Installation Manual - TP5700

Installation
Industrial Generator Sets
Models:
20--3250 kW
TP-5700 1/13p
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.
Product Identification Information
Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that
operation manual, spec sheet, or sales invoice.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Generator Set Identification Numbers Engine Identification
Record the product identification numbers from the Record the product identification information from the
generator set nameplate(s). engine nameplate.
Model Designation Manufacturer

Specification Number Model Designation
Serial Number Serial Number
Accessory Number Accessory Description

Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Section 2 Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Weight and Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.3 Lifting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.4 Lifting the Subbase Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.5 Lifting the Generator Set with Attached Enclosure . . . . . . . . . . . . . . . . . 20
2.1.6 Lifting the Generator Set, Enclosure,
and Subbase Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.7 Lifting Single Point Lift Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Generator Set Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.1 Single-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.2 Dual-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.3 Four-Pad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.4 Mounting Pad Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 IBC Seismic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Vibration Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Dual-Bearing Alternator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 4 Air and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Air-Cooled Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Liquid-Cooled Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.3 Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Unit-Mounted Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Remote Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5.2 Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.3 Fill Lines (Balance or Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5.4 Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator . . . . . . . . . . 36
4.5.7 Procedure to Fill with Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5.8 Procedure to Fill without Deaeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5.9 Checks after Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6 City Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.6.1 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Cooling Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.8 Block Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TP-5700 1/13 Table of Contents 3

Table of Contents, continued
Section 5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 Flexible Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Condensation Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4 Double-Sleeved Thimbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5 Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6 Exhaust System Backpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 6 Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1.1 Main Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.1.2 Day Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.3 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.4 Auxiliary Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2 Gas Fuel Systems, Common Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2.1 Gas Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2.2 Gas Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 LP Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.1 LP Gas Vapor-Withdrawal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3.2 LP Gas Liquid-Withdrawal Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4 Natural Gas Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.5 Combination Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.5.1 Combination Natural Gas and LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.6 Pipe Size Requirements for Gas Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Section 7 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.1 Generator Set Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.3 Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.4 Grounding and Grounded Conductor (Neutral) Connections . . . . . . . . . . . . . . . . . 63
7.5 Terminal Connector Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.6 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.7 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.8 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.8.1 Bus Bar Kits/Bus Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.8.2 Gas Fuel Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.8.3 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.8.4 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.8.5 Wireless Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.9 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Table of Contents TP-5700 1/13

Section 8 Decision-Makerr 550 Controller Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1.1 Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1.2 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.1.3 Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.1.4 Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . 72
8.1.5 Ground Fault Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.1.6 Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1.7 Low Fuel (Level/Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.1.8 Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.1.9 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.1.10 Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.1.11 Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1.12 Shunt-Trip Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1.13 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1.14 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.15 Twenty-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.2 Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Section 9 Decision-Makerr 3000 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.1.1 Common Fault/Failure (32A) Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.1.3 Input/Output (I/O) Module Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Section 10 Decision-Makerr 6000 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.1.1 Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.1.2 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.1.4 Ground Fault Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.1.5 Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.1.12 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1.13 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1.14 Twenty-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
TP-5700 1/13 Table of Contents 5

Section 11 Remote Adjustment/Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
11.1 Automatic Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
11.2 Decision-Makerr 550 Controller, Voltage Regulator
and Paralleling Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
11.3 Decision-Makerr 3000 Controller Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . 116
11.4 Decision-Makerr 6000 Controller Voltage Regulator
and Paralleling Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
11.5 Reactive Droop Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
11.6 Remote Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.7 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . . . . . . . . . . 120
11.8 Remote Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
11.9 Remote Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
11.10 Remote Voltage Regulator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
11.11 Voltage Regulator DVR 2000EC/Remote Voltage Regulator Kit,
350 kW and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.12 Voltage Regulator, PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Appendix D Fuel Physical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Appendix E Gas Fuel Vapor Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Appendix F Gas Fuel System Installation Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Appendix G Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6 Table of Contents TP-5700 1/13

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and WARNING
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of working on the generator set.
safety precautions and instructions: explosive fumes.
Remove the negative (--) lead first
Danger, Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can
DANGER cause severe injury or death. Battery
acid can cause blindness and burn
Disabling the generator set. skin. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or
working on the generator set or open a sealed battery or mutilate the
substantial property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the
Warning indicates the presence of a battery cables, negative (--) lead first. case of eye contact. Never add acid to
hazard that can cause severe Reconnect the negative (--) lead last a battery after placing the battery in
personal injury, death, or when reconnecting the battery. Follow service, as this may result in
substantial property damage. these precautions to prevent starting of hazardous spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.
TP-5700 1/13 Safety Precautions and Instructions 7

Battery gases. Explosion can cause Servicing the fuel system. A flash Generator set operation. Carbon
severe injury or death. Battery gases fire can cause severe injury or monoxide can cause severe
can cause an explosion. Do not smoke death. Do not smoke or permit flames nausea, fainting, or death. Carbon
or permit flames or sparks to occur or sparks near the carburetor, fuel line, monoxide is an odorless, colorless,
near a battery at any time, particularly fuel filter, fuel pump, or other potential tasteless, nonirritating gas that can
when it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. cause death if inhaled for even a short
battery in a fire. To prevent burns and Catch fuels in an approved container time. Avoid breathing exhaust fumes
sparks that could cause an explosion, when removing the fuel line or when working on or near the generator
avoid touching the battery terminals carburetor. set. Never operate the generator set
with tools or other metal objects. inside a building unless the exhaust
Remove all jewelry before servicing Servicing the fuel system. A flash gas is piped safely outside. Never
the equipment. Discharge static fire can cause severe injury or operate the generator set where
electricity from your body before death. Do not smoke or permit flames exhaust gas could accumulate and
touching batteries by first touching a or sparks near the fuel injection seep back inside a potentially occupied
grounded metal surface away from the system, fuel line, fuel filter, fuel pump, building.
battery. To avoid sparks, do not disturb or other potential sources of spilled
the battery charger connections while fuels or fuel vapors. Catch fuels in an Carbon monoxide symptoms.
the battery is charging. Always turn the approved container when removing Carbon monoxide can cause severe
battery charger off before the fuel line or fuel system. nausea, fainting, or death. Carbon
disconnecting the battery connections. monoxide is a poisonous gas present
Servicing the air cleaner. A sudden in exhaust gases. Carbon monoxide is
Ventilate the compartments containing backfire can cause severe injury or
batteries to prevent accumulation of an odorless, colorless, tasteless,
death. Do not operate the generator nonirritating gas that can cause death if
explosive gases. set with the air cleaner removed. inhaled for even a short time. Carbon
Battery short circuits. Explosion Combustible materials. A fire can monoxide poisoning symptoms
can cause severe injury or death. cause severe injury or death. include but are not limited to the
Short circuits can cause bodily injury Generator set engine fuels and fuel following:
and/or equipment damage. vapors are flammable and explosive. D Light-headedness, dizziness
Disconnect the battery before Handle these materials carefully to D Physical fatigue, weakness in
generator set installation or minimize the risk of fire or explosion. joints and muscles
maintenance. Remove all jewelry Equip the compartment or nearby area D Sleepiness, mental fatigue,
before servicing the equipment. Use with a fully charged fire extinguisher. inability to concentrate
tools with insulated handles. Remove Select a fire extinguisher rated ABC or or speak clearly, blurred vision
the negative (--) lead first when BC for electrical fires or as D Stomachache, vomiting, nausea
disconnecting the battery. Reconnect recommended by the local fire code or If experiencing any of these symptoms
the negative (--) lead last when an authorized agency. Train all and carbon monoxide poisoning is
reconnecting the battery. Never personnel on fire extinguisher possible, seek fresh air immediately
connect the negative (--) battery cable operation and fire prevention and remain active. Do not sit, lie down,
to the positive (+) connection terminal procedures. or fall asleep. Alert others to the
of the starter solenoid. Do not test the possibility of carbon monoxide
battery condition by shorting the poisoning. Seek medical attention if
terminals together. Exhaust System the condition of affected persons does
not improve within minutes of breathing
fresh air.
Engine Backfire/Flash WARNING
Fire Fuel System
WARNING
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
Fire. The exhaust system must be

Can cause severe injury or death. leakproof and routinely inspected.
Explosive fuel vapors.
Do not smoke or permit flames or Can cause severe injury or death.
sparks near fuels or the fuel system.
Use extreme care when handling,
storing, and using fuels.
8 Safety Precautions and Instructions TP-5700 1/13

Fuel tanks. Explosive fuel vapors Engine noise. Hazardous noise can
WARNING can cause severe injury or death. cause hearing loss. Generator sets
Gasoline and other volatile fuels stored not equipped with sound enclosures
in day tanks or subbase fuel tanks can can produce noise levels greater than
cause an explosion. Store only diesel 105 dBA. Prolonged exposure to
fuel in tanks. noise levels greater than 85 dBA can
cause permanent hearing loss. Wear
Avoid high pressure fluids. Draining the fuel system. Explosive hearing protection when near an
Can cause severe injury or death. fuel vapors can cause severe injury operating generator set.
or death. Spilled fuel can cause an
Do not work on high pressure fuel or explosion. Use a container to catch
hydraulic systems without fuel when draining the fuel system.
protective equipment to protect Wipe up spilled fuel after draining the
Hazardous Voltage/
hands, eyes, and body. Avoid the system. Moving Parts
hazard by relieving pressure before
disconnecting fuel injection Gas fuel leaks. Explosive fuel
pressure lines. Search for leaks vapors can cause severe injury or DANGER
using a piece of cardboard. Always death. Fuel leakage can cause an
protect hands, eyes, and body from explosion. Check the LPG vapor or
high pressure fluids. If an accident natural gas fuel system for leakage by
occurs, seek medical attention using a soap and water solution with
immediately. the fuel system test pressurized to
6--8 ounces per square inch Hazardous voltage.
The fuel system. Explosive fuel (10--14 inches water column). Do not Will cause severe injury or death.
vapors can cause severe injury or use a soap solution containing either
Disconnect all power sources before
death. Vaporized fuels are highly ammonia or chlorine because both
opening the enclosure.
explosive. Use extreme care when prevent bubble formation. A
handling and storing fuels. Store fuels successful test depends on the ability
in a well-ventilated area away from of the solution to bubble.
WARNING
spark-producing equipment and out of
LPG liquid withdrawal fuel leaks.
the reach of children. Never add fuel to
Explosive fuel vapors can cause
the tank while the engine is running
severe injury or death. Fuel leakage
because spilled fuel may ignite on
can cause an explosion. Check the
contact with hot parts or from sparks.
LPG liquid withdrawal fuel system for
Do not smoke or permit flames or Hazardous voltage. Moving parts.
leakage by using a soap and water
sparks to occur near sources of spilled Can cause severe injury or death.
solution with the fuel system test
fuel or fuel vapors. Keep the fuel lines
pressurized to at least 90 psi
and connections tight and in good Operate the generator set only when
(621 kPa). Do not use a soap solution
condition. Do not replace flexible fuel all guards and electrical enclosures
containing either ammonia or chlorine
lines with rigid lines. Use flexible are in place.
because both prevent bubble
sections to avoid fuel line breakage
formation. A successful test depends
caused by vibration. Do not operate
on the ability of the solution to bubble.
the generator set in the presence of WARNING
fuel leaks, fuel accumulation, or
sparks. Repair fuel systems before
resuming generator set operation. Hazardous Noise
Explosive fuel vapors can cause
severe injury or death. Take CAUTION
additional precautions when using the Hazardous voltage.
following fuels: Backfeed to the utility system can
cause property damage, severe
Gasoline—Store gasoline only in injury, or death.
approved red containers clearly
marked GASOLINE. If the generator set is used for
Hazardous noise. standby power, install an automatic
Propane (LPG)—Adequate Can cause hearing loss. transfer switch to prevent inadvertent
ventilation is mandatory. Because interconnection of standby and
propane is heavier than air, install Never operate the generator set
normal sources of supply.
propane gas detectors low in a room. without a muffler or with a faulty
Inspect the detectors per the exhaust system.
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.

