Beruflich Dokumente
Kultur Dokumente
Models:
20--2800 kW
TP-5700 12/07h
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Engine Identification
Model Designation
Manufacturer
Specification Number
Serial Number
Model Designation
Serial Number
Accessory Number
Accessory Description
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2 Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Generator Set Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2
Determining Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.3
Lifting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.4
Lifting Subbase Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.5
Lifting Weather Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.6
Lifting Sound Shield Installed on Mounting Base (Concrete Slab) . . . .
2.1.7
Lifting Sound Shield with Integral Structural Steel Mounting to
Generator Set Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Generator Set Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
17
17
17
19
19
19
Section 3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Single-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2
Dual-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Four-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4
Mounting Pad Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Vibration Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Dual-Bearing Alternator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
22
22
22
22
23
24
25
25
25
25
25
25
26
27
27
27
28
28
30
32
32
32
33
34
34
34
35
35
35
36
36
TP-5700 12/07
19
19
Table of Contents
37
37
37
38
38
39
39
47
47
47
49
50
50
51
51
51
51
51
51
52
52
53
53
54
54
54
55
56
59
59
64
64
65
66
67
67
68
68
68
69
69
69
69
69
70
70
75
75
75
75
76
76
Table of Contents
TP-5700 12/07
77
77
78
78
78
80
81
83
84
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
93
94
95
96
97
98
TP-5700 12/07
86
88
89
Table of Contents
Notes
TP-5700 12/07
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.
Accidental Starting
WARNING
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.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death, or substantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
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
NOTICE
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
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition.
Replace missing or
damaged decals.
TP-5700 12/07
WARNING
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 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.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) 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
Exhaust System
WARNING
WARNING
Carbon monoxide.
Can cause severe
fainting, or death.
Fire.
Can cause severe injury or death.
nausea,
Fuel System
WARNING
TP-5700 12/07
WARNING
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
WARNING
WARNING
Hazardous Noise
CAUTION
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
10
WARNING
Airborne particles.
Can cause severe
blindness.
injury
or
Heavy Equipment
WARNING
Unbalanced weight.
Improper 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.
TP-5700 12/07
Hot Parts
WARNING
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
WARNING
TP-5700 12/07
246242
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.
NOTICE
Electrostatic discharge damage.
Electrostatic
discharge
(ESD)
damages electronic circuit boards.
Prevent
electrostatic
discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
ground.
11
Notes
12
TP-5700 12/07
Introduction
This manual provides installation instructions for
industrial generator sets. Operation manuals and wiring
diagram manuals are available separately.
Some additional model-specific installation information
may be included in the respective generator set
controller operation manual.
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
GeneratorsElectric.
D Visit
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
TP-5700 12/07
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
Introduction
13
Notes
14
Service Assistance
TP-5700 12/07
Section 1 General
Industrial power systems give years of dependable
service if installed using the guidelines provided in this
manual and in applicable codes. Incorrect installation
can cause continuing problems. Figure 1-1 illustrates a
typical installation.
2
1
9
10
TP-5700-1
1.
2.
3.
4.
Figure 1-1
8. Electrical conduit
9. Water trap with drain
10. Fresh air intake
TP-5700 12/07
Section 1 General
15
outlet
backpressure
size and
maximum allowable
(gas models)
D Air requirements
16
Section 1 General
TP-5700 12/07
2.1.2
Determining Weights
D Weather housing
D Sound shield
General Precautions
2.1.3
Lifting Methods
1
TP-5700-2
1. Reinforcing plate
Figure 2-1
TP-5700 12/07
17
TP-5700-2
Figure 2-3
TP-5700-2
1
1. Spreader bars may be necessary to protect generator set
Figure 2-2
TP-5700-2
1. Lifting fixture
Figure 2-4
18
TP-5700 12/07
2.1.4
2.1.5
2.1.6
2.1.7
guidelines
when
transporting
the
TP-5700 12/07
19
Notes
20
TP-5700 12/07
Section 3 Location
3.1 Location Factors
Outdoor Installations:
D Select a location that provides adequate air flow.
5
6
Indoor Installations:
3
D Allow adequate ventilation with a minimum amount of
TP-5700-3
ductwork.
D Allow safe expulsion of exhaust.
D Allow for storage of sufficient fuel to sustain
TP-5700 12/07
7
1. Engine end
2. Generator set skid
3. Extend the concrete surface a minimum of 152 mm (6 in.)
beyond the generator set
4. Battery rack
5. Allow at least 457 mm (18 in.) between the generator set
and adjacent walls or other obstructions on all sides for
ease of servicing the generator set
6. Alternator end
7. Mounting pad (concrete surface)
Figure 3-1
Section 3 Location
21
3.2.1
Single-Pad Mounting
3.2.3
Four-Pad Mounting
TP-5700-3
Figure 3-4
3.2.4
Four-Pad Mounting
TP-5700-3
Figure 3-2
3.2.2
Single-Pad Mounting
Dual-Pad Mounting
TP-5700-3
Figure 3-3
Dual-Pad Mounting
22
Section 3 Location
TP-5700 12/07
GM41122
1
3
GM39515
2
TP-5700-3
1. To engine-generator
2. Skid crossmember
3. Neoprene vibration isolator
Figure 3-5
TP-5700 12/07
Figure 3-6
Section 3 Location
23
GM31000
Figure 3-7
24
1.
2.
3.
4.
5.
Section 3 Location
TP-5700 12/07
4.3.2
TP-5700-4
System Features
Figure 4-1
Ventilating Fan
Installation Considerations
TP-5700-4
Figure 4-2
TP-5700 12/07
25
4.3.3
TP-5700-4
Figure 4-3
Recommended Coolant
TP-5700-4
Figure 4-4
26
TP-5700 12/07
4.4.1
System Features
The systems major components include an enginedriven 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.
4.4.2
Installation Considerations
2
3
TP-5700-4
6
1.
2.
3.
4.
5.
6.
Figure 4-5
TP-5700 12/07
27
4.5.1
General
6
TP-5700-4
5
1. Exterior
2. Interior
3. Air outlet duct
Figure 4-6
4. Generator set
5. Dampers
6. Controlled air outlet louvers
28
TP-5700 12/07
5
6
7
8
9
14
13
12
1.
2.
3.
4.
5.
6.
7.
Figure 4-7
8.
9.
10.
11.
12.
13.
14.
TT11863
10
11
Engine outlet
Engine water pump
Suction side
Fill/drain (lowest point of engine
Shutoff valve
Radiator outlet
Maximum allowable static (vertical) head (varies with engine)
TT11864
12
1.
2.
3.
4.
Radiator inlet
Pressure cap
Surge tank/expansion tank
Horizontal radiator
Figure 4-8
5. Radiator outlet
6. Vent line(s)
7. Fill line
11
8. Shutoff valve
9. Engine outlet
10. Engine inlet
10
11. Fill/drain (lowest point of
engine)
12. Shutoff valve
TP-5700 12/07
29
30
Note: The water in the hot well tank drains into the
radiator when the generator set is not running.
