ormation on fuel requirements Note Design and install gas fuel systems in accordance with NFPA 54 National Fuel Gas Code and applicable local codes 1 7 1 Fuel Lines Gas lines Never use fuel piping to ground electrical equipment The gas supplier is responsible for installation repair and alteration to gas piping Use Schedule 40 black iron pipe for gas piping Copper tubing may be used if the fuel does not contain hydrogen sulfide or other ingredients that react chemically with copper Line size Size piping according to the requirements of the equipment Refer to the the instructions in Section 3 7 In addition to the actual fuel consumption consider the following pressure loss factors 12 Section 1 General e Pipe length e Other appliances on the same fuel supply e Number of fittings Flexible connections Rigid mount the piping but protect it from vibration Use flexible connections spanning a minimum of 152 mm 6 in between the stationary piping and the engine fuel inlet connection 1 7 2 Gas Regulators Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines See the generator set specification sheet for fuel supply pressure requirements Primary gas regulator The primary regulator reduces the high pressure from a tank or transmission line to the lower pressure required by the secondary regulator on the engine The fuel supplier provides the primary regulator The fuel supp
81. re available factory installed and or shipped loose Obtain the most current list of accessories from the generator set specification sheet or by contacting your local authorized service distributor dealer Have accessories installed by a trained authorized Kohler distributor dealer or authorized representative Follow the installation instructions provided with each kit Use separate conduit for AC and DC leads to reduce the possibility of electrical interference Use shielded cable for all analog inputs Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas Verify that the accessory installation complies with the National Electrical Code NEC and all applicable local and state codes Accessory Wiring To determine the appropriate size for the customer supplied wiring of engine battery powered accessories use the guidelines in Figure 4 1 Use 18 20 gauge wire for signal wires up to 305 m 1000 ft Length m ft Wire Gauge 30 5 100 152 4 500 304 8 1000 Wire Length and Size Lead N and 42B Figure 4 1 See Section 7 Diagrams and Drawings for more information regarding generator set electrical connections The following sections detail a few common accessories and their functions The instructions provided with the accessory kit supersede these instructions if different 4 2 Common Fault and Run Relay Board The optional rela
82. retor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 6 Safety Precautions and Instructions Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Carbon
83. rmit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions TP 6727 11 09 Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches vvater column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble Hazardous Noise A CAUTION Hazardous nois
84. rwise install a wye or tee type condensation trap with a drain plug or petcock between the engine and the exhaust silencer as shown in Figure 2 10 The trap prevents condensed moisture in the engine exhaust from draining into the engine after shutdown Periodically drain collected moisture from the trap 1 Pipe Plug Figure 2 9 Silencer Condensation Drain Plug TP 6727 11 09 1 Condensation trap us Figure 2 10 Condensation Trap 2 3 3 Piping Note Select piping with a diameter that is the same size as or larger than the manifold outlet s inside diameter e Keep exhaust lines as short and straight as possible e Use schedule 40 black iron pipe e Usesweep elbows with a radius of atleastthree times the pipe diameter e Use exhaust piping that conforms to applicable codes e Support the exhaust piping securely allowing for thermal expansion e Insulate the exhaust piping with high temperature insulation to reduce the heat rejected by exhaust piping and consequently the amount of ventilating air required Exhaust temperatures measured at the engine s exhaust outlet are listed on the generator set specification sheets Route the exhaust piping a minimum of 914 mm 36 in from combustible material including building materials and natural surroundings TP 6727 11 09 When planning exhaust silencer and piping placement consider the location o
85. s 6 4 22 6 An engine driven battery charging alternator charges 7 9 31 1 the battery whenever the generator set operates 9 5 42 4 Engine driven systems can quickly restore the charge 12 7 56 5 used in a normal cranking cycle 14 3 67 8 When the engine is not operating a very low charge rate For values of slot width or length not corresponding to ue those specified select the largest torque value from an AC powered battery charger is usually sufficient associated with the conductor size Slot width is the to maintain a full charge on the batteries Select an nominal design value Slot length is to be measured at automatic float equalize battery charger with a 3 amp or the bottom of the slot greater rating Figure 1 3 Tightening Torque for Pressure Wire Connectors with Internal Drive Socket Head Screws Use separate self contained battery chargers or units built into the automatic transfer switch Run leads from a transfer switch mounted battery charger in conduit separate from the conduit that holds the generator load 1 8 6 Batteries cables or remote engine start circuits Battery location Refer to the generator set dimension drawing for the battery location Battery type Starting batteries are usually the lead acid type and are sized according to the engine manufacturer s recommendation for a particular ambient temperature and required cranking time The 14 Section 1 General TP 6727 1