Connecting the battery and the Testing live electrical circuits.
CAUTION battery charger. Hazardous voltage Hazardous voltage or current can
can cause severe injury or death. cause severe injury or death. Have
Reconnect the battery correctly, trained and qualified personnel take
positive to positive and negative to diagnostic measurements of live
negative, to avoid electrical shock and circuits. Use adequately rated test
damage to the battery charger and equipment with electrically insulated
battery(ies). Have a qualified probes and follow the instructions of
Welding the generator set.
electrician install the battery(ies). the test equipment manufacturer when
Can cause severe electrical
performing voltage tests. Observe the
equipment damage. Servicing the day tank. Hazardous following precautions when performing
voltage can cause severe injury or voltage tests: (1) Remove all jewelry.
Never weld components of the death. Service the day tank electrical
generator set without first (2) Stand on a dry, approved
control module (ECM) as prescribed in electrically insulated mat. (3) Do not
disconnecting the battery, controller the equipment manual. Disconnect the
wiring harness, and engine touch the enclosure or components
power to the day tank before servicing. inside the enclosure. (4) Be prepared
electronic control module (ECM). Press the day tank ECM OFF for the system to operate automatically.
pushbutton to disconnect the power. (600 volts and under)
Grounding electrical equipment. Notice that line voltage is still present
Hazardous voltage can cause within the ECM when the POWER ON Servicing the generator set when it
severe injury or death. Electrocution light is lit. Ensure that the generator set is operating. Exposed moving parts
is possible whenever electricity is and day tank are electrically grounded. can cause severe injury or death.
present. Ensure you comply with all Do not operate the day tank when Keep hands, feet, hair, clothing, and
applicable codes and standards. standing in water or on wet ground test leads away from the belts and
Electrically ground the generator set, because these conditions increase the pulleys when the generator set is
transfer switch, and related equipment risk of electrocution. running. Replace guards, screens,
and electrical circuits. Turn off the and covers before operating the
main circuit breakers of all power Short circuits. Hazardous generator set.
sources before servicing the voltage/current can cause severe
equipment. Never contact electrical injury or death. Short circuits can
cause bodily injury and/or equipment WARNING
leads or appliances when standing in
water or on wet ground because these damage. Do not contact electrical
conditions increase the risk of connections with tools or jewelry while
electrocution. making adjustments or repairs.
Remove all jewelry before servicing
Welding on the generator set. Can the equipment.
cause severe electrical equipment
Engine block heater. Hazardous Airborne particles.
damage. Before welding on the
voltage can cause severe injury or Can cause severe injury or
generator set perform the following
death. The engine block heater can blindness.
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect cause electrical shock. Remove the
Wear protective goggles and clothing
all engine electronic control module engine block heater plug from the
when using power tools, hand tools,
(ECM) connectors. (3) Disconnect all electrical outlet before working on the
or compressed air.
generator set controller and voltage block heater electrical connections.
regulator circuit board connectors. Electrical backfeed to the utility.
(4) Disconnect the engine battery- Hazardous backfeed voltage can
charging alternator connections. cause severe injury or death. Install
(5) Attach the weld ground connection a transfer switch in standby power
close to the weld location. installations to prevent the connection
Installing the battery charger. of standby and other sources of power.
Hazardous voltage can cause Electrical backfeed into a utility
severe injury or death. An electrical system can cause severe
ungrounded battery charger may injury or death to utility personnel
cause electrical shock. Connect the working on power lines.
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.

Heavy Equipment Hot Parts Notice
WARNING WARNING NOTICE
This generator set has been
rewired from its nameplate voltage
to
Hot coolant and steam.
Can cause severe injury or death.
Unbalanced weight.
Improper lifting can cause severe Before removing the pressure cap, 246242
injury or death and equipment stop the generator set and allow it to
damage. cool. Then loosen the pressure cap
Do not use lifting eyes.
to relieve pressure. NOTICE
Lift the generator set using lifting bars Voltage reconnection. Affix a notice
inserted through the lifting holes on to the generator set after reconnecting
the skid. WARNING the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
WARNING distributor/dealer.
Hot engine and exhaust system. NOTICE

Can cause severe injury or death. Parallel Operation. This product
Do not work on the generator set until includes features intended to support
it cools. operation in parallel with the utility grid,
but these features have not been
Unbalanced and elevated weight. evaluated for compliance with specific
Improper lifting can cause severe Servicing the exhaust system. Hot utility interconnection protection
injury or death and equipment parts can cause severe injury or standards or requirements.
damage. death. Do not touch hot engine parts.
The engine and exhaust system NOTICE
Do not lift the generator set from the components become extremely hot
engine or alternator eyes. Never Canadian installations only. For
during operation.
stand under a unit being lifted. standby service connect the output of
Always maintain a safe distance from Servicing the engine heater. Hot the generator set to a suitably rated
the unit being lifted. parts can cause minor personal transfer switch in accordance with
See the lifting instructions in the injury or property damage. Install the Canadian Electrical Code, Part 1.
installation manual that was provided heater before connecting it to power.
with the unit. Operating the heater before NOTICE
installation can cause burns and Electrostatic discharge damage.
component damage. Disconnect Electrostatic discharge (ESD)
power to the heater and allow it to cool damages electronic circuit boards.
before servicing the heater or nearby Prevent electrostatic discharge
parts. 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.

Notes

Introduction
This manual provides installation instructions for Read this manual and carefully follow all procedures
industrial generator sets. Operation manuals and wiring and safety precautions to ensure proper equipment
diagram manuals are available separately. operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
Some additional model-specific installation information beginning of this manual. Keep this manual with the
may be included in the respective generator set equipment for future reference.
controller operation manual.
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.
Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit
the Kohler Power Systems website at East China Regional Office, Shanghai
KOHLERPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
TP-5700 1/13 Introduction 13

Notes
14 Service Assistance TP-5700 1/13

Section 1 General
Industrial power systems give years of dependable Your authorized generator set distributor/dealer may
service if installed using the guidelines provided in this also provide advice about or assistance with your
manual and in applicable codes. Incorrect installation installation.
can cause continuing problems. Figure 1-1 illustrates a
typical installation.
2 3
9 4
8
TP-5700-1
1. Exhaust thimble (for wall or ceiling) 6. Mounting base

2. Silencer 7. Controller
3. Supports 8. Electrical conduit
4. Flexible sections 9. Water trap with drain
5. Duct work for cooling air outlet 10. Fresh air intake
Figure 1-1 Typical Stationary-Duty Generator Set Installation
TP-5700 1/13 Section 1 General 15

This manual references several organizations and their These organizations provide information specifically for
codes that provide installation requirements and US installations. Installers must comply with their
guidelines such as the National Fire Protection respective national and local codes.
Association (NFPA) and Underwriter’s Laboratories Inc.
(UL). Before beginning generator set installation, record the
following data from the generator set’s specification
D NFPA 54 National Fuel Gas Code sheet and keep this data accessible for reference during
installation:
D NFPA 70 National Electrical Coder; the National
Electrical Code is a registered trademark of the NFPA D Dimensions and weight (verify dimensions and
weight using the submittal data)
D NFPA 99 Standard for Health Care Facilities
D Exhaust outlet size and maximum allowable
D NFPA 101 Life Safety Code backpressure
D NFPA 110 Emergency and Standby Power Systems D Battery CCA rating and quantity
D UL 486A--486B Wire Connectors D Fuel supply line size and fuel pressure requirement
(gas models)
D UL 486E Equipment Wiring Terminals for Use with
Aluminum and/or Copper Conductors D Air requirements
D UL 2200 Stationary Engine Generator Assemblies
16 Section 1 General TP-5700 1/13

Section 2 Loading and Transporting
The loading and transporting processes expose the

generator set to many stresses and the possibility of
improper handling. Therefore, after transporting
industrial generator sets:
D Check the alignment of the radiator and supports to

ensure that the radiator is evenly spaced from the
generator and that supports are square and of even
length. Check the radiator fan for uniform alignment 1
and equal clearance within the radiator shroud.
TP-5700-2
Adjust if necessary.
1. Reinforcing plate
D After confirming the correct alignment, tighten the
Figure 2-1 Lifting Hook Placement (above 1000 kW)
hardware to its specified torque. Reference
Appendix C, General Torque Specifications. D Generator sets typically above 1000 kW may have
reinforcing plates on the skid. Do not attach lifting
hooks to the reinforcing plate. See Figure 2-1.
2.1 Lifting
D Lifting should only be conducted by those trained and
WARNING experienced in lifting and rigging to achieve a safe
and effective lift. Consideration needs to be given to,
but not necessarily limited to the following items:
d Weight and center of gravity of the equipment
being lifted
d Weight and center of gravity of the lifting device
Unbalanced and elevated weight.
d Boom angles
Improper lifting can cause severe
injury or death and equipment d Selection of rated rigging
damage.
d Stability of lifting foundation
Do not lift the generator set from the
engine or alternator eyes. Never d Wind and weather conditions
stand under a unit being lifted. d Local or regional codes may require or restrict
Always maintain a safe distance from types of rigging.
the unit being lifted.
See the lifting instructions in the D Use a spreader bar to prevent lifting cables from
installation manual that was provided
with the unit.
contacting air cleaners, shrouds, other protruding
components. If the cables still do not clear these
components, remove the components.
2.1.1 General Precautions
2.1.2 Weight and Center of Gravity
Follow these general precautions when lifting all
generator sets and related equipment. Refer to the respective specification sheet and/or the
submittal drawing for the weight and center of gravity of
D Install proper size rigging at the skid lifting eyes all components being lifted. The total combined weight
providing a direct pull on the skid lifting eye. Make and center of gravity must be known to select the proper
sure the rigging does not work as a pry bar lever rigging. If the weight and center of gravity is not readily
against the lifting eye. available, contact your distributor/dealer.
D Do not lift the generator set using the lifting eyes As applicable, determine with weights and center of
attached to the engine and/or alternator as these gravity of the following components:
lifting eyes can not support the total weight of the
generator set. D Generator set
D Enclosure system (includes silencer, inlet baffles,
D Always protect cables, chains, and straps from sharp louvers, etc.)
edges.
D Subbase fuel tank (lift only empty fuel tanks).
TP-5700 1/13 Section 2 Loading and Transporting 17

2.1.3 Lifting the Generator Set
The distributor/lifting contractor should choose one of
the following methods to lift the generator set depending
upon the location circumstances and the generator set’s
weight and size. Remove cover plates as needed to
access the generator set skid lifting eyes.
Single Spreader Bar and Hook Method

Refer to Figure 2-2.
Double Spreader Bar and Hook Method

Single Spreader Bar and Skid Lifting Bar Method
TP-5700-2/L9
Figure 2-3 Double Spreader Bar and Hook Method
TP-5700-2/L8
Figure 2-2 Single Spreader Bar and Hook Method
TP-5700-2/L10
Figure 2-4 Single Spreader Bar and Skid Lifting Bar

Method
18 Section 2 Loading and Transporting TP-5700 1/13

Double Spreader Bar and Skid Lifting Bar Method
TP-5700-2/L6
Figure 2-6 Fuel Tank with Single Spreader Bar

TP-5700-2/L11
Method
Figure 2-5 Double Spreader Bar and Skid Lifting
Bar Method
2.1.4 Lifting the Subbase Fuel Tank