Note: Determine the size requirements of the remote
radiator and hot well tank/heat exchanger for
each application. Do not use a standard remote
radiator with a hot well tank/heat exchanger.
4.5.2
Vent Lines
TP-5700 12/07
6
7
8
3
12
11
1.
2.
3.
4.
Figure 4-9
5.
6.
7.
8.
10
TT11865
9.
10.
11.
12.
Generator set
Fill/drain (lowest point of engine)
Shutoff valve
Hot well tank
1
4
5
6
7
10
11
12
1.
2.
3.
4.
Expansion/surge tank
Remote radiator
Vent line
Expansion/surge tank
5.
6.
7.
8.
Vent line(s)
Fill line
Shutoff valve
Generator set
TT11865
9.
10.
11.
12.
31
4.5.3
4.5.5
Installation Considerations
Figure 4-11.
D Wire the cooling fan motor to the generator set output
4.5.4
Location Considerations
strong winds.
D Use isolators to keep area vibration from affecting the
32
TP-5700 12/07
1
2
10
8
3
7
5
GJ-273000-B
1.
2.
3.
4.
Drain valve
Belt guard bracket
Right-hand belt guard
Left-hand belt guard
4.5.6
33
4.5.7
4.5.9
Fill the system with coolant and check all connections for
tightness and leaks.
4.5.8
Verify that all electrical connections are secure and that the
power source matches the motor nameplate.
Verify that no loose foreign material is in the fans air stream.
With the unit running, check for:
fan clearance
excessive vibration
excessive noise
coolant leaks
34
TP-5700 12/07
4.6.2
Installation Considerations
System Features
4
6
5
Side View
End View 10
11
8
HC-273000-E/TP-5700-4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
TP-5700 12/07
35
TP-5700-4
3. Cooling tower
4. Makeup water connection
7. Heat exchanger
8. Auxiliary water pump
36
TP-5700 12/07
5
6
7
8
1.
2.
3.
4.
TP-5700-5
Supports
Pitch line downward
Silencer
Water trap
Figure 5-1
5.
6.
7.
8.
Drain petcock
Flexible section
Solid section 152--203 mm (6--8 in.)
Manifold
1. Pipe Plug
Figure 5-3
TP-5700-5
7
8
TP-5700-5
1.
2.
3.
4.
5.
Figure 5-2
6.
7.
8.
9.
TP-5700 12/07
Figure 5-4
TP-5700-5
Condensation Trap
Section 5 Exhaust System
37
5.3 Piping
2
6
3
codes.
6
D Support the exhaust piping securely, allowing for
thermal expansion.
D Insulate the exhaust piping with high-temperature
10
15
12
38
11
14
13
TP-5700-5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Figure 5-5
TP-5700 12/07
application.
Use the following procedure to verify that the installed
exhaust system does not exceed the engines maximum
exhaust backpressure limit as specified in the generator
set specification sheet.
TP-5700 12/07
39
Inlet Area, m2
Type
Bend
Radius
Conversion Factor
90
Close
R=D
32 x D* / 12
90
Medium
R = 2D
10 x D* / 12
90
Sweep
R = 4D
8 x D* / 12
45
Close
R=D
15 x D* / 12
45
Sweep
R = 4D
9 x D* / 12
0.00056
0.0060
1 1/4
0.00097
0.0104
1 1/2
0.00131
0.0141
0.00216
0.0233
2 1/2
0.00308
0.0332
0.00477
0.0513
0.00821
0.0884
0.0129
0.139
0.0187
0.201
0.0322
0.347
10
0.0509
0.548
12
0.0722
0.777
14
0.0872
0.939
16
0.1140
1.227
18
0.1442
1.553
40
Figure 5-6
Flex Sections
2 x Length[ / 12
TP-5700 12/07
kPa
in. of Hg
6.4
1.9
6.1
1.8
5.8
1.7
5.4
1.6
5.1
1.5
4.7
1.4
4.4
1.3
4.1
1.2
3.7
1.1
3.4
1.0
3.0
0.9
2.7
0.8
2.4
0.7
2.0
0.6
1.7
0.5
1.4
0.4
1.0
0.3
0.7
0.2
0.3
0.1
Pressure
Drop
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.1
3.4
3.6
4.0
4.3
5.8
4.9
(m/min.)
10
11
12
13
14
15
16
(ft./min.)
A = Hospital Silencer
B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer
Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa
(0.25 in. of mercury or 3.4 in. of water) to the backpressure.
Figure 5-7
TP-5700 12/07
41
mm of Water
Pressure
Drop
in. of Water
660.4
26
609.6
24
558.8
22
508.0
20
457.2
18
406.4
16
355.6
14
304.8
12
254.0
10
203.2
152.4
101.6
50.8
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.1
3.4
3.6
4.0
4.3
(m/min.)
11
12
13
14
(ft./min.)
10
A = Hospital Silencer
B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer
Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa
(86 mm of water or 3.4 in. of water) to the backpressure.
Figure 5-8
42
TP-5700 12/07
Example:
11.0 equiv. m x 0.04 kPa/m =
0.4 total system backpressure in kPa
36.1 equiv. ft. x 0.004 in. Hg/ft. =
0.14 total system backpressure in inches of Hg
TP-5700 12/07
43
cfm
28.3
1000
25.5
900
22.7
800
19.8
700
17.0
600
14.2
11.3
500
400
8.5
300
7.1
250
5.7
200
4.2
150
2.8
100
2.5
90
2.3
80
2.0
70
1.4
50
1.1
40
(cfm x 0.02832 =
44
P Backpressure
kPa per m
in. Hg per foot
1.033
1.0
0.515
0.5
0.104
0.1
0.052
0.05
0.009
0.01
0.005
0.005
31.8
1.25
38.1
1.5
44.5
1.75
50.8
2.0
63.5
2.5
0.001
0.001
0.001
0.0005
76.2
3.0
0.000
0.0001
88.9
3.5
0.000
0.00005
101.6
4.0
0.000
0.00001
114.3
4.5
60
1.7
Figure 5-9
D Pipe Diameter
mm
inches
25.4
1.0
m3/min.)
127.0
5.0
(in. x 25.4 = mm)
TP-5700 12/07
D Pipe Diameter
mm
inches
cfm
453.1
16000
339.8
12000
283.2
10000
254.9
9000
226.6
8000
198.2
7000
169.9
6000
141.6
5000
113.3
4000
85.0
56.6
42.5
1500
28.3
1000
25.5
900
22.7
800
101.6
127.0
152.4
177.8
203.2
228.6
254.0
10
304.8
12
330.2
13
355.6
14
406.4
16
P Backpressure
kPa per m
in. Hg per foot
1.033
1.0
0.515
0.5
0.104
0.1
0.052
0.05
0.009
0.01
0.005
0.005
3000
2000
76.2
0.001
0.001
0.001
0.0005
0.000
0.0001
0.000
0.00005
0.000
0.00001
Figure 5-10 Backpressure using Pipe Size 5 in. (127 mm) or Larger
TP-5700 12/07
45
Notes
46
TP-5700 12/07
6.1.1
Main Tank
13
12
11
8
TP-5700-6
10
1.