86. tacle through a circuit that is powered at all times by the utility and by the generator set during utility power outages 2 Some codes require the use of a disconnect switch Check the code requirements for your location and install a disconnect switch if required 3 Use separate conduit for the power cables and the low voltage engine start leads Local codes and the length of run as well as the transfer switch wire size requirements will determine the wire size needed for the AC leads Route the load leads into the junction box through the access opening in the back of the box 4 Connect the load leads from the line circuit breaker in the generator set junction box to the transfer switch emergency power connection points See Figure 3 1 and refer to the transfer switch Installation Manual for ATS connection instructions 5 Use a minimum of 16 gauge wire for the engine start connections Connect the engine start leads to leads 3 and 4 at the customer interface connector and to the engine start terminals on the transfer switch Refer to the transfer switch 28 Section 3 Installation Instructions Installation Manual for ATS connection instructions 6 If an auxiliary fault switch is used connect it to leads 30 and N at the customer interface connector Optional Five Relay Interface Board RIB The optional relay interface board RIB has 5 relays and a customer connection harness The standard RIB has 3 relays with no
87. ted radiator common cooling system Figure 2 1 shows a typical unit mounted radiator installation Note the direction of airflow and refer to the figure as needed during installation Use ductwork to direct airflow Direct the radiator air outside the room or enclosure using sheet metal ductwork with structural supports Keep ductwork as short straight and unobstructed as possible Combined static pressure restrictions greater than 0 12 kPaor 13 mm 0 5 in water column on the radiator inlet and outlet openings cause reduced airflow and contribute to overheating especially in high ambient air temperatures Use heavy canvas silicone rubber or similar flexible material for the connection between the radiator duct flange and the ductwork to prevent noise and vibration transmission Outlet and inlet location and sizing Size the outlet duct area 15096 larger than the radiator duct flange area Size the inlet air opening at least as large but preferably 5096 larger than the outlet If screens louvers or filters are used on either the inlet or outlet increase the inlet or outlet size according to the recommendations given in Section 2 2 1 Installation Considerations TP 6727 11 09 Since the exhaust air of larger units is both high volume and high velocity direct the exhaust flow away from areas occupied by people or animals Louvers Design temperature controlling louvers to prevent air inlet restrictions and air pressure redu
88. the remote digital gauge Set the ADC 2100 communications parameter to CnO1 or Cn06 to enable J1939 CANbus communication to communicate with the digital gauge See Section 5 3 for important controller power down information See Section 5 4 for more information on controller configuration The ADC 2100 must be powered on in order to communicate with the digital gauge The digital gauge cannot be used to start the generator set ifthe ADC 2100 has powered down See Section 5 3 and the instructions provided with the remote digital gauge for more information 1 SELECT button 2 UP arrow button 3 DOWN arrow button Figure 4 4 Remote Digital Gauge Use one or more remote extension harness kits to connect the gauge to the generator set Do not use more than 3 remote harness kits and do not exceed 22 86 m 75 ft in harness length See Figure 4 5 for kit selection Remote Extension Harness Kit Number GM32333 KP1 GM32333 KP2 Figure 4 5 Remote Extension Harness Kits For Gauge to Generator Set 36 Section 4 Accessories 4 4 Block Heaters Block heaters are available as installed accessories on all generator sets Use block heaters on all standby applications where the generator set is subject to temperatures below 16 C 60 F Connect the block heater to a power source that is energized when the generator set is not running Note Block heater damage The block heater will fail if the energized heater element is