This section deals with lifting the subbase fuel tank as a
single unit.
D The subbase fuel tank must have lifting eyes in order

to use the following methods.
D The subbase fuel tank must be empty. Do not lift a

fuel tank containing fuel (or any liquid).
D Remove any vent piping longer than 1 m (3.3 ft.) from

the fuel tank. Do not lift a fuel tank with attached vent
piping longer than 1 m (3.3 ft.). TP-5700-2/L7
D Attach one or two spreader bars as shown. Figure 2-7 Fuel Tank with Double Spreader Bar
Method
Fuel Tank with Single Spreader Bar Method
Fuel Tank with Double Spreader Bar Method

2.1.5 Lifting the Generator Set with
Attached Enclosure
Enclosure Attached Directly to the Generator Set

Skid
Refer to Figure 2-8. Lift the assembly by lifting on the
skid as shown in 2.1.3 Lifting Methods for Generator
Set.
Do not attach hoisting equipment to the enclosure.
G6-99
Subbase Fuel Tank Lifting Eyes
Generator Set Skid Skid Lifting Eyes

G6-109 G6-102
Figure 2-8 Typical Enclosure Attached Directly to Figure 2-9 Typical Enclosure Attached Directly to
the Generator Set Skid the Subbase Fuel Tank
Enclosure Attached Directly to the Subbase Fuel Lift the entire enclosure, generator set, and subbase
Tank fuel tank assembly by lifting on the subbase fuel tank
lifting eyes. Lift using all of the lifting eyes provided on
Refer to Figure 2-9. Lift the assembly by lifting on the the subbase fuel tank. Select the procedure from the
subbase fuel tank lifting eyes. Lift using all of the lifting following illustrations based on the matching number of
eyes provided on the subbase fuel tank. Select the available subbase fuel tank lifting eyes. Do not attach
procedure from the following illustrations based on the hoisting equipment to the enclosure base.
matching number of available subbase fuel tank lifting
eyes.
Do not attach hoisting equipment to the enclosure.
Enclosure Attached to the Enclosure Base and

Assembled to the Subbase Fuel Tank
With the subbase fuel tank detached from the enclosure Enclosure
base, lift only the enclosure and generator set using the Base
enclosure base lifting eyes. Lift using all of the lifting
eyes provided on the enclosure base. Select the
procedure from the following illustrations based on the
matching number of available enclosure base lifting
eyes.
G6-104
Figure 2-10 Typical Enclosure Attached to the

Enclosure Base and Assembled to the
Subbase Fuel Tank

2.1.6 Lifting the Generator Set,
Enclosure, and Subbase Fuel
Tank Assembly
When using the subbase fuel tank to lift the generator
set and/or enclosure as a package, use ALL of the lifting
eyes on the subbase fuel tank.
Hoisting using Four Eye Lifting Method
Apply the same lifting methods using single or double

spreader bars as shown in 2.1.3 Lifting the Generator
Set.
Hoisting using Six Eye Lifting Method

TP-5700/L2
Apply one spreader bar and two chain falls (Figure 2-11) Figure 2-12 Six Eyes, Three Spreader Bars, and Two
or three spreader bars and two chain falls (Figure 2-12) Chain Falls Lifting Method
for six eye lifting.
D Install a pair of outer slings to the maximum angle as Hoisting using Eight Eye Lifting Method
shown in Figure 2-11 and Figure 2-12.
Apply two spreader bars and four chain falls
D Remove the slack from the slings in the system but do (Figure 2-13) for eight eye lifting.
not lift the unit.
D Install a pair of outer slings up to the maximum angle
D Install adjustable chain falls and strap or cable them as shown in Figure 2-13.
from the spreader bar to the middle lifting eyes.
D Remove the slack from the slings in the system but do
Adjust to remove the slack.
not lift the unit.
D Check and remove any slack that has developed in
D Install adjustable chain falls and strap or cable them
the primary slings and check that all chains/straps/
cables are carrying load.

TP-5700/L3
Figure 2-13 Eight Eyes, Two Spreader Bars, and

Four Chain Falls Lifting Method
TP-5700/L1
Figure 2-11 Six Eyes, Single Spreader Bar, and Two

Chain Falls Lifting Method

Hoisting using Ten Eye Lifting Method
Apply three spreader bars and six chain falls
(Figure 2-14) for ten eye lifting.
D Install a pair of outer slings up to the maximum angle

as shown in Figure 2-14.
D Remove the slack from the slings in the system but do

not lift the unit.


TP-5700/L5
Figure 2-15 Twelve Eyes, Three Spreader Bars, and
Eight Chain Falls Lifting Method
2.1.7 Lifting Single Point Lift

Assemblies
Some units have an enclosure integral to the skid and
attach a single point lifting eye located at the top and
center of the enclosure. The entire assembly may be
lifted with this eye.
2.2 Generator Set Transporting

Follow these guidelines when transporting the
TP-5700/L4 generator set:
Figure 2-14 Ten Eyes, Three Spreader Bars, and Six D Select the transporting vehicle/trailer based on the
Chain Falls Lifting Method dimensions and weight of the generator set as
specified in the generator set dimension drawing or
Hoisting using Twelve Eye Lifting Method specification sheet. Ensure that the gross weight and
overall height of the generator set and vehicle/trailer
Apply three spreader bars and eight chain falls in transport does not exceed applicable
(Figure 2-15) for twelve eye lifting. transportation codes.
D Install a pair of outer slings up to the maximum angle D Use low boy-type trailers that meet clearance
as shown in Figure 2-15. requirements when transporting units larger than
1000 kW. Load large (unboxed) radiator-equipped
D Remove the slack from the slings in the system but do generator sets with the radiator facing the rear to
not lift the unit. reduce wind resistance during transit. Secure fans to
prevent fan rotation in transit.
from the spreader bar to the middle lifting eyes. D Securely fasten the generator set to the vehicle/trailer
Adjust to remove the slack. and cover. Even the heaviest of generator sets can
move during shipment unless they are secured.
D Check and remove any slack that has developed in Fasten the generator set to the vehicle/trailer bed with
the primary slings and check that all chains/straps/ a correctly sized chain routed through the mounting
cables are carrying load. holes of the generator set skid. Use chain tighteners
to remove slack from the mounting chain. Cover the
entire unit with a heavy-duty canvas or tarpaulin
secured to the generator set or trailer.

Section 3 Location
3.1 Location Factors D Provide adequate protection to prevent injury in the

stub-up area. If the stub-up area opening is exposed,
Ideally, the generator set should be mounted on provide a cover or fill in the area to avoid the risk of
concrete at ground level. For above-ground installations, tripping or falling into the stub-up opening.
including roof installations, weight considerations are
especially important. The building engineer determines Outdoor Installations:
whether the structure can support the weight of the
generator set. D Select a location that provides adequate air flow.
Avoid locations next to tall buildings that block normal
The location of the generator set must meet the air flow and cause air vacuum pockets. Avoid areas
following criteria. that are subject to high winds, excessive dust, or other
airborne contaminants. High dust areas may require
General: more frequent air cleaner maintenance. High
temperature conditions affect generator set efficiency.
D Support the weight of the generator set and related Select a shaded area away from direct sunlight and/or
equipment such as fuel storage tanks, batteries, other heat-producing equipment when practical.
radiators, and mounting pad(s). Keep in mind that the
mounting pad weight may exceed the weight of the D If the generator set enclosure is mounted on multiple
generator set. pads where it is elevated above the main surface it
may cause discharge air recirculation underneath the
D Meet applicable fire rating codes and standards. unit. A typical location could be a building roof where
the main surface is uneven for a single pad. Refer to
D Install the unit so that the risk of contact by people 4.3.2 Installation Considerations for information to
with the hot generator set surfaces is minimized. minimize discharge air recirculation.
D Position the generator set over a noncombustible
surface. If the mounting surface directly under or near 3.2 Mounting Surface
the generator set is porous or deteriorates from
exposure to engine fluids, construct a containment Figure 3-1 shows typical mounting surface details for
pan for spilled fuel, oil, coolant, and battery sizing the concrete surface beyond the generator set
electrolyte. Do not allow accumulation of combustible and allowing for clearances during generator set
materials under the generator set. service. Follow the dimensional details provided in
Figure 3-2, Figure 3-3, or Figure 3-4 depending upon
D Permit vibration isolation and dampening to reduce the mounting method.
noise and prevent damage.
D Be clean, dry, and not subject to flooding. 1 2 4
D Provide easy access for service and repair.

3
5
Indoor Installations:
3 6
D Allow adequate ventilation with a minimum amount of
ductwork.
3
D Allow safe expulsion of exhaust. TP-5700-3
7
D Allow for storage of sufficient fuel to sustain 1. Engine end
emergency operation. See the generator set 2. Generator set skid
specification sheet for fuel consumption. 3. Extend the concrete surface a minimum of 152 mm (6 in.)
beyond the generator set
D Allow for locating the fuel tank within the vertical lift 4. Battery rack
5. Allow at least 457 mm (18 in.) between the generator set
capabilities of the fuel pump and any auxiliary pumps. and adjacent walls or other obstructions on all sides for
See Section 6, Fuel Systems. ease of servicing the generator set
6. Alternator end
D Minimize the risk of public or unauthorized access. 7. Mounting pad (concrete surface)
Figure 3-1 Mounting Surface Detail (top view)
TP-5700 1/13 Section 3 Location 23

3.2.1 Single-Pad Mounting 3.2.4 Mounting Pad Specifications
The manufacturer recommends a single, level concrete Mounting pad weight. The weight of the single
mounting pad as shown in Figure 3-2. This method mounting pad or combined weight of multiple mounting
provides maximum stability for the generator set; pads should equal or exceed the combined weight of the
however, draining the oil and servicing the generator set generator set and attached accessories.
may require raising the set from the pad.
Use an oil drain pump if clearance below the oil drain or

extension is insufficient for a pan large enough to hold all
the engine’s oil.
TP-5700-3
Figure 3-4 Four-Pad Mounting
To determine the weight of the mounting pad(s),

TP-5700-3
determine the volume (length x width x height) of each
pad in cubic meters (cubic feet). Multiply this result by
Figure 3-2 Single-Pad Mounting 2400 kg (150 lb.) to determine a pad’s weight. In
multiple-pad installations, add the weights of all pads to
determine the total mounting pad weight.
3.2.2 Dual-Pad Mounting
Mounting pad specifications. Mounting pad
The two-pad arrangement shown in Figure 3-3 provides
easy access to conveniently drain the oil. Follow the oil composition should follow standard practice for the
required loading. Typical specifications call for 17238--
draining considerations outlined in Section 3.2.1.
20685 kPa (2500--3000 psi) concrete reinforced with
eight-gauge wire mesh or No. 6 reinforcing bars on
305 mm (12 in.) centers. The top surface of the mounting
pad on which the generator set mounts should be within a
flatness of 3 mm (1/8 in.).
The recommended concrete mixture by volume is

1:2:3 parts of cement, sand, and aggregate,
respectively. Surround the pad with a 200--250 mm
(8--10 in.) layer of sand or gravel for proper support and
isolation of a pad located at or below grade.
TP-5700-3 Anchor the generator set to the concrete using bolts cast
into the surface of the pad. Otherwise, drill holes in the
Figure 3-3 Dual-Pad Mounting
mounting pad and use expansion anchor bolts. Anchor
the generator set skid or fuel tank (if equipped) using all
3.2.3 Four-Pad Mounting of the provided anchor holes on the bottom of the skid.
The four-pad arrangement shown in Figure 3-4 Note: Refer to the generator set and accessory
provides more room under the engine for service than dimension drawings for conduit and fuel-line
the previous two methods. Follow the oil draining placement. The drawings give dimensions for
considerations outlined in Section 3.2.1. electrical and fuel connection roughins and
stubups.
24 Section 3 Location TP-5700 1/13