2.
3.
4.
5.
6.
7.
Figure 6-1
8.
9.
10.
11.
12.
13.
TP-5700 12/07
47
2
1
4
3
TP-5700-6
Figure 6-2
Fuel expansion. Never fill the tank more than 95% full
to allow for fuel expansion. On overhead main tanks,
use a fuel shutoff solenoid to prevent hydraulic lock or
tank overflow caused by excessive static head fuel
pressures.
48
TP-5700 12/07
6.1.2
Day Tanks
4
1
2
7
5
12
11
10
8
TP-5700-6
1.
2.
3.
4.
5.
6.
Figure 6-3
7.
8.
9.
10.
11.
12.
Diesel Fuel System with Overhead Main Tank and Day Tank
TP-5700 12/07
49
6.1.3
Fuel Lines
50
6.1.4
TP-5700 12/07
6.2.3
TP-5700-6
Fuel Pumps
1. Fuel tank
2. Fuel pump
Figure 6-4
6.2.1
3. Gasoline shut-off
4. Gasoline carburetor
6.2.2
Fuel Lines
6.3.1
Gas Lines
Line size. Use the smallest diameter fuel line that will
not restrict the required fuel flow.
TP-5700 12/07
D Number of fittings
51
6.3.2
Gas Regulators
Engine
20 kW
Ford
1.7--2.74 (4--6)
18--28 (7--11)
30--125 kW
GM
1.7--2.74 (4--6)
18--28 (7--11)
135--275 kW
Detroit Diesel
Series 50/60
1.2--5 (2.9--11.6)
13--51 (5--20)
400--800 kW
Waukesha
2--34 (4.6--80)
20--348 (8--137)
Figure 6-5
kPa
(oz./in.2)
Water Column,
cm (in.)
TP-5700 12/07
6.4.1
LP Gas Vapor-Withdrawal
Systems
6.4.2
LP Gas Liquid-Withdrawal
Systems
TP-5700-6
Figure 6-6
TP-5700 12/07
1. Carburetor
2. Converter (vaporizer)
3. Solenoid valve (quantity of two in series may be
required for UL applications)
4. LP gas filter (supplied by gas supplier or installer)
Figure 6-7
53
6.6.1
TP-5700-6
Figure 6-8
5
9
10
6
4
050604
Figure 6-9
54
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Carburetor
Load adjustment valve
Converter (vaporizer)
Solenoid valve (quantity of two in series may be required for
UL applications)
LP gas filter (supplied by gas supplier or installer)
LP gas supply
Natural gas supply
Primary gas regulator (supplied by gas supplier or installer)
Secondary natural gas regulator
Pressure gauge
TP-5700 12/07
4 5
6
7
8
1.
2.
3.
4.
5.
6.
7.
8.
TP-5700-6
7
Carburetor
Load adjustment valve
Secondary LP gas regulator
Solenoid valve (quantity of two in series may be
required for UL applications)
LP gas supply
Natural gas supply
Low pressure switch
Secondary natural gas regulator
6.6.2
TP-5700 12/07
TP-5700-6
1.
2.
3.
4.
5.
6.
Fuel pump
Gasoline shutoff
Gasoline carburetor
Fuel mixer
Secondary gas regulator
Solenoid valve (quantity of two in series
may be required for UL applications)
7. Gas fuel supply
8. Gasoline fuel supply
55
Specific Gravity
Correction Factor
Sewage Gas
0.55
1.040
Natural Gas
0.65
0.962
Air
1.00
0.775
Propane (LP)
1.50
0.633
Butane
2.10
0.535
Nominal
Iron Pipe
Size
(IPS), In.
1/4
3.0 (10)
6.1 (20)
9.1 (30)
12.2 (40)
15.2 (50)
18.3 (60)
21.3 (70)
9.25 (0.364)
1.2
(43)
0.82
(29)
0.68
(24)
0.57
(20)
0.51
(18)
0.45
(16)
0.42
(15)
3/8
12.52 (0.493)
2.7
(95)
1.8
(65)
1.5
(52)
1.3
(45)
1.1
(40)
1.0
(36)
0.93
(33)
1/2
15.80 (0.622)
5.0
(175)
3.4
(120)
2.7
(97)
2.3
(82)
2.1
(73)
1.9
(66)
1.7
(61)
3/4
20.93 (0.824)
10.2
(360)
7.1
(250)
5.7
(200)
4.8
(170)
4.3
(151)
3.9
(138)
3.5
(125)
26.64 (1.049)
19.3
(680)
13.2
(465)
10.6
(375)
9.1
(320)
8.1
(285)
7.4
(260)
6.8
(240)
1 1/4
35.05 (1.380)
39.6
(1400)
26.9
(950)
21.8
(770)
18.7
(660)
16.4
(580)
13.9
(490)
13.0
(460)
1 1/2
40.89 (1.610)
59.5
(2100)
41.3
(1460)
33.4
(1180)
28.0
(990)
25.5
(900)
22.9
(810)
21.2
(750)
77.9
(2750)
62.3
(2200)
53.8
(1900)
47.6
(1680)
43.0
(1520)
39.6
(1400)
99.7
(3520)
85.0
(3000)
75.0
(2650)
68.0
(2400)
63.7
(2250)
2
2 1/2
3
77.93 (3.068) 311.5 (11000) 218.0 (7700) 177.0 (6250) 150.0 (5300) 134.6 (4750) 121.8 (4300) 110.4 (3900)
102.26 (4.026) 651.2 (23000) 447.4 (15800) 362.5 (12800) 308.7 (10900) 274.7 (9700) 249.1 (8800) 229.4 (8100)
Nominal
Iron Pipe
Size
(IPS), In.
1/4
24.4 (80)
27.4 (90)
30.5 (100)
38.1 (125)
45.7 (150)
m3/hr.
53.3 (175)
61.0 (200)
(ft3/hr.)