89. tion change the system voltage setting and adjust the output voltage Note Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage Reconnection Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect engine starting battery negative lead first Disconnect power to battery charger if equipped 3 Select desired voltage connection from Figure 6 2 Connect the leads according to the diagram for desired phase and voltage 4 Reconnect generator set engine starting battery negative lead last 5 Follow the instructions in Section 5 4 to enter the ADC 2100 configuration menu and check the system configuration Verify that the system voltage and frequency parameter Uu is correct for single phase or three phase configurations 6 Connect a digital multimeter DVM to the generator set output 7 Follow the instructions in Section 5 5 to start the generator set and enter the ADC 2100 voltage adjustment menu 8 Check the voltmeter for the correct voltage Adjust output voltage if necessary using the ADC 2100 voltage adjustment menu 9 Stop the generator set after the adjustment procedure TP 6727 11 09 12 LEAD ALTERNATOR 3 WIRE SINGLE PHASE 60 HZ 100 200V 60 HZ 120 240V 50 HZ 100 200V 50 HZ 110 220V SOME SETS NOT RATED FOR SINGLE PHASE SEE MANUALS CIS NO
90. tral either bonded to ground or isolated from ground at the generator TP 6727 11 09 1 8 4 Load Lead Connections Feed load leads to the generator set junction box through the back of the box See Figure 1 1 Route DC leads in separate conduit from AC conductors 1 Customer interface connector 2 Load lead access Figure 1 1 Load Lead Connection 1 8 5 Terminal Connector Torque Use the torque values shown in Figure 1 2 or Figure 1 3 for terminal connectors Refer to UL 486A UL 486B and UL 486E for information on terminal connectors for aluminum and or copper conductors Comply with applicable national and local codes when installing a wiring system Note If a connector has a clamp screw such as a slotted hexagonal head screw with more than one means of tightening test the connector using both applicable torque values provided in Figure 1 2 Section 1 General 13 Tightening Torque Nm in Ib Wire Size for Unit Hexagonal Head External Connection Slot Head 4 7 mm No 10 or Larger Drive Socket Wrench Slot Width 1 2 mm 0 047 in Slot Width gt 1 2 mm 0 047 in Split Bolt Other AWG kcmil mm Slot Length 6 4 mm 0 25 in Slot Length gt 6 4 mm 0 25 in Connectors Connections 18 10 0 82 5 3 2 3 20 4 0 85 9 0 85 75 8 8 4 2 8 25 4 5 40 9 0 85 75 6 4 13 3 21 2 4 0 85 5 1 45 18 6
91. uction The information in this section applies to all installations Review this section and the safety precautions before starting the installation procedure The generator set specification sheet also contains data that may be required during the installation process The generator set and accessories must be installed by a trained authorized Kohler distributor dealer or authorized representative The installation must comply with all applicable national and local codes 1 2 Enclosed and Open Generator Sets Enclosed generator sets include a factory supplied weather or sound housing The exhaust systems of enclosed units are complete for outdoor installations Review Section 1 and then refer to Section 3 for the outdoor installation of enclosed units Note Do not install enclosed units inside a building Open generator sets do not include a factory supplied weather or sound enclosure Install open generator sets inside a building with the exhaust gas piped safely outside Adequate cooling and combustion air are required Review Sections 1 and 2 for the installation of open units before proceeding to the installation procedure in Section 3 Note Do not install open commercial generator sets in residential applications 1 3 Location Factors Ideally the generator set should be mounted on concrete at ground level For above ground installations including roof installations weight considerations are especially important T
92. y board replaces the standard relay interface board RIB and provides two additional relays to control customer provided equipment e Common fault relay e Auxiliary run relay TP 6727 11 09 Section 4 Accessories The relay board location is shown in Figure 4 2 Connect customer equipment to the relay board harness Figure 4 3 lists the customer connections The common fault relay is energized on a fault The auxiliary run relay is energized when the generator setis running Connect to each relay s normally open or normally closed contacts depending on the application 1 Relay board location 2 Relay board harness Figure 4 2 Common Fault and Run Relay Board Harness Lead Connector Number Pin Number Connection Common fault normally open Common fault common Common fault normally closed Run relay normally open Run relay common Run relay normally closed Figure 4 3 Common Fault and Run Relay Board Harness Connections Section 4 Accessories 35 4 3 Remote Digital Gauge The digital gauge allows for remote starting stopping and monitoring of certain generator set functions See Figure 4 4 The remote digital gauge does not display oil pressure for model 15 30REYG generator sets The generator set has a 12 pin customer interface connector for connection to the remote digital gauge Refer to TT 1439 for instructions to install connect and operate

15REYG 30REYG Installation

Contents

Download Pdf Manuals

Related Search

Related Contents