3.3 IBC Seismic Installation Note: Dimensions
51 (2) shown are mm (inches)
International Building Code (IBC) seismic installations
involve additional mounting and installation 11
191 (7.5) 11 (0.44) DIA.
considerations. Refer to respective seismic installation (0.44)
4-HOLES
ADV drawing(s) for seismic isolator requirements. 203 (8)
16 (0.62)
3.4 Vibration Isolation DIA.
Use one of the vibration isolation types detailed in the

127 (5)
following paragraphs. Also, connections between the REF.
generator set or its skid and any conduits, fuel lines, or
exhaust piping must include flexible sections to prevent 290173-V
breakage and to isolate vibration. These connections
are detailed in subsequent sections. Figure 3-6 Vibration Isolators GM39515 and
GM41122
Isolator types. The two primary types of isolators are
neoprene and spring-type. Figure 3-5 shows neoprene
isolators between the engine-generator and the skid,
referred to as integral vibration isolation mounting.
Integral vibration isolation units come from the factory
with neoprene vibration isolation. Neoprene isolators
provide 90% vibration isolation efficiency and are often
sufficient for installations at or below grade.
Note: Dimensions
shown are in mm.
1 mm equals
0.039 inches.
2 GM66019-
Figure 3-7 Vibration Isolators GM66019, GM66304,

TP-5700-3 and GM76149
1. To engine-generator 3. Neoprene vibration isolator
2. Skid crossmember
Figure 3-5 Neoprene-Type Integral Vibration

Isolators
Figure 3-6 through Figure 3-10 shows the spring-type
isolator kit installed with direct-mounted units.
Direct-mounted units have no factory vibration isolation.
Spring-type isolators provide 98% vibration efficiency
and are recommended for above grade installations and
other locations where vibration sensitivity could be an
issue.
Generator sets with integral vibration isolation.

Skids for generator sets 20 kW and larger use I or C Note: Dimensions
section-fabricated steel with a width of 52--76 mm shown are in mm.
1 mm equals
(2--3 in.) per channel. The length varies with the size of 0.039 inches.
the unit, resulting in a static load on the generator set
skid of 69--172 kPa (10--25 psi) if the total bottom GM66020-
surface of the channel is in contact with the mounting
Figure 3-8 Vibration Isolators GM66020, GM66022,
pad.
GM66023, GM66024, and GM66313
Generator sets with direct mounting. Larger
generator sets typically mount directly to a structural
steel base. For these units, install the recommended
vibration isolators between the base and the mounting
pad in the holes provided. Because of the reduced
mounting surface area of these individual mounts, the
static load on the mounting surface increases to the
range of 345--690 kPa (50--100 psi).
Note: Dimensions
shown are in mm. Generator sets mounted on subbase fuel tanks. Do
1 mm equals not install vibration spring isolators under the subbase
0.039 inches. fuel tank.
Dual isolation. For applications involving integral

vibration isolators and where the factory does not offer
spring-type isolators as a standard accessory, spring-
type isolators may be installed under the skid provided
they equal the number of neoprene isolators, are inline
GM66025-
front-to-back with the existing neoprene isolators, and
additional support plates are installed, as required. See
Figure 3-9 Vibration Isolator GM66025
Figure 3-11.
6X 21 (0.81) DIA HOLE FOR ATTACHMENT TO CONCRETE
4X (BASE PLATE) 19 (0.75) DIA HOLE FOR ATTACHMENT

3.5 Dual-Bearing Alternator
TO STEEL (VIEW CUT AWAY FOR CLARITY)
Alignment
29 (1.13) 305 (12)
Generator sets equipped with dual-bearing alternators
require alignment after mounting the generator set skid
159
to a mounting pad. Refer to Service Bulletin SB-566 for
(6.25) details.
57
(2.25)
73
(2.88)
38 181 (7.13)
22 286 (11.25)
(0.88) (1.5)
19 (0.75)
REMOVABLE
Note: Dimensions ADJUSTING BOLT
shown are mm (inches)
156 (6.13)
FREE &
OPERATING
HEIGHT
GM84038-
Figure 3-10 Vibration Isolator GM84038

1 2
Axial
Direction
GM31000
6 5 4
1. Generator set skid rail
2. Generator set neoprene integral vibration isolators
3. Skid rail gussets
4. Support plate, 13 mm (1/2 in.) thick steel, of sufficient length to distribute loads directly to skid rail gussets.
5. Locate accessory spring-type vibration isolators axially aligned with neoprene isolators
6. Concrete mounting pad
Figure 3-11 Accessory Vibration Mount Location

Notes

Section 4 Air and Cooling
4.1 General and fabricate flashing/skirting around the multiple pads

to minimize unwanted discharge air recirculation.
Combustion and heat dissipation require an ample flow
of clean, cool air regardless of whether the generator set Ventilating fans. Some buildings tend to restrict airflow
is air- or liquid-cooled. Approximately 70% of the heat and may cause generator set overheating. Use
value of fuel consumed by an engine is lost through the ventilating fans and/or ductwork to increase airflow in
cooling and exhaust systems. the building if the generator set’s cooling fan does not
provide adequate cooling. See Figure 4-1. Remote
Battery compartment ventilation. To prevent the radiator and city-water cooled models require
accumulation of explosive gases, ventilate ventilating fans. When using ductwork and ventilating
compartments containing batteries. 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 4-2. Follow
4.2 Air-Cooled Engines the fan manufacturer’s recommendations to determine
the size of the inlet and outlet openings.
Refer to the generator set specification sheet for air
requirements. Generally, airflow requirements do not
present a problem since air-cooled models are
designed for outside installation.
When planning outside installation, consider how

buildings and landscaping affect airflow. Also consider
seasonal changes such as snow or foliage
accumulation and potential flooding conditions. Follow
a regular maintenance routine to remove snow and
foliage accumulations.
4.3 Liquid-Cooled Engines

4.3.1 System Features
Generator sets designed for interior installation feature
liquid cooling systems. The three most common liquid TP-5700-4
cooling systems are unit-mounted radiator, remote
radiator, and city-water cooling. Observe the common Figure 4-1 Ventilating Fan
installation considerations outlined below as well as the
installation considerations for your generator set’s
cooling system as detailed in subsequent sections.
4.3.2 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.
Elevated outdoor installations. If the generator set

enclosure is mounted on multiple pads, in cases where a
single pad is not practical such as an uneven building
roof, it may cause discharge air recirculation under the
unit. Enclosures are constructed with the intent of single
TP-5700-4
pad mounting where the unit is sealed to prevent
discharge air recirculation. If multiple pad installation is Figure 4-2 Exhaust Fan-Operated Louvers
unavoidable, use a single pad above the multiple pads
TP-5700 1/13 Section 4 Air and Cooling 29

Thermostatically-controlled louvers. Do not allow Electric louvers are usually connected to the optional
uncontrolled recirculation of air within an enclosure. generator set run relay. Typically, the louvers are
The ventilation system must provide a temperature energized to open when the generator set is operating.
differential sufficient to prevent high engine temperature However, some louvers are energized to close and
shutdown on even the hottest days. when deenergized are spring-actuated to open when
the generator set is operating.
In areas of great temperature variation, install movable
louvers to thermostatically regulate airflow and room Filters. Install a furnace-type or similar filter in the inlet
temperature. See Figure 4-3 and Figure 4-4. Refer to opening if the generator set operates in an atmosphere
4.4.2, Installation Considerations, Louver use for further highly contaminated with impurities such as dust and
information. 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:
D Louvers: Enlarge the opening 50%.
D Window screening: Enlarge the opening 80%.
D Furnace-type filters: Enlarge the opening 120%.
4.3.3 Recommended Coolant

All applications require antifreeze/coolant protection.
Add antifreeze/coolant before starting the generator set
TP-5700-4 or energizing the block heater(s). Most diesel engine
Figure 4-3 Stationary Air Inlet Louvers manufacturers require the use of an inhibitor additive to
the antifreeze/coolant.
Use a proper mixture of glycol (ethylene, propylene, or

extended life organic acid), water, and supplemental
coolant additive (SCA). The antifreeze/coolant and
additive mixture reduces corrosion, sludge formation,
and cavitation erosion and provides boil and freeze
protection.
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.
Refer to the engine manufacturer’s operation manual for

engine antifreeze/coolant specifications, concentration
TP-5700-4 levels, and inhibitor selection recommendations.
Figure 4-4 Moveable Air Inlet Louvers
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.
30 Section 4 Air and Cooling TP-5700 1/13

4.4 Unit-Mounted Radiator Cooling Use ductwork to direct airflow. Direct the radiator air
outside the room or enclosure using sheet metal
The unit-mounted radiator is the most common cooling ductwork with structural supports. Keep ductwork as
system for engine-driven generator sets 20 kW and short, straight, and unobstructed as possible.
larger. Combined static pressure restrictions greater than
0.12 kPa or 13 mm (0.5 in.) water column on the radiator
inlet and outlet openings cause reduced airflow and
4.4.1 System Features contribute to overheating especially in high ambient air
The system’s major components include an engine- temperatures. Use heavy canvas, silicone rubber, or
driven fan and circulating water pump, a radiator, and a similar flexible material for the connection between the
thermostat. The pump circulates water through the radiator duct flange and the ductwork to reduce noise
engine until it reaches operating temperature. Then the and vibration transmission.
engine thermostat opens, allowing water circulation
through the radiator. The thermostat restricts water flow Outlet and inlet location and sizing. Size the outlet
duct area 150% larger than the radiator duct flange
as necessary to prevent overcooling. The fan blows air
area. Size the inlet air opening at least as large but
from the engine side of the radiator across the cooling
surface. preferably 50% larger than the outlet.
If screens, louvers, or filters are used on either the inlet

4.4.2 Installation Considerations or outlet, increase the inlet or outlet size according to the
recommendations given in Section 4.3.2, Installation
Figure 4-5 shows a typical unit-mounted radiator Considerations.
installation. Note the direction of airflow and refer to the
figure as needed during installation. Since the exhaust air of larger units is both high volume
and high velocity, direct the exhaust flow away from
1 areas occupied by people or animals.
Louver use. Design temperature-controlling louvers to

prevent air inlet restrictions and air pressure reductions
2
inside the building. Low building pressure can
3 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 4-6 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
TP-5700-4
outdoor temperature is below 18°C--21°C (65°F--70°F).
6 5 4 Reverse the louver settings when the outdoor
1. Air inlet opening
temperature is above 21°C--24°C (70°F--75°F).
2. Ductwork mounting flange
3. Air outlet duct
4. Support legs 1 2 3 4
5. Flexible section with radiator duct flange
6. Pusher fan
Figure 4-5 Radiator-Cooled Generator Set

Installation
Avoid suction fan use. The alternator airflow should 6

move in the same direction as the engine’s standard TP-5700-4
pusher fan. Using a suction fan to reverse airflow is not 5
recommended because it may interfere with the 1. Exterior 4. Generator set
alternator cooling airflow. This in turn reduces the 2. Interior 5. Dampers
maximum engine power available because higher 3. Air outlet duct 6. Controlled air outlet louvers
temperature combustion air is drawn into the air cleaner.
Figure 4-6 Air Control Louvers