9.25 (0.364)
0.39
(14)
0.37
(13)
0.34
(12)
0.31
(11)
0.28
(10)
0.25
(9)
0.23
(8)
3/8
12.52 (0.493)
0.88
(31)
0.82
(29)
0.76
(27)
0.68
(24)
0.62
(22)
0.57
(20)
0.54
(19)
1/2
15.80 (0.622)
1.6
(57)
1.5
(53)
1.4
(50)
1.2
(44)
1.1
(40)
1.0
(37)
0.99
(35)
3/4
20.93 (0.824)
3.3
(118)
3.1
(110)
2.9
(103)
2.6
(93)
2.4
(84)
2.2
(77)
2.0
(72)
26.64 (1.049)
6.2
(220)
5.8
(205)
5.5
(195)
5.0
(175)
4.5
(160)
4.1
(145)
3.8
(135)
1 1/4
35.05 (1.380)
13.0
(460)
12.2
(430)
11.3
(400)
10.2
(360)
9.2
(325)
8.5
(300)
7.9
(280)
1 1/2
40.89 (1.610)
19.5
(690)
18.4
(650)
17.6
(620)
15.6
(550)
14.2
(500)
13.0
(460)
12.2
(430)
52.50 (2.067)
36.8
(1300)
34.5
(1220)
32.6
(1150)
28.9
(1020)
26.9
(950)
24.1
(850)
22.7
(800)
2 1/2
62.71 (2.469)
58.1
(2050)
55.2
(1950)
52.4
(1850)
46.7
(1650)
42.5
(1500)
38.8
(1370)
36.2
(1280)
97.7
(3450)
92.0
(3250)
83.5
(2950)
75.0
(2650)
69.4
(2450)
64.6
(2280)
3
4
102.26 (4.026) 212.4 (7500) 203.9 (7200) 189.7 (6700) 169.9 (6000) 155.7 (5500) 141.6 (5000) 130.3 (4600)
Note: When the fuel has a specific gravity of 0.7 or less no correction factor is necessaryuse this table without a correction factor.
Figure 6-14 Maximum Flow Capacity of Pipe in Cubic Meters (Cubic Feet) of Gas per Hour
56
TP-5700 12/07
divided
Example:
38.1 m (125 ft.).
Example:
At 28.9 m 3/hr. (1020 ft 3/hr.) the pipe size = 2 in. IPS.
6. Move vertically down the table in Figure 6-14
from the determined value in Length of Pipe
column.
Example:
38.1 m (125 ft.)
Stop at the value that is equal to or greater than
corrected consumption value from step 3.
Example:
28.9m 3/hr. (1020 ft. 3/hr.).
by
0.633 =
TP-5700 12/07
57
Notes
58
TP-5700 12/07
WARNING
WARNING
TP-5700 12/07
59
Figure 7-1
60
TP-5700 12/07
Figure 7-2
TP-5700 12/07
61
Figure 7-3
62
TP-5700 12/07
Figure 7-4
TP-5700 12/07
63
Al Only
60_C (140_F)
or
75_C (167_F)
60_C (140_F)
75_C (167_F)
Use 75_C wire, either No. *[ AWG Cu or No. *[ Use 75_C wire, No.*[ AWG
AWG Al
90_C (194_F)
Use 90_C wire, either No. *[ AWG Cu or No. *[ Use 90_C wire, No.*[ AWG
AWG Al
* The wire size for 60_C (140_F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for the
wire given in Table 310-16 of the National Electrical Coder, in ANSI/NFPA 70, and on 115% of the maximum current that the circuit carries
under rated conditions. The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
[ Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the
guidelines in the preceding footnote.
Figure 7-5
64
2
TP-5700-7
Figure 7-6
The four bus bars contained in the optional bus bar kits
simplify the connection process by offering a neutral bus
bar in addition to the three load bars. Optional bus lugs
offer an array of terminal and wire connections.
TP-5700 12/07
Allowable
Ampacity,
Amps
EQUIPMENT
GROUND
VIEWED FROM
ENGINE END
Figure 7-7
TP-5700-7
Min. Size of
Equipment Copper
Grounding Conductor,
AWG or kcmil
Recommended
Compression Lug,
ILISCO Part No. or
Equivalent (UL Listed)
20
12
SLUH-90
60
10
SLUH-90
90
SLUH-90/125
100
SLUH-90/125
150
SLUH-90/125/225
200
SLUH-90/125/225
300
SLUH-90/125/225
400
SLUH-90/125/225
500
SLUH-125/225
600
SLUH-125/225
800
1/0
SLUH-225/300/400
1000
2/0
SLUH-225/300/400
1200
3/0
SLUH-225/300/400
1600
4/0
SLUH-225/300/400/650
2000
250
SLUH-225/300/400/650
2500
350
SLUH-300/400/650
3000
400
SLUH-400/650
4000
500
SLUH-400/650
5000
700
SLUH-650
6000
800
SLUH-650
Figure 7-8
The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
TP-5700 12/07
65
Tightening Torque,
Nm (in. lb.)
(1/8)
5.1
(45)
4.0 (5/32)
11.4
(100)
4.8 (3/16)
13.8
(120)
5.6 (7/32)
17.0
(150)
6.4
(1/4)
22.6
(200)
7.9 (5/16)
31.1
(275)
9.5
(3/8)
42.4
(375)
12.7
(1/2)
56.5
(500)
14.3 (9/16)
67.8
(600)
Figure 7-9
18--10 (0.82--5.3)
2.3 (20)
4.0 (35)
Hexagonal HeadExternal
Drive Socket Wrench
Split-Bolt
Connectors
9.0
(80)
9.0
Other
Connections
8.5 (75)
8 (8.4)
2.8 (25)
4.5 (40)
(80)
8.5 (75)
6--4 (13.3--21.2)
4.0 (35)
5.1 (45)
18.6 (165)
12.4 (110)
3 (26.7)
4.0 (35)
5.6 (50)
31.1 (275)
16.9 (150)
2 (33.6)
4.5 (40)
5.6 (50)
31.1 (275)
16.9 (150)
1 (42.4)
5.6 (50)
31.1 (275)
16.9 (150)
1/0--2/0 (53.5--67.4)
5.6 (50)
43.5 (385)
20.3 (180)
3/0--4/0 (85.0--107.2)
5.6 (50)
56.5 (500)
28.2 (250)
250--350 (127--177)
5.6 (50)
73.4 (650)
36.7 (325)
400 (203)
5.6 (50)
93.2 (825)
36.7 (325)
500 (253)
5.6 (50)
93.2 (825)
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.
66
TP-5700 12/07
D Is
7.6 Batteries
Battery location. When determining the battery
placement, ensure that the location:
clean, dry, and not exposed to extreme
temperatures
electrolyte level (when using maintenance type
batteries)
D Is close to the generator set to keep cables short,
1
2
1.
2.
3.
4.
Battery cables
Battery secured in mounting rack
End view
Generator set skid
3
TP-5700-7
67
7.8.1
Audiovisual Alarm
Front View
Side View
Wire Gauge
30.5
(100)
18--20
152.4
(500)
14
304.8 (1000)
10
A-292887
7.8.2
The four bus bars contained in the optional bus bar kits
simplify the connection process by offering a neutral bus
bar in addition to the three load bars. Optional bus lugs
offer an array of terminal and wire connections. See
Figure 7-14.
L1
L2
L3
L0
TP-5700-7
TP-5700 12/07
7.8.3
CHARGER
MALFUNCTION
LV
HV
CM
BATTERY CHARGER
ALARM
TERMINAL
STRIP
TT-680
C-294301
7.8.4
7.8.5
TP-5352-1
7.8.7
7.8.6
TP-5700-7
69
7.8.8
7.8.9
A-258782
42A 2
K1 K2 K3
K4 K5 K6
K7
PCB LOAD
ASSY A--320639
10A @120VAC RES.
INPUT CONTACT RATINGS:
.01A @28VDC MIN.
10A @28VDC MAX.
NOK1C
NOK2 C
NOK3C
NOK4 C
NOK5 C
NOK6 C
NOK7C
NOK8C
LOT NO.
NOK9C
NO
K10C
NOK11C
NOK12C
NOK13C
NOK14C
42B
P
FBA--1 10 AMP
A-293983
70
TP-5700 12/07
Fault
LEDs
System
Ready LED
Generator
Running LED
Comm.
Status LED
Common
Fault LED
Common
Fault Output
Horn
Red
Red SF
Off
Green
Off
On
On
Yellow
Red SF
Green
Green
Off
On
On
Red
Red SF
Off
Green
Off
On
On
Yellow
Red SF
Green
Green
Off
On
On
Red
Red SF
Off
Green
Off
On
On
Overspeed Shutdown
Red
Red SF
Off
Green
Off
On
On
Emergency Stop
Red
Red SF
Off
Green
Off
On
On
Red
Red SF
Off
Green
Off
On
On
Yellow
Red SF
Off
Green
Off
On
On
Yellow
Red SF
Green
Green
Off
On
On
Yellow
Green
Green
Green
Off
Off
Off
Yellow
Green
Green or Off
Green
Off
Off
Off
System Ready
Green
Green
Green or Off
Green
Off
Off
Off
Red
Red SF
Green or Off
Green
Off
On
On
No Device at Powerup
Red
Off
Off
Red SF
Off
On
On
Red
Off
Off
Red FF
Off
On
On
Red
Off
Off
Red SF
Off
On
On
Not-In-Auto
Red
Red SF
Green or Off
Green
Off
On
On
Yellow
Red SF
Green or Off
Green
Off
On
On
Yellow
Green
Green or Off
Green
Off
Off
Off
Yellow
Green
Green or Off
Green
Off
Off
Off
Red
Green
Green or Off
Green
Off
On
On
Red
Green
Green or Off
Green
Off
On
On
Red
Red SF
Green or Off
Green
Off
On
On
Red
Red SF
Green or Off
Green
Off
On
On
Red
Red SF
Green or Off
Green
Off
On
On
Common Fault
Red
Green
Green or Off
Green
Red SF
On
On
TP-5700 12/07
71
16--LIGHT CONTROLLER
550 CONTROLLER
550 CONTROLLER
TP-5700 12/07
73
TP-5700 12/07
X-796
A-273945
TP-5700 12/07
75
NEGATIVE CONNECTION
Based on ADV-5795-S-E
76
TP-5700 12/07
WARNING
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 equipment connected to the set, disable the
generator set as follows: (1) Turn the generator set master
switch and switchgear engine control 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 the starting of the
generator set by an automatic transfer switch or a remote
start/stop switch.
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.
TP-5700 12/07
WARNING
77
Figure 8-1
Wiring Instructions:
1. Remove lead connecting TB4-V8 & (black)
stator or PT2 lead V8
2. Reroute this lead and connect it to QCON2
3. Reroute (black) stator or PT2 lead V8 and
connect it to QCON1
X-467-4 (Rheostat)
283869 (Nameplate)
Note: Position locating ring
or rheostat so terminals are
in the 6 oclock position as
shown. Nameplate is located
on front of rheostat.
GM39328-A
Figure 8-2
Wiring Diagram
Test Procedure
To test and adjust the reactive droop compensator,
proceed as follows. Read the entire procedure before
beginning.
1. With the reactive droop rheostat set at minimum
(full counterclockwise position), record the rpm or
frequency and voltage at 1/4 load steps to full load
on unit #1. Repeat Step 1 for unit #2.
2. Compare the readings and make final adjustments
so that the voltage is within 1 volt at each load step
and the speed is within 3 rpm or the frequency is
within 0.1 Hz for each unit. Adjust the voltage using
the local or remote voltage adjusting potentiometer.
Adjust the speed at the governor or at the remote
speed adjusting potentiometer.
3. Check the droop compensation on each unit as
follows:
a. With unit #1 operating at the correct speed and
voltage, apply a lagging power factor load. This
load should preferably be 1/2 to full load and
must be inductive, as resistance loads cannot
be used.
TP-5700 12/07
79
EXISTING TERMINAL
BLOCK
76.2 REF.
VIEW A--A
GM31213
76.2 REF.
VIEW C--C
VIEW B--B
A
JUNCTION
BOX
SEE DETAIL D
123456
76.2 REF.
SEE DETAIL D
EXISTING
TERMINAL BLOCK
SEE DETAIL D
EXISTING TERMINAL
BLOCK
(INSIDE OF J--BOX)
GM30860
VOLTAGE
REGULATOR
102.0 REF.
C.T. TERMINAL
BLOCK
(INSIDE OF J--BOX)
254.0 REF.
38.0 REF.
GM30862 DECAL,
SPEED ADJUST
305.0 REF.
RELAY PANEL
LO
DETAIL D
(INSIDE OF BOX)
230--300 KW
350--400 KW
450--2000 KW
GM30859-A
Figure 8-3
80
TP-5700 12/07
RED
RED
WHT
BLK
*
916
510
952
1 2 3 4 5 6
953
1 2 3 4 5 6
7
510
952
RED
WHT
BLK
WHT
BLK
See Notes
3
3
DDEC
CONNECTIONS
MDEC
CONNECTIONS
GM30859-A
Notes:
Wire number is 542 on 2000/4000 series engine or
545 on 60 series engine (for DDEC connections only).
. Remove and tape wire 542 (545) when installing
manual speed adjust kits.
6
5
Figure 8-4
TT-919
1.
2.
3.
4.
Potentiometer
Panel
Nameplate
Nut
Figure 8-5
5. Knob
6. Screw
7. Washer
Potentiometer Installation
TP-5700 12/07
81
327097-A
Figure 8-6
82
TP-5700 12/07
Figure 8-7
GM16088A-F
Figure 8-8
TP-5700 12/07
83
1
14 13 1211 10 9 8 7 6 5 4 3 2
141312 1110 9 8 7 6 5 4 3 2 1
7N
V8
NO. 2 ON MARKER
STRIP MUST BE IN LINE
WITH 7N LEAD ON
TERMINAL BLOCK.