4.5 Remote Radiator Cooling The following subsections provide general design
guidelines for a remote radiator system.
A remote radiator system allows installation of
generator sets in locations where it would otherwise be
difficult to bring the volume of air required to cool a unit-
4.5.1 General
mounted radiator. In these systems, the engine water System limitations. Cooling systems are limited by
pump pushes coolant through a radiator mounted radiator cap ratings. The maximum radiator operating
remotely from the generator set and, typically, in an pressure is 138 kPa (20 psi) and the maximum operating
open area. An electric motor-driven fan mounted on the temperature is 121°C (250°F). Radiators are available
radiator circulates air across the radiator’s cooling fins. for vertical or horizontal discharge. See Figure 4-7 and
Figure 4-8.
In order to assess a remote radiator cooling system, the
cooling system designer needs the following data. From Air requirements. Refer to the generator set
the respective generator set specification sheet, obtain specification sheet for radiator air and engine/alternator
the: air requirements. Cooling air required for generator sets
equipped with a remote radiator is based on a 14°C
D Engine jacket water flow, Lpm (gpm)
(25°F) rise and an ambient temperature of 29°C (85°F).
The amount of air required to ventilate the generator set
D Cooling air required for generator set based on 14°C
(25°F) rise and an ambient temperature of 29°C room or enclosure determines the size of the air inlet and
(85°F), m3/min. (cfm) outlet. Configure the ventilation air inlet and outlet so
that air flows across the generator set.
D Maximum static (vertical) head allowable above
engine, kPa (ft. H2O) Use a ventilating fan, if necessary, to dissipate alternator
and engine heat loss.
From the engine and/or radiator data sheet, obtain the:
Note: All remote radiators are sized for mounting in an
D Maximum water pump inlet restriction kPa (psi) open area with no additional external devices
attached. Attached devices, confined installation,
D Maximum allowable coolant pressure differential louvers, dampers, ductwork, or other inlet or
external to engine kPa (psi) outlet air restriction require resizing the radiator
to compensate for reduced airflow.
2 3 4
5
6
1
8
9
14
13
12 10
11 TT11863
1. Remote vertical radiator 8. Engine outlet

2. Pressure cap 9. Engine water pump
3. Surge tank/expansion tank 10. Suction side
4. Radiator inlet 11. Fill/drain (lowest point of engine
5. Fill line 12. Shutoff valve
6. Vent line 13. Radiator outlet
7. Shutoff Valve 14. Maximum allowable static (vertical) head (varies with engine)
Figure 4-7 Remote Vertical Radiator System

1 2 3 4 5 6 7 8 9
12 TT11864
11 10
1. Radiator inlet 4. Horizontal radiator 7. Fill line 10. Engine inlet

2. Pressure cap 5. Radiator outlet 8. Shutoff valve 11. Fill/drain (lowest point of engine)
3. Surge tank/expansion tank 6. Vent line(s) 9. Engine outlet 12. Shutoff valve
Figure 4-8 Remote Horizontal Radiator System
Static (vertical) head. If the vertical distance from the Note: The water in the hot well tank drains into the
engine water pump to the radiator (known as static radiator when the generator set is not running.
head) is within the engine manufacturer’s
recommendations, and the pressure drop through the Note: Determine the size requirements of the remote
piping and remote radiator does not exceed the engine radiator and hot well tank/heat exchanger for
manufacturer’s limits, use the engine water pump to each application. Do not use a standard remote
circulate water through the remote radiator. The radiator with a hot well tank/heat exchanger.
allowable static head ranges from 5.2 m--15.2 m
(17 ft.--50 ft.) and is listed on the generator set 4.5.2 Vent Lines
specification sheet. Exceeding the allowable static head
causes excessive pressure on engine components Route the vent lines at a continuous upward slope from
resulting in problems such as leaking water pump seals. the engine connection exit to the expansion tank. Port
all vent lines individually into the expansion tank above
Note: Size the pressure relief valve or cap to remain the coolant level.
under the engine pressure limit.
Locate the vent lines in the expansion tank to prevent
Hot well tank/heat exchanger. When the static splash on the coolant level sensor. Thoroughly vent the
(vertical) head exceeds the distance stated in the systems by installing vent lines to all the vent points on
specification sheet, use a hot well tank or heat the engine and the charge air cooler circuits including
exchanger and auxiliary circulating pump as shown in the radiator core. Refer to the installation drawings for
Figure 4-9 or Figure 4-10. Always wire the circulating vent points.
pump in parallel with the remote radiator fan so that both
operate whenever the generator set operates. Size the vent line the same as the connection point on
the engine. The vent lines may be slightly larger;
A partial baffle divides a hot well tank into two or more however, vent lines sized too large will increase fill line
compartments. The engine pump forces heated water flow and possibly reduce head pressure applied to the
into the hot side, and the auxiliary pump then draws the engine water pump inlets.
water off and forces it into the radiator. After circulating
through the radiator, coolant drains back to the cold side
of the well where the engine water pump removes it. A
hot well or heat exchanger also isolates head pressures
from the engine.

1
5 6
7
4
8
3
12
11
10 TT11865
1. Vacuum relief check valve 5. High volume breather 9. Generator set
2. Remote radiator 6. Expansion space 10. Fill/drain (lowest point of engine)
3. Auxiliary water pump 7. Vent line(s) 11. Shutoff valve
4. Baffles 8. Shutoff valve 12. Hot well tank
Figure 4-9 Compound Remote Radiator/Hot Well Tank Cooling System
3 4 5
2
6
10
11 9
12 TT11865
1. Expansion/surge tank 5. Vent line(s) 9. Fill/drain (lowest point of engine)

2. Remote radiator 6. Fill line 10. Shutoff valve
3. Vent line 7. Shutoff valve 11. Heat exchanger
4. Expansion/surge tank 8. Generator set 12. Auxiliary water pump
Figure 4-10 Compound Remote Radiator/Heat Exchanger Cooling System

4.5.3 Fill Lines (Balance or Static) 4.5.5 Installation Considerations
Connect the fill line(s) to the bottom of the expansion When installing the remote radiator:
tank. Make the lines as short as possible, continuously
descending, and connected directly before the engine D Use a remote radiator setup kit to aid installation. See
water pump(s). To provide a positive head pressure to Figure 4-11.
the engine water pump inlet, properly locate the fill line
(or makeup line). See the installation drawings for the fill D Wire the cooling fan motor to the generator set output
line connection points. so that the fan operates whenever the generator set
operates. There is no need for a thermostatic control
Connect the vent and fill lines to the expansion tank at of the fan motor because the engine thermostat
the greatest possible distance from each other to prevents overcooling as it does on generator set-
prevent aeration and preheating of the coolant returning mounted radiator systems. Follow all applicable
down the fill line. national and local codes when wiring the cooling fan.
The minimum fill line sizes cannot be smaller than the D Follow the wiring diagram on the remote radiator’s
connection point on the engine. Do not allow fittings on fan motor. The motor rotation must match the fan
the fill lines to reduce the effective size. If other cooling blade design. The manufacturer supplies most units
system components vent too much coolant to the with counterclockwise fan rotation as viewed from
expansion tank, larger diameter fill lines may be motor side. The fan is a blower type, moving air from
needed. the fan side of the radiator, through the core, and out
the front side.
4.5.4 Location Considerations D Preferably, connect no devices to either side of the

radiator. Resize the radiator if adding louvers or duct
When choosing the radiator’s location:
work to the radiator to compensate for reduced
D For economical installation and operation, locate the
airflow.
radiator as close as practical to the engine and at the D Ensure that the radiator is level and securely bolted to
same elevation to reduce piping, coolant, and wiring
a firm, solid foundation.
costs.
D Brace the radiator as needed, especially in areas with
D Locate the radiator surge tank fill opening and vent
strong winds.
line(s) at the highest point in the cooling system.
D Use isolators to keep area vibration from affecting the
D Position the radiator no closer than one fan diameter
radiator or to keep vibration produced by the radiator
from a wall, another radiator, or any other obstruction from affecting surrounding areas.
that would restrict air movement and future service
access. D Use hose clamps on all nonthreaded connections.
D Locate the radiator to prevent recirculation of the

heated exhaust air back into the intake stream.
D Mount the radiator in an area where prevailing winds

do not hamper free airflow.
D Locate the radiator where it is not subject to deep

snow or ice accumulation, flooding, industrial fallout,
leaf accumulation, heavy dust and chaff, or other
detrimental seasonal or environmental conditions.
D For rooftop installations, do not locate the radiator

near critical sound areas, building ventilation, or hood
exhausts.

3 4
1 2
10
9
5
GJ-273000-B
1. Top mounting bracket 5. Left-hand belt guard 8. Lower radiator hose inlet
2. Upper radiator hose outlet 6. Front belt guard 9. Right-hand belt guard
3. Drain valve 7. Bottom belt guard 10. Top belt guard
4. Belt guard bracket
Figure 4-11 Remote Radiator Setup Kit, Typical
4.5.6 Surge (Expansion) Tank for Use piping of ample size and with as few short sweep
Horizontal Discharge Radiator bends or elbows, tees, and couplings as possible. Use
long sweep elbows or long bends, if bends are required.
A horizontal discharge remote radiator requires the use
of a surge (expansion) tank as shown in Figure 4-8. Installation. Support piping externally, not from the
Locate the tank at the highest point in the cooling radiator or engine.
system. The surge tank provides venting, surge/
expansion protection, and filling/makeup functions. On standard remote radiators, connect radiator bottom
outlets only to the suction side of the pump. Plumb the
D Equip the surge tank with a sight-glass gauge, lines to prevent air from becoming trapped in the lines.
overflow tube, and pressure cap. Route piping in one general direction, either upward or
downward. A combination of both upward and
D Size the surge tank to handle at least 6%--10% of the
downward piping creates air pockets in the piping.
total cooling system volume. Follow the engine Route vent lines to the expansion/surge tank without
manufacturer’s recommendation when available. creating low spots in the lines.
D Connect the main line from the surge tank to the
Flexible connections. Provide flexible connections
highest point of the remote radiator. Most vertical when connecting piping to the radiator assembly. Use
core radiators have the surge tank as part of the hose clamps at all nonthreaded connections.
radiator top tank. The setup illustrated in Figure 4-8
provides for radiator and engine deaeration and a Shutoff valves. Locate shutoff valves between the
positive pressure at the pump suction inlet. engine and cooling system to allow for isolation of both
the radiator and the engine. A shutoff valve eliminates
D Use a strainer to filter dirt, scale, and core sand from
the need to drain the entire cooling system during
the coolant line. service.
Piping. Size water piping between the engine and the
remote radiator large enough to eliminate the need for a
booster pump. If the cooling system requires a booster
pump, contact your distributor/dealer.
4.5.7 Procedure to Fill with Deaeration 4.5.9 Checks after Initial Startup
For radiators designed for full deaeration, fill the radiator If any problems arise during startup, immediately shut
according to the following procedure. down the generator set. See Figure 4-12, Cooling
System Checklist. Even after a successful startup, shut
1. Fill the cooling system from the bottom when down the generator set after 5--10 minutes and recheck
possible. Otherwise, fill the radiator at the filler the belt tension to make sure no hardware has loosened
neck. during operation. Perform another recheck after
8--12 hours of operation.
2. Next, fill the radiator through one of the top tank or
expansion/surge tank inlets located before the final n Operation
hose connection.
Verify the cooling fan’s position in the fan shroud.
3. Continue filling the system to cover the filler neck Check the mounting hardware.
bottom until coolant appears in the sight glass Check the fan motor for free rotation.
located in the radiator top tank.
Check V-belts for alignment and tension.
4. Check and correct any leaks in the system. Fill the system with coolant and check all connections for
tightness and leaks.
4.5.8 Procedure to Fill without Verify that all electrical connections are secure and that the
power source matches the motor nameplate.
Deaeration
Verify that no loose foreign material is in the fan’s air
For radiators designed without deaeration, fill the stream.
radiator according to the following procedure. With the unit running, check for:
fan clearance
1. Initially, fill the radiator through one of the top tank
inlets located before the final hose connection for excessive vibration
faster and more complete fillup. excessive noise
coolant leaks
2. Fill the cooling system from the bottom when
possible. Otherwise, fill the radiator at the filler Figure 4-12 Cooling System Checklist
neck with coolant covering the filler neck bottom
until coolant appears in the sight glass located in
the radiator top tank.
3. Check for and correct any leaks in the system.