3B
5B
V7
1B
68
67
Figure 8-9
84
BS-272000-D
TP-5700 12/07
REMOTE VOLTAGE
ADJUST POTENTIOMETER
(BACK VIEW)
7N
3
12 11 10
V8
3B
7N
V8
3B
5B
V7
10
10
V7
11
11
1B
1B
VOLTAGE
REGULATOR
GENERATOR SET
JUNCTION BOX
12
12
68
13
13
67
14
5B
12 11 10
CONNECT TO
AC HARNESS
14
TG2
LEGEND
3B PHOTO--COUPLING
5B PHOTO--COUPLING
67 VOLTAGE ADJUST
68 VOLTAGE ADJUST
V7 AC VOLTAGE SENSING
V8 AC VOLTAGE SENSING
7N BATTERY GROUND
1B BATTERY VOLTAGE PLUS
BS-272000-D
BS-272000-D
TP-5700 12/07
85
View C
See View C
See View C
View A
View B
GM129340-B
BA F
CDE
GND
GM16780-A
86
TP-5700 12/07
Junction Box
Legend
PMG
STAT
TB5
QCON(#)
-----
Generator
GM20500-
87
2
3
C-255670-B
1. 60 Hz voltage adjustment
2. 50 Hz voltage adjustment
3. Stability adjustment
88
TP-5700 12/07
1
+ C4
R9
D3
R10
D1
R2
R3
R4
SHTDWN
OUT
R33
C18
C9
R24
C10
Q1
R36
R17 C12
C13
R19R26
R20
R27
R45
10
11
12
U7
R38
D7
R51
R72
L3
L8
V1
P40
12
L4
R59 R63
C38 R64
VADJ
C30
U5
R39 R43 C26
R40 D4 R46
C31
R47
D5 R48
R62
C37
C22
C23
R30
R31 R41 R44 R49
C39
L1 C40
L2
C41
R65 L5
R66
R74
R67
R73
R76
F1 (F+)
R77
V8
V7
R75
R52 STAB
R8 V/HZ
C45
C36
R53
R42 C25
C35
C46
R58
R61 R71
C34
Q2
R29 + C21
R15R25
C17
R7 R16
C11 U4
R18
R57
U6 C33
Z1
C19
R37
U1
D8
R50
C27
R35
C20
C2
C3
R34
R22 C15
R23
C16
C7 U3
R5 R13 C8
R14
D6
R12
C5
R6
R1
C1
C6
R11
D2
T1
F2 (F--)
T2
VAR/PF--VAR/PF+
GM31850A-E
AC
AC
AC
4. Stability potentiometer
5. Volts/Hz potentiometer
Socket
P40-
Lead
Description/Function
68
V7
V8
FP
67
EOV
Not used
FN
7N
10
1B
11
55
12
66
TP-5700 12/07
F+
F --
1.
2.
3.
4.
5.
6.
7.
8.
66
55
Sensing leads
Stator main windings
Rotor main field
Voltage regulator power supply leads
Rotating rectifier assembly (RRA)
Exciter armature
Exciter field winding
Voltage regulator (P40 socket)
TP-6349-4
89
90
TP-5700 12/07
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
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 Board
circuit breaker
cubic centimeter
cold cranking amps
counterclockwise
Canadian Electrical Code
certificate, certification, certified
cubic feet per hour
TP-5700 12/07
cfm
CG
CID
CL
cm
CMOS
est.
E-Stop
etc.
exh.
ext.
F
fglass.
FHM
fl. oz.
flex.
freq.
FS
ft.
ft. lb.
ft./min.
ftp
g
ga.
gal.
gen.
genset
GFI
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
GND,
gov.
gph
gpm
gr.
GRD
gr. wt.
HxWxD
HC
HCHT
HD
HET
ground
governor
gallons per hour
gallons per minute
grade, gross
equipment ground
gross weight
height by width by depth
hex cap
high cylinder head temperature
heavy duty
high exhaust temp., high
engine temp.
hexagon
mercury (element)
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
hex
Hg
HH
HHC
HP
hr.
HS
hsg.
HVAC
HWT
Hz
IC
ID
IEC
IEEE
IMS
in.
in. H2O
in. Hg
in. lb.
Inc.
ind.
int.
int./ext.
I/O
IP
ISO
J
JIS
Appendix 91
k
K
kA
KB
KBus
kg
kg/cm2
kilo (1000)
kelvin
kiloampere
kilobyte (210 bytes)
Kohler communication protocol
kilogram
kilograms per square
centimeter
kgm
kilogram-meter
kg/m3
kilograms per cubic meter
kHz
kilohertz
kJ
kilojoule
km
kilometer
kOhm, k kilo-ohm
kPa
kilopascal
kph
kilometers per hour
kV
kilovolt
kVA
kilovolt ampere
kVAR
kilovolt ampere reactive
kW
kilowatt
kWh
kilowatt-hour
kWm
kilowatt mechanical
kWth
kilowatt-thermal
L
liter
LAN
local area network
L x W x H length by width by height
lb.
pound, pounds
lbm/ft3
pounds mass per cubic feet
LCB
line circuit breaker
LCD
liquid crystal display
ld. shd.
load shed
LED
light emitting diode
Lph
liters per hour
Lpm
liters per minute
LOP
low oil pressure
LP
liquefied petroleum
LPG
liquefied petroleum gas
LS
left side
Lwa
sound power level, A weighted
LWL
low water level
LWT
low water temperature
m
meter, milli (1/1000)
M
mega (106 when used with SI
units), male
m3
cubic meter
m3/hr.
cubic meters per hour
m3/min. cubic meters per minute
mA
milliampere
man.
manual
max.
maximum
MB
megabyte (220 bytes)
MCCB
molded-case circuit breaker
MCM
one thousand circular mils
meggar
megohmmeter
MHz
megahertz
mi.
mile
mil
one one-thousandth of an inch
min.
minimum, minute
misc.
miscellaneous
MJ
megajoule
mJ
millijoule
mm
millimeter
mOhm, mmilliohm
MOhm, Mmegohm
MOV
metal oxide varistor
MPa
megapascal
mpg
miles per gallon
mph
miles per hour
MS
military standard
ms
millisecond
m/sec.
meters per second
MTBF
mean time between failure
92 Appendix
MTBO
mtg.
MTU
MW
mW
F
N, norm.
NA
nat. gas
NBS
NC
NEC
NEMA
rms
rnd.
ROM
rot.
rpm
RS
RTU
RTV
RW
SAE
scfm
SCR
s, sec.
SI
SI/EO
sil.
SN
SNMP
SPDT
SPST
spec
specs
sq.
sq. cm
sq. in.
SS
std.
stl.
tach.
TD
TDC
TDEC
TDEN
TDES
TDNE
TDOE
TDON
temp.
term.
THD
TIF
TIR
tol.
turbo.
typ.
UF
UHF
UL
UNC
UNF
univ.
US
UV
V
VAC
VAR
VDC
VFD
VGA
VHF
W
WCR
w/
w/o
wt.
xfmr
TP-5700 12/07
3
G-585
Figure 1
G-585
1.
2.
3.
4.
5.
6.
Cap screw
Entry hole types
Standard nut and SAE washer
Whiz nut or spiralock: up to 1/2 in. dia. hardware
Weld nuts: above 1/2 in. dia. hardware
Exit hole types
Figure 2
TP-5700 12/07
Appendix
93
Size
Assembled into
Aluminum
Grade 2 or 5
Torque
Torq
e
Measurement
Grade 2
Grade 5
Grade 8
8-32
Nm (in. lb.)
1.8
(16)
2.3
(20)
10-24
Nm (in. lb.)
2.9
(26)
3.6
(32)
10-32
Nm (in. lb.)
2.9
(26)
3.6
(32)
1/4-20
Nm (in. lb.)
6.8
(60)
10.8
(96)
14.9
(132)
1/4-28
Nm (in. lb.)
8.1
(72)
12.2
(108)
16.3
(144)
5/16-18
Nm (in. lb.)
13.6
(120)
21.7
(192)
29.8
(264)
5/16-24
Nm (in. lb.)
14.9
(132)
23.1
(204)
32.5
(288)
3/8-16
Nm (ft. lb.)
24.0
(18)
38.0
(28)
53.0
(39)
3/8-24
Nm (ft. lb.)
27.0
(20)
42.0
(31)
60.0
(44)
7/16-14
Nm (ft. lb.)
39.0
(29)
60.0
(44)
85.0
(63)
7/16-20
Nm (ft. lb.)
43.0
(32)
68.0
(50)
95.0
(70)
1/2-13
Nm (ft. lb.)
60.0
(44)
92.0
(68)
130.0
(96)
1/2-20
Nm (ft. lb.)
66.0
(49)
103.0
(76)
146.0
(108)
9/16-12
Nm (ft. lb.)
81.0
(60)
133.0
(98)
187.0
(138)
9/16-18
Nm (ft. lb.)
91.0
(67)
148.0
(109)
209.0
(154)
5/8-11
Nm (ft. lb.)
113.0
(83)
183.0
(135)
259.0
(191)
5/8-18
Nm (ft. lb.)
128.0
(94)
208.0
(153)
293.0
(216)
3/4-10
Nm (ft. lb.)
199.0
(147)
325.0
(240)
458.0
(338)
3/4-16
Nm (ft. lb.)
222.0
(164)
363.0
(268)
513.0
(378)
1-8
Nm (ft. lb.)
259.0
(191)
721.0
(532)
1109.0
(818)
1-12
Nm (ft. lb.)
283.0
(209)
789.0
(582)
1214.0
(895)
See Note 3
x 1.00
6.2
(4.6)
9.5
(7)
13.6
(10)
M8
x 1.25
15.0
(11)
23.0
(17)
33.0
(24)
M8
x 1.00
16.0
(11)
24.0
(18)
34.0
(25)
M10 x 1.50
30.0
(22)
45.0
(34)
65.0
(48)
M10 x 1.25
31.0
(23)
47.0
(35)
68.0
(50)
M12 x 1.75
53.0
(39)
80.0
(59)
115.0
(85)
M12 x 1.50
56.0
(41)
85.0
(63)
122.0
(90)
M14 x 2.00
83.0
(61)
126.0
(93)
180.0
(133)
M14 x 1.50
87.0
(64)
133.0
(98)
190.0
(140)
M16 x 2.00
127.0
(94)
194.0
(143)
278.0
(205)
M16 x 1.50
132.0
(97)
201.0
(148)
287.0
(212)
M18 x 2.50
179.0
(132)
273.0
(201)
390.0
(288)
M18 x 1.50
189.0
(140)
289.0
(213)
413.0
(305)
See Note 3
Notes:
1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings
when they differ from the above torque values.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.
94
Appendix
TP-5700 12/07
Butane
Propane
Natural Gas
Manufactured or
Sewage Gas
Gasoline
Diesel Fuel
Normal
atmospheric state
Gas
Gas
Gas
Gas
Liquid
Liquid
Boiling point,
Initial, C (F)
End, C (F)
0 (32)
42 (--44 )
--162 (--259)
36 (97)
216 (420)
177 (350)
357 (675)
94670
102032
3264
83340
91500
2516
63310
1000
600--700
116400
124600
6390
130300
139000
Density,
Ft3 of gas/gal.
31.26
36.39
57.75
19.5
4.81
4.24
2.65
6.16
7.08
Octane Number
Research
Motor
94
90
110+
97
110+
80--100
75--90
Figure 3
Characteristic, LP Gas*
Butane
Formula
C4H10
C3H8
0 (32)
--42 (--44)
2.00
1.53
0.58
0.51
Btu/lb. of gas
21221
21591
6.506
8.547
808.0
785.0
Combustion Data:
Ft3 air required to burn 1 ft3 of gas
Flash point, C (F)
Ignition temperature in air, C (F)
Max. flame temperature in air, C (F)
Propane
31.02
23.86
N/A
--104 (--156)
482--538 (900--1000) 493--549 (920--1020)
1991 (3615)
1979 (3595)
1.9
8.6
2.4
9.6
92
Over 100
Figure 4
TP-5700 12/07
Appendix 95
Pressure
--40C
(--40F)
--28C
(--20F)
--18C
(0F)
--7C
(20F)
4C
(40F)
15C
(60F)
27C
(80F)
38C
(100F)
Temperature
Figure 1
Temperature,
Temperature
C (F)
--40 (--40)
0.1
(1)
--36 (--33)
0.4
(5)
--28 (--20)
0.7 (10)
--23 (--10)
1.2 (17)
0.2
(3)
--18
(0)
1.7 (24)
0.4
(5)
--12 (10)
2.2 (32)
0.6
(8)
--7 (20)
3.0 (42)
0.9 (13)
--1 (30)
3.7 (52)
1.3 (19)
4 (40)
4.6 (65)
1.8 (26)
0.1
(2)
10 (50)
5.5 (78)
2.4 (34)
0.5
(7)
15 (60)
6.5 (93)
3.0 (42)
0.8 (12)
21 (70)
7.7 (109)
3.5 (50)
1.2 (17)
27 (80)
9.6 (136)
4.2 (60)
1.7 (24)
32 (90)
10.3 (147)
5.1 (72)
2.2 (32)
38 (100)
11.9 (169)
6.0 (85)
2.8 (40)
43 (110)
14.1 (200)
7.0 (100)
3.5 (50)
Figure 2
Propane
50/50 Mixture
Butane
96 Appendix
TP-5700 12/07
K
Equals
60
100
D x L x 100
50
90
D x L x 90
40
80
D x L x 80
30
70
D x L x 70
20
60
D x L x 60
10
45
D x L x 45
% of Container
Filled
Figure 2
Lb. of
Lb
Propane
in Cyl.
--18C
(0F)
--7C
(20F)
4C
(40F)
16C
(60F)
21C
(70F)
100
113000
167000
214000
277000
300000
90
104000
152000
200000
247000
277000
80
94000
137000
180000
214000
236000
70
83000
122000
160000
199000
214000
60
75000
109000
140000
176000
192000
Prevailing Air
Temperature
50
64000
94000
125000
154000
167000
--26C (--15F)
0.25
40
55000
79000
105000
131000
141000
--23C (--10F)
0.50
30
45000
66000
85000
107000
118000
--21C (--5F)
0.75
20
36000
51000
68000
83000
92000
--18C
(0F)
1.00
10
28000
38000
49000
60000
66000
--15C
Figure 1
(5F)
1.25
--12C (10F)
1.50
--26C (15F)
1.75
--7C (20F)
2.00
Figure 3
TP-5700 12/07
Multiplier
Appendix 97
Definitions
Underfrequency Unloading
Underfrequency unloading is a function used in the
alternator excitation control system to improve the
overall generator set system (engine and alternator)
response. In particular, underfrequency unloading
relates to large-block load applications. When applied
to engine-driven alternators, large-block loads cause a
subsequent transient torque load on the engine. This
torque load can reduce the engines speed below the
normal operating point. Typically, the engine speed
controller or governor will compensate for this by
commanding an increase in fuel. If, however, the fuel
system is inadequate to recover from a relatively large
load, the speed may never recover. In these instances,
other measures must be taken. This is where the
underfrequency unloading occurs.