4.6 City Water Cooling 4.6.2 Installation Considerations
Vibration isolation requirements. Water inlet and
4.6.1 System Features outlet connections are mounted on the generator set
skid and isolated from engine vibration by flexible
City water-cooling systems use city water and a heat
sections. If the generator set is vibration-mounted to the
exchanger for cooling. They are similar to remote skid and the skid is bolted directly to the mounting base,
radiator systems because they require less cooling air no additional flexible sections are needed between
than unit-mounted radiator systems. Figure 4-13 shows
connection points on the skid and city water lines. If the
some of the elements of a typical installation. generator set skid is mounted to the base with vibration
The heat exchanger limits the adverse effects of city isolators, use flexible sections between the connection
water chemistry to one side of a heat exchanger, which points on the skid and city water lines.
is relatively easy to clean or replace, while engine Shutoff valve location. A solenoid valve mounted at
coolant circulates in a closed system similar to the
the inlet connection point automatically opens when the
radiator system. The heat exchanger allows engine generator set starts, providing the engine cooling
temperature control, permits the use of antifreeze and system with pressurized water from city water mains.
coolant conditioners, and is suited to the use of an
This valve automatically closes when the unit shuts
engine block heater as a starting aid. down. Use an additional customer-supplied valve
ahead of the entire system to manually shut off city water
for generator set service.
1 2
6
5
7
Side View End View 10 8

11 9
HC-273000-E/TP-5700-4
1. Coolant expansion tank 7. City water supply
2. Coolant expansion tank pressure cap 8. Heated city water into floor drain
3. Ventilation fan (for heat rejected from exhaust and engine) 9. Connect heat exchanger outlet to floor drain
4. Connect heat exchanger inlet to city water supply 10. Heat exchanger
5. Flexible section 11. Solenoid valve
6. Manual shutoff valve
Figure 4-13 City-Water Cooling System with Heat Exchanger

4.7 Cooling Tower The engine cooling system circulates coolant through
the heat exchanger outer shell. Raw water circulates
A cooling tower system is a variation of a city water through the heat exchanger tubes absorbing heat from
cooling with heat exchanger system. In warm, dry the engine coolant. The heated raw water flows into a
climates, a cooling tower is a suitable source of pipe at the top of the cooling tower and sprays down into
generator set cooling water. the tower to cool by evaporation. Because some water
is constantly being lost through evaporation, the system
A cooling tower system consists of the engine cooling must provide makeup water.
system plus a raw-water system. The engine cooling
system usually includes the engine water pump, a heat
exchanger, a surge tank, and the engine water jacket.
The raw-water system consists of the cooling tower, a
raw-water pump, and the tube portion of the heat
exchanger. A typical system is shown in Figure 4-14.
4
3
1 2
TP-5700-4
8 7 6 5
1. Engine water pump 3. Cooling tower 5. Cooling tower drain 7. Heat exchanger
2. Surge tank 4. Makeup water connection 6. Heat exchanger drain 8. Auxiliary water pump
Figure 4-14 Cooling Tower System
4.8 Block Heaters The block heater thermostat is set to 43°C (110°F) on all
generator sets models except the 1750/2000REOZMB.
Block heaters are available as installed accessories on The 1750/2000REOZMB models have a thermostat
all generator sets. Generator sets installed in NFPA setting of 50°C (122°F) for optimum operation. This
applications generally require use of a block heater. adjustment is made by removing the thermostat cap.
Equip generator sets with block heaters on all standby
applications where the generator set is subject to Note: Block heater damage. The block heater will fail
temperatures below 0--20°C (32--68°F). See the if the energized heater element is not immersed
respective generator set spec sheet for specific in coolant. Fill the cooling system before turning
temperature recommendations. Connect the block on the block heater. Run the engine until it is
heater to a power source that is energized when the warm and refill the radiator to purge the air from
generator set is not running. the system before energizing the block heater.

Notes

Section 5 Exhaust System
Satisfactory generator set performance requires proper The flexible line limits stress on the engine exhaust
exhaust system installation. Figure 5-1 and Figure 5-2 manifold or turbocharger. Never allow the engine
show typical arrangements of recommended exhaust manifold or turbocharger to support the silencer or
systems. The following sections detail exhaust system exhausting piping.
components.
Note: Do not bend the flexible section or use it to
compensate for misalignment between the
5.1 Flexible Exhaust Line engine exhaust and the exhaust piping.
Install a section of seamless stainless steel flexible When using threaded flexible exhaust connectors,
exhaust line at least 305 mm (12 in.) long within 610 mm place a 152--203 mm (6--8 in.) length of pipe between
(2 ft.) of the engine exhaust outlet. See Figure 5-1 and the flexible exhaust connectors and the exhaust
Figure 5-2. manifold. See Figure 5-1. The pipe reduces the
temperature of the flexible connection, simplifies flexible
1 section removal, and reduces strain on the engine
exhaust manifold.
4 3 2
5.2 Condensation Trap
5 Some silencers are equipped with a drain pipe plug for
6 draining condensation; see Figure 5-3. Otherwise,
install a wye- or tee-type condensation trap with a drain
7 plug or petcock between the engine and the exhaust
silencer as shown in Figure 5-4. The trap prevents
8 TP-5700-5 condensed moisture in the engine exhaust from
draining into the engine after shutdown. Periodically
1. Supports 5. Drain petcock
drain collected moisture from the trap.
2. Pitch line downward 6. Flexible section
3. Silencer 7. Solid section 152--203 mm (6--8 in.)
4. Water trap 8. Manifold
Figure 5-1 Exhaust System, End Inlet Silencer
2 1
1. Pipe Plug TP-5700-5
9 3
Figure 5-3 Silencer Condensation Drain Plug
4
5
6
7
8
TP-5700-5
1. Exhaust wall thimble 6. Outer diameter adapter and clamp 1

2. Silencer 7. Flexible section
3. 45° Y fitting 8. Manifold
4. Water trap 9. 45° elbow
5. Drain petcock
1. Condensation trap TP-5700-5
Figure 5-2 Exhaust System, Side Inlet Silencer

Figure 5-4 Condensation Trap
TP-5700 1/13 Section 5 Exhaust System 41

5.3 Piping
2
1
Note: Select piping with a diameter that is the same size
as, or larger than, the manifold outlet’s inside
6
diameter.
3
D Keep exhaust lines as short and straight as possible.
9
D Use schedule 40 black-iron pipe.
8 4
D Use sweep elbows with a radius of at least three times
the pipe diameter.
7
D Use exhaust piping that conforms to applicable
codes.
6 5
D Support the exhaust piping securely, allowing for
thermal expansion.
D Insulate the exhaust piping with high-temperature 11

10
insulation to reduce the heat rejected by exhaust
piping and consequently the amount of ventilating air
required. 15
In general, exhaust temperatures measured at the 12

engine’s exhaust outlet are less than 538°C (1000°F),
except for infrequent brief periods; therefore, low-heat
appliance standards apply. Each generator set 14 13
specification sheet provides exhaust temperatures.
For units with exhaust temperatures below 538_C TP-5700-5
(1000_F), route the exhaust piping a minimum of

457 mm (18 in.) from combustible material, including
1. Rain cap (or gradual U bend)
building materials and natural surroundings. If exhaust 2. Rain shield
temperatures exceed 538_C (1000_F), the minimum 3. 254 mm (10 in.) minimum
distance is 914 mm (36 in.). 4. 25 mm (1 in.) minimum
5. Exhaust pipe
When planning exhaust silencer and piping placement, 6. Ventilation holes at both ends
7. 254 mm (10 in.) minimum
consider the location of combustible materials. If the 8. 25 mm (1 in.) minimum
proximity of the exhaust system to the combustible 9. Flashing
materials cannot be avoided, follow a regular 10. Inner sleeve
maintenance schedule to ensure that combustible 11. Outer sleeve
12. Thimble outer diameter
materials are kept away from the exhaust pipes after 13. 254 mm (10 in.) minimum outside
installation. Combustible materials include building 14. 254 mm (10 in.) minimum inside
materials as well as natural surroundings. Keep dry field 15. Exhaust pipe diameter
grass, foliage, and combustible landscaping material a
safe distance from the exhaust system. Figure 5-5 Double-Sleeved Thimbles and Rain Cap
Construct the thimble so it extends at least 254 mm

5.4 Double-Sleeved Thimbles (10 in.) both inside and outside the structure’s surface.
Openings at both ends of the thimble allow cooling air to
If the exhaust pipe passes through a wall or roof, use a circulate through the thimble. If screening is used on the
double-sleeved exhaust thimble to prevent the outer end to keep birds and animals from entering the
transmission of exhaust pipe heat to the combustible thimble, use a mesh large enough to allow unrestricted
material. Figure 5-5 shows construction details of a air circulation through the thimble. See Section 5.5 for
typical double-sleeved thimble in which exhaust piping additional exhaust outlet location and protection
passes through a combustible structure. Sheet metal considerations.
shops usually fabricate thimbles using installation
engineer’s specifications and drawings.
42 Section 5 Exhaust System TP-5700 1/13

5.5 Exhaust Outlet Exhaust System Backpressure Calculation
Procedure
Outlet location. Engine performance and efficiency
depend on the location of the exhaust outlet. Direct the Determine the total backpressure by calculating the
exhaust outlet away from the air inlet to prevent exhaust effects of the individual exhaust system components
gases from entering the air inlet and clogging the dry- and adding the results. Make calculations using either
type air filter elements. Hot exhaust drawn through the English or metric units. Exhaust pipe references are
radiator adversely affects engine cooling. Locate the nominal pipe NPT (in.) sizes. The procedure shows an
exhaust outlet to prevent exhaust fumes from entering a example with italic text. Calculations relate to end inlet
building or enclosure. silencers.
Noise reduction. The exhaust outlet configuration Note: When calculating backpressure drop for side inlet
affects the apparent noise level for people or animals in silencers, use the end inlet values shown and add
the vicinity. An upward-directed outlet seems quieter 0.75 kPa (0.25 in. of mercury or 3.4 in. of water) to
than one directed downward or horizontally. backpressure calculations.
Additionally, a 30- to 45-degree angled cut at the end of
1. Select the exhaust silencer type for the
a horizontal exhaust outlet pipe reduces turbulence at
application—hospital, critical, residential, or
the outlet, thereby reducing the noise level.
industrial. See the silencer specification sheet for
Rain cap. To prevent precipitation from entering the definitions for each exhaust silencer type. Confirm
exhaust pipe, install a rain cap on vertical outlets. See silencer type availability for your generator set with
Figure 5-5. In a climate where freezing is common, do your authorized distributor/dealer, as some
not use a rain cap. Instead, extend the exhaust piping at generator sets do not use all four types.
least 610 mm (24 in.) beyond the roof line and create a
Example: Determine the silencer backpressure for
gradual U bend at the end to direct the exhaust outlet
the recommended critical silencer on a 230 kW,
downward. Keep the pipe outlet at least 457 mm (18 in.)
60 Hz diesel generator set.
from the roof to prevent hot exhaust from igniting the roof
material. 2. Refer to the generator set specification sheet for:
Note: Do not use a rain cap in areas subject to freezing a. Engine exhaust flow at rated kW in m3/min.
temperatures. (cfm)
Generator set with enclosure. To avoid exceeding the Example: 57.5 m 3/min. (2030 cfm)
engine manufacturer’s maximum allowable
backpressure specification, enclosure tail pipe b. Maximum allowable backpressure in kPa (in. of
extensions or attachments are not recommended. Hg)
Example: 10.2 kPa (3.0 in. Hg)
5.6 Exhaust System Backpressure 3. Refer to the submittal catalog for:
Exhaust backpressure limits engine power and a. The recommended critical silencer part number
excessive backpressure causes serious engine Example: 343616
damage. Excessive backpressure usually results from
one or more of the following reasons: b. Silencer inlet diameter in mm (in.)
Example: 152 mm (6 in.)
D The exhaust pipe diameter is too small.
D The exhaust pipe is too long. c. Silencer inlet position (end or side)
D The exhaust system has too many sharp bends. Example: end inlet
D The exhaust silencer is too small. d. The flexible exhaust adapter part number
D The exhaust silencer is not the correct design for the Example: 343605
application.
e. Flexible exhaust adapter, flexible section length
Use the following procedure to verify that the installed Example: 857 mm (33.75 in.)
exhaust system does not exceed the engine’s maximum
exhaust backpressure limit as specified in the generator
set specification sheet.

4. Determine the exhaust gas velocity through the Note: When calculating backpressure drop for
silencer as follows: side inlet silencers, use the end inlet values
shown and add 0.75 kPa (0.25 in. of
a. Using the exhaust silencer inlet diameter mercury or 3.4 in. of water) to backpressure
determined in step 3, determine corresponding calculations.
inlet area using Figure 5-6.
Note: Refer to Figure 5-8 to calculate in inches of
Example: 0.0187m 2 (0.201 sq. ft.)
water and feet per minute.
b. Use this data to calculate the exhaust gas
velocity. Divide the engine exhaust flow from 6. Total the number of elbows and flexible sections in
the exhaust system between the engine and the
step 2 in m3/min. (cfm) by the silencer inlet area
m2 (sq. ft.) to get flow velocity in m (ft.) per exhaust system outlet. Compare the radius of the
minute. bend (R) to the pipe diameter where (D) is the
nominal pipe diameter in inches. Determine the
Example: equivalent length in m (ft.) of straight pipe for the
57.5 m 3/min. / 0.0187 m 2 = 3075 m/min. elbows and flexible sections from the following:
(2030 cfm / 0.201 sq. ft. = 10100 ft./min.)
Bend Bend
Nominal Pipe Size, Angle Type Radius Conversion Factor
in. NPT Inlet Area, m2 Inlet Area, ft2 90° Close R=D 32 x D* / 12
1 0.00056 0.0060
90° Medium R = 2D 10 x D* / 12
1 1/4 0.00097 0.0104
90° Sweep R = 4D 8 x D* / 12
1 1/2 0.00131 0.0141
45° Close R=D 15 x D* / 12
2 0.00216 0.0233
2 1/2 0.00308 0.0332 45° Sweep R = 4D 9 x D* / 12
3 0.00477 0.0513 Flex Sections 2 x Length[ / 12

4 0.00821 0.0884 * Use the diameter of the silencer inlet in inches from
step 3 for the initial calculation. If the results from step 9
5 0.0129 0.139
indicate excessive backpressure drop, then recalculate
6 0.0187 0.201 using the larger-diameter pipe size selected.
8 0.0322 0.347 [ Use the flexible exhaust adapter length from step 3 and
10 0.0509 0.548 add any additional flex sections in the exhaust system
expressed in inches.
12 0.0722 0.777
14 0.0872 0.939
Convert the equivalent pipe length calculated in
16 0.1140 1.227
feet to meters using ft. x 0.305 = m, as needed.
18 0.1442 1.553
Examples:
Figure 5-6 Cross Sectional Area for Standard
Silencer Sizes 45_ sweep elbows:
9 x 6.0 in. / 12 = 4.5 equiv. ft. or 1.4 equiv. m
5. Refer to Figure 5-7. Use the exhaust gas velocity
determined in step 4 and find the exhaust gas 90_ close elbows:
velocity value in thousands on the bottom scale. 32 x 6.0 in. / 12 = 16.0 equiv. ft. or 4.9 equiv. m
Move vertically up until this value intersects the
curve of the corresponding silencer type as Flexible sections:
determined in step 1. Move left on the horizontal 2 x 33.75 in. / 12 = 5.6 equiv. ft. or 1.7 equiv. m
axis and determine the backpressure drop value in
kPa (in. of Hg). Equivalent of straight pipe:
4.5 + 16.0 + 5.6 = 26.1 equiv. straight ft.
Example: Exhaust velocity, 3075 m/min. (10100 ft./ 1.4 + 4.9 + 1.7 = 8.0 equiv. straight m
min.) intersects with critical silencer curve B and
the corresponding backpressure value is
approximately 2.8 kPa (0.85 in. of mercury).
Silencer type is end inlet from step 3 information
with no additional backpressure drop value per the
following note.

kPa in. of Hg
A B
6.4 1.9
6.1 1.8
5.8 1.7
C
5.4 1.6
5.1 1.5
4.7 1.4
D
4.4 1.3
4.1 1.2
3.7 1.1
Pressure
3.4 1.0
Drop
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
0 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.)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 (ft./min.)
Exhaust Gas Velocity in Thousands
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 Silencer Backpressure Drop (in. of Hg)

mm of Water in. of Water
A B
660.4 26
609.6 24
558.8 22
508.0 20 C
457.2 18
406.4 16
Pressure D
Drop 355.6 14
304.8 12
254.0 10
203.2 8
152.4 6
101.6 4
50.8 2
0 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.)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (ft./min.)
Exhaust Gas Velocity in Thousands
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 Silencer Backpressure Drop (in. of water)

7. Determine the total length of straight pipe used in 9. Add the backpressure of the piping determined in
the exhaust system. Add this calculation to the step 8 to the backpressure of the silencer
equivalent length for elbows and flexible sections determined in step 5. The total should not exceed
obtained in step 6. the engine manufacturer’s maximum allowable
Example: system backpressure determined in step 2 or on
the generator set’s specification sheet. If the total
Straight pipe = 3.0 m (10 ft.). exceeds the maximum, use a larger pipe size or
Equivalent straight pipe from step 6: 8.0 m (26.1 ft.) silencer or both. Repeat the calculation if new
components are selected to verify that the system
3.0 m + 8.0 m = 11.0 m or backpressure would not exceed the limit using the
10 ft. + 26.1 ft. = 36.1 ft. total larger component(s).
Example:
8. Refer to Figure 5-9 if the pipe size is 102 mm (4 in.)
or less or Figure 5-10 if the pipe size is 127 mm 0.4 kPa (step 8) + 2.8 kPa (step 5) = 3.2 kPa
(5 in.) or larger. Maximum allowable backpressure = 10.2 kPa
3.2<10.2 backpressure drop is acceptable
Place a straight edge across the chart with the
edge in line with the pipe size in inches (D) on the 0.14 in. Hg. (step 8) + 0.85 in. Hg. (step 5) =
right column from step 3 and the engine exhaust 0.99 in. Hg.
flow (Q) from step 2 on the left column. Maximum allowable backpressure = 3.0 in. of Hg.
0.99< 3.0 backpressure drop is acceptable
Read backpressure kPa/m or in. of Hg/ft. (∆P) from
the center column. Calculate the total piping
system backpressure by multiplying the total
equivalent straight pipe in m (ft.) from step 7 by the
kPa/m or in. of Hg/ft. of pipe from this step.
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

Q Engine Exhaust Flow
m3/min. cfm
28.3 1000
25.5 900 D Pipe Diameter
mm inches
22.7 800
25.4 1.0
19.8 700
17.0 600
Δ P Backpressure
14.2 500 kPa per m in. Hg per foot 31.8 1.25
1.033 1.0
0.515 0.5
11.3 400
38.1 1.5
8.5 300
0.104 0.1
7.1 250 44.5 1.75
0.052 0.05
5.7 200 50.8 2.0
0.009 0.01
4.2 150 0.005 0.005
63.5 2.5
0.001 0.001
2.8 100
2.5 90 0.001 0.0005 76.2 3.0
2.3 80
2.0 70
0.000 0.0001 88.9 3.5
1.7 60
0.000 0.00005
1.4 50 101.6 4.0
1.1 40 114.3 4.5

0.000 0.00001
127.0 5.0
(cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)
Figure 5-9 Backpressure using Pipe Size 4 in. (102 mm) or Less

Q Engine Exhaust Flow D Pipe Diameter
m3/min. cfm mm inches
76.2 3
453.1 16000
Δ P Backpressure
339.8 12000 kPa per m in. Hg per foot
1.033 1.0 101.6 4

283.2 10000
0.515 0.5
254.9 9000
226.6 8000
198.2 7000 127.0 5

0.104 0.1
169.9 6000
0.052 0.05
141.6 5000
152.4 6
113.3 4000 0.009 0.01

177.8 7
0.005 0.005
85.0 3000
203.2 8
0.001 0.001
228.6 9
0.001 0.0005
56.6 2000
254.0 10
42.5 1500 0.000 0.0001
0.000 0.00005 304.8 12
330.2 13
28.3 1000
355.6 14
25.5 900 0.000 0.00001
22.7 800
406.4 16
(cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)
Figure 5-10 Backpressure using Pipe Size 5 in. (127 mm) or Larger

Notes

Section 6 Fuel Systems
Comply with applicable state and local codes when 6.1.1 Main Tank
installing any fuel system.
Storage. Because it is less volatile than gas or gasoline,
diesel fuel is safer to store and handle. Regulations for
6.1 Diesel Fuel Systems diesel storage tank placement are less stringent than
the regulations for gas or gasoline storage. In some
The main components of a typical diesel fuel system are locations, large main tanks are permitted inside the
a main fuel storage tank, a day tank, fuel lines, and an building or enclosure.
auxiliary fuel pump. See Figure 6-1.
1 2 3 4
13
12
11
8 7 6 5
TP-5700-6
10
1. Injector return line 8. Fuel supply line from main fuel tank to day tank
2. Day tank vent 9. Overflow line
3. Day tank 10. Foot valve
4. Auxiliary fuel pump 11. Main fuel storage tank
5. Tank drain 12. Fuel tank vent
6. Electric fuel level control switch 13. Tank filling inlet
7. Fuel supply line from day tank to engine connection
Figure 6-1 Diesel Fuel System
TP-5700 1/13 Section 6 Fuel Systems 51

Tank location. Locate fuel storage tanks above ground Provide easy access to fuel filters and sediment drains
or bury them underground in accordance with for regular and frequent service. Clean fuel is especially
applicable codes. Figure 6-2 shows a commonly used important to diesel engines, which have easily clogged
above-ground subbase tank contained in the generator fuel injectors and pumps.
set mounting base.
2 4
1 3
TP-5700-6
1. Generator set skid 3. Subbase fuel tank
2. Side view 4. End view
Figure 6-2 Subbase Fuel Tank
Tank size. Codes requiring standby power often specify Fuel alternatives. Most diesel engines operate
a minimum onsite fuel supply. Such requirements are satisfactorily on No. 2 domestic burner oil available in
included in NFPA 70, National Electrical Code, and most parts of the US. If the site heating system is oil-
NFPA 99, Standard for Health Care Facilities. Diesel fired, consider supplying the engine with fuel from the
fuel deteriorates if stored for more than one year; same tank used for heating oil to reduce costs and to
therefore, size the tank to ensure that regular generator ensure a continually fresh fuel supply for the engine.
set exercising will use the tank’s contents within one This practice necessitates that the fuel oil meets the
year. If there are no applicable code requirements, the engine manufacturer’s minimum requirements for wax
manufacturer recommends a tank sized for eight hours point, pour point, sulfur content, and cetane number as
of operation at rated load. Refer to the generator set these factors influence cold weather starting and
specification sheet for fuel consumption data. generator set power output. When supplying multiple
applications from the same main fuel tank, provide each
Tank venting. Vent the main fuel tanks to allow air and with a separate supply line.
other gases to escape to the atmosphere without
allowing dust, dirt, and moisture to enter the tank.
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.
52 Section 6 Fuel Systems TP-5700 1/13