When the excitation control system detects a drop in the
speed or electrical frequency below some
predetermined point, the control system enters an
unloading condition. This can be described as moving
to a lower voltage regulation point. By reducing the
output voltage of the alternator, the load on the
generator set is reduced.
This can be shown
98 Appendix
TP-5700 12/07
Three-Phase Sensing
Three-phase sensing describes how the excitation
control or voltage regulator determines the condition of
the alternator output voltage. Early types of regulators
sensed the voltage on just one phase of the alternator.
Single-phase sensing is not uncommon today as most
TP-5700 12/07
Appendix 99
Reactive Droop
Reactive droop refers to another compensation
technique used in excitation control systems. Reactive
droop means that the generator set voltage droops with
increasing reactive current. Although this sounds like
an undesirable effect, it is quite beneficial in paralleling
applications with multiple generator sets. Because the
terminals of the generator set are connected to another
generator set(s), the voltage at the terminals is not
solely determined by either generator sets excitation.
Rather, it is determined by the combination of the
excitation level, the generated voltage, and the voltage
drop across the armature impedance or armature
reactance for each generator set.
Normally the generated voltage is higher than the
voltage at the terminals because the generator set
current causes a drop across the armature impedance.
In a parallel application, the generated voltage of one
generator set may be slightly higher than the generated
voltage of another generator set. Differences in
potential between the generator sets will cause current
to flow into the lower voltage generator set and will also
cause the generator sets to share the load current
disproportionately. Both results are undesirable.
By introducing reactive droop, the reactive current can
be better predicted and controlled. If the current is
measured, the regulator/controller can adjust the
excitation up or down accordingly, reducing excitation
as more current is supplied or increasing excitation as
the reactive current decreases. If all the parallel
generator sets incorporate this type of compensation,
the reactive current can be shared equally based on the
proportional size of the generator sets. For an example,
see below.
The stability and accuracy of this technique depends on
several factors. Most important, the regulation point for
each generator set must be equal. That is, each voltage
adjust setting must be the equal to the other(s). This is a
basic requirement prior to the actual paralleling
connection. Also, the effects of the reactive current in
each generator set must be compensated for
individually, which requires an adjustable droop for each
generator set. This adjustment happens to be the
reactive droop adjust. The reactive droop adjust is
quantified as the droop in operating voltage from the
adjusted setting when full rated load with 0.8 power
factor (PF) is applied. A droop setting of 4% voltage at
full rated load is a recommended starting point. If the
reactive current is not shared proportionately in each
generator set, the respective droops may need
adjustment. Adjust those generator sets that have
proportionately higher current for more droop and those
generator sets with lower reactive current for less droop.
100 Appendix
TP-5700 12/07
Reactive current:
I = (VAR / 3) / VL-N
135 amps = ( 112500 / 3) / 277
Where:
VAR Control
VAR control is analogous to the reactive droop function
described above. It differs in that it applies to utility
paralleling applications. Because the utility represents
a nearly infinite bus, the voltage at the load terminals is
not controlled at all by the generator set, and it is
impossible to compare the ratio of the generator set
current to the utility based on its rated output. In this
situation, the excitation control changes from voltage
feedback to VAR feedback. More specifically, the
excitation is controlled to maintain a certain VAR output
rather than a voltage output. This is called VAR control
and again is used only in utility paralleling applications.
The VAR adjust can be set to any value within the
generator sets rated capability. Because the VARs
cause heating in the armature, any value beyond the
generator sets rating could damage the alternator. In
most cases, the generator set will be adjusted to
generate VAR (lagging PF) but could absorb VARs
(leading PF) as well. However, the VAR setting is
maintained regardless of the relative PF. If the particular
load requires more VARs than the generator set setting,
the excess is derived from the utility bus.
TP-5700 12/07
Appendix 101
Frequency Setpoint
The frequency setpoint is the cut-in point for
underfrequency unloading. At any operating frequency
below the frequency setpoint, the output voltage will be
reduced. The frequency may be entered with resolution
to tenths of a Hz. The range of acceptable entries is 30
to 70 Hz. Any entry beyond these limits causes a
RANGE ERROR display and the setting will not change.
The default value is one cycle-per-second (or two for
non-ECM engines) below the normal system frequency.
The frequency setpoint changes to the default value if
the system frequency changes. A setting of 30 Hz
essentially disables the underfrequency unload feature
because most engines do not normally drop to speeds
this low, even during load applications.
TP-5700 12/07
Voltage Droop
Generating/Absorbing
KVAR Adjust
Using the kVAR adjust sets the desired operating value
for the generator sets reactive load when the generator
set operates in a utility paralleling application. The
desired generator set load is entered directly as kVARs.
The value entered may be as low as zero or as high as
the rated value (rated kW x 0.75). Any entry beyond the
rated value will not be accepted, and a RANGE ERROR
message will be displayed.
The default value for kVAR adjust is zero. Each time the
systems rated kW is changed, the kVAR adjust will
revert to zero. The displayed kVAR setting may change
if the kVAR setting is changed via other inputs.
TP-5700 12/07
PF Adjust
Use the PF adjust to set the desired operating
relationship for the generator sets output voltage and
current when the generator set is connected in parallel
with the utility. The excitation is regulated to maintain a
PF equal to the entered value. The value entered may
be as low as 0.7 for leading PFs or as low as 0.6 for
lagging PFs. Any entries below these limits will cause a
RANGE ERROR message to display.
The upper limit for PF adjust is 1.0 and the default value
is 0.8 lagging. Each time the systems rated kW is
changed, the PF adjust will revert to this default value.
The PF adjust display setting may change if the PF
adjust is changed via other inputs.
Lagging/Leading
It is possible to select either a leading or lagging PF for
utility parallel applications. The selected mode is
displayed. A NO entry switches the controller to use the
other reference. Because the most common mode of
operation will be with a lagging PF, LAGGING is the
default value. Because this mode should not be
changed while the generator set is running, attempting
to change this mode during operation will return a
RANGE ERROR message. Always shut down the
generator set to change the lagging/leading mode
setting.
Appendix 103
Notes
104 Appendix
TP-5700 12/07
TP-5700 12/07h
E 1993, 2001, 2006, 2007 by Kohler Co. All rights reserved.