6.1.2 Day Tanks (100_F) and are subject to damage if operated with fuel
temperatures above 60_C (140_F), a day tank providing
The terms day tank and transfer tank are at least four hours of fuel consumption should be used to
interchangeable. Having a day tank adjacent to the provide enough capacity to cool the fuel returning from
engine allows the engine fuel transfer pump to easily the engine. If smaller day tanks are used, the generator
draw fuel during startup and provides a convenient set manufacturer may recommend installing a fuel
location to connect fuel injector return lines. See cooler or routing engine fuel return lines to the main
Figure 6-3. storage tank. See Figure 6-3.
Connect a float-switch-controlled solenoid antisiphon Optional equipment includes fuel level gauges, manual
valve or a float valve to prevent siphoning fuel from the priming pumps, float switches for pump control, float
main storage tank if the main tank fuel level is above the valves, rupture basins, and low level alarms. Remove
day tank inlet. the plastic shipping plugs and install metallic pipe plugs
in all unused fuel tank ports to provide a liquid-tight seal.
Tank size. Standard tanks are available in sizes from
38--3952 L (10--1044 gal.) with or without integral
electric fuel transfer pumps. Because engines are
subject to fuel temperature deration above 38_C
1 2
12 11 10
9 8
TP-5700-6
1. Return line from fuel pump 7. Fuel shutoff solenoid

2. Return line from fuel injectors/fuel rack 8. Day tank
3. Vent (to outside) 9. Fuel supply line from day tank to engine connection
4. Overhead main tank 10. Filter
5. Maximum 76 m (25 ft.), minimum 25 mm (1 in.) 11. Flexible line
6. Fuel supply line from main fuel tank to day tank 12. Fuel pump
Figure 6-3 Diesel Fuel System with Overhead Main Tank and Day Tank

6.1.3 Fuel Lines 6.1.4 Auxiliary Fuel Pumps
The following items describe fuel line selection and Primary, engine-driven fuel pumps typically develop a
application. Never use the fuel piping or fuel line clamps maximum of 48 kPa (7 psi) pressure and draw fuel to
to ground any electrical equipment. approximately 1.2--1.4 m (4--5 ft.) vertically or 6 m
(20 ft.) horizontally. When the main tank is located a
Line type. Use Schedule 40 black-iron pipe, steel greater distance from the engine or for a more reliable
tubing, or copper tubing for diesel fuel systems. Diesel fuel system, use an auxiliary pump alone or in
fuel reacts adversely with galvanized tanks and piping, connection with a day tank. See Figure 6-3. Limit
producing flaking sediment that quickly clogs filters and auxiliary fuel pump pressure to approximately 35 kPa
causes fuel pump and fuel injector failure. Ensure that (5 psi).
any flexible fuel lines used are approved for diesel fuel.
Use a shutoff solenoid valve wired into the engine run
Line size. Use the smallest diameter fuel line that still circuit or a check valve to help keep the fuel line primed.
delivers enough fuel to the engine with an acceptable Install the check valve on the outlet side of the auxiliary
pressure drop of 6.9 kPa (1.0 psi). Using oversize piping fuel pump to minimize inlet restriction.
increases the chance of air introduction into the fuel
system during engine priming, which increases the Auxiliary fuel pump options. On engines using less
potential for fuel pump damage and hard starting. than 38 L (10 gal.) of fuel per hour (approximately
100 kW or less), connect an engine starting battery-
Flexible connectors. Use flexible connections powered electric fuel transfer pump in series with the
spanning a minimum of 152 mm (6 in.) between the engine-driven transfer pump. Locate the electric pump
stationary piping and the engine fuel inlet connection. nearer to the fuel tank than to the engine. An auxiliary
pump located at the fuel tank approximately doubles the
Return lines. A diesel system delivers more fuel to the horizontal and vertical distance limits of a single engine-
injectors than the engine uses; therefore, a system has driven pump.
one supply line from the fuel tank and at least one return
line from the fuel injectors. Size the fuel return lines no On engines using more than 38 L (10 gal.) of fuel per
smaller than the fuel supply lines. hour or when drawing fuel more than 1.8 m (6 ft.)
vertically or 12 m (40 ft.) horizontally, use an electric
Route the return fuel line to either the day tank or the motor-driven positive displacement pump with a day
main storage tank. Place the return lines as far away tank and float switch. Electrically connect the fuel pump
from the pickup or fuel diptube as possible to prevent air to the transfer switch load side for maximum reliability.
entry and to keep warm fuel from being reintroduced to This type of pump can typically lift fuel 5.5 m (18 ft.) or
the engine. If fuel lines are routed to the day tank, note draw it horizontally up to 61 m (200 ft.).
the day tank size requirements in Section 6.1.2, Day
Tanks. Where vertical runs exceed 5.5 m (18 ft.) or horizontal
runs exceed 61 m (200 ft.), remote-mount the pump
A properly designed fuel return line is unrestricted and adjacent to the fuel storage tank. This type of installation
as short as possible, and it allows gravity return of fuel to allows these pumps to push fuel over 305 m (1000 ft.)
the storage tanks. In installations where gravity return is horizontally or more than 31 m (100 ft.) vertically and
not possible, obtain approval of the design from the deliver adequate fuel for generator sets up to 2000 kW.
generator set supplier based upon the engine’s Always connect a positive-displacement pump directly
specifications before installing a fuel system with static to a day tank and float switch to protect the engine fuel
head pressure on the return lines. Fuel return line system from excessive fuel pressures.
restriction can cause engine hydraulic lock or
uncontrollable overspeed on some systems.

6.2 Gas Fuel Systems, Common For UL compliance, the fuel solenoid valves are needed
per UL 2200, Section 35.3.2.2.1.
Components
The typical gas system uses two gas regulators:
Gas fuel systems operate on either LP (liquefied
petroleum) or natural gas. D Primary gas regulator. Provides initial control of gas
from the fuel supply. The primary gas regulator
Note: Design and install gas fuel systems in
reduces the high pressure from a tank or transmission
accordance with NFPA 54, National Fuel Gas
line to the low pressure required by the secondary gas
Code, and applicable local codes.
regulator(s). Typically, the primary gas regulator is
All gas systems include a carburetor, secondary gas set at the higher pressure value when a range is
regulator, electric gas fuel solenoid shutoff valve, and given. The gas supplier typically provides the primary
flexible fuel connector. gas regulator, as conditions that dictate the type of
gas regulator used vary depending on the method of
supplying fuel. The supplier is also responsible for
6.2.1 Gas Lines providing sufficient gas pressure to operate the
primary gas regulator. Primary gas regulator must be
Never use fuel piping to ground electrical equipment. vented to the outside if installed within any building.
The gas supplier is responsible for installation, repair,
and alteration to gas piping. D Secondary gas regulator. This low-pressure gas
regulator is mounted on the engine and limits the
Line type. Use Schedule 40 black-iron pipe for gas maximum inlet pressure to engine. The engine
piping. Copper tubing may be used if the fuel does not operates satisfactorily at the lower pressure value when
contain hydrogen sulfide or other ingredients that react a range is given, but these lower pressures may result
chemically with copper. in poor response to load changes or a lack of power if
the primary gas regulator is not near the engine.
Line size. Size piping according to the requirements of
the equipment. Refer to the generator set specification Modification for fuel type. Many gas regulators are
sheet or the dimension drawing for detailed information compatible with both natural gas and LP gas. Typically,
on your system. In addition to the actual fuel the user installs the spring and retainer in the gas
consumption, consider the following pressure loss regulator when connecting to natural gas and removes it
factors: from the gas regulator when connecting to LP vapor gas.
D Pipe length Refer to the appropriate generator set’s operation
D Other appliances on the same fuel supply manual and/or the decal attached to the generator set
for information regarding spring/adjustment screw
D Number of fittings
usage for specific models. Some models may require
Flexible connections. Rigid-mount the piping but new diaphragm kits and/or inverting the gas regulator
protect it from vibration. Use flexible connections when changing fuel type.
spanning a minimum of 152 mm (6 in.) between the
stationary piping and the engine fuel inlet connection. Installation position for fuel type. The gas regulator
functions normally pointing downward for both natural
gas and LP gas. If only natural gas fuel is used, the gas
6.2.2 Gas Regulators regulator may be installed pointing upward.
Gas regulators reduce high incoming fuel pressures to Pressure testing. Some gas regulators provide for
lower levels acceptable for engines. Refer to the installation of a pressure gauge to test inlet and outlet
generator set spec sheet for fuel supply pressures. pressures. If no such provision is available, install pipe
Install a solenoid valve upstream from the gas regulator tees in the fuel line to test pressure and use pipe plugs to
and the flexible fuel connector to prevent the plug unused openings.
accumulation of an explosive mixture of gas and air
caused by leaks in the flexible connection or the gas
regulator. The generator set installer normally wires the
engine battery-powered solenoid valve to the engine
starting controls to open the valve when the engine
cranks or runs.

6.3 LP Fuel Systems 6.3.1 LP Gas Vapor-Withdrawal
Systems
Fuel characteristics. LP fuel exists as a vapor and a
liquid in pressurized tanks. Since LP fuel does not A vapor-withdrawal system draws on the fuel vapor that
deteriorate in storage, a large supply of fuel can be kept collects in the space above the liquid fuel. Consider the
onsite indefinitely for operation during emergency following during installation:
conditions. This makes LP gas ideal for applications
with uninterrupted (onsite) fuel supply requirements. D Generally, allow 10%--20% of tank capacity for fuel
expansion from a liquid to a vapor state. The liquid
Fuel mixture. LP gas is propane, butane, or a mixture level in LP gas tanks must never exceed 90% of the
of the two gases. The ratio of butane to propane is tank capacity.
especially important when the fuel flows from a large
outdoor tank. A fuel supplier may fill the tank in the warm D Maintain air temperature surrounding the tank high
summer months with a mixture composed mainly of enough to vaporize the liquid fuel.
butane; however, this mixture may not provide sufficient
vaporized pressure at cold temperatures to start and Applications in colder climates may require an
operate the engine. A local fuel supplier is likely to be independent heat source to increase natural
the best source of information on what size tank is vaporization within the tank. Withdraw liquid fuel and
necessary to provide adequate fuel vapor. vaporize it in an electrically heated, engine water jacket-
heated, or LP gas-heated vaporizer. Figure 6-4 shows
The fuel mixture and vaporization pressure at the the components of the vapor-withdrawal system used in
anticipated temperatures influence the selection of gas a typical stationary application. The LP gas regulator is
regulator equipment. Pure butane gas has little or no typically installed in the inverted position (pointing
vaporization pressure in temperatures below 4°C downward).
(40°F). Even at 21°C (70°F), the pressure is
approximately 124 kPa (18 psi). Some primary gas 1 2 3 4
regulators do not operate at tank pressures below
207 kPa (30 psi) while others operate at incoming
pressures as low as 20.7--34.5 kPa (3--5 psi).
Fuel consumption and tank size. Since LP fuel is

supplied in pressurized tanks in liquid form, it must be
converted to a vapor state before being introduced into Note: Install a gauge to test
the carburetor. The amount of vapor contained in 3.8 L fuel pressure during setup
(1.0 gal.) of liquid (LP) fuel is: and replace with a pipe plug
when setup in complete, if
required. 5
Butane Gas 0.88 m3 (31.26 cu. ft.)
Propane Gas 1.03 m3 (36.39 cu. ft.) 1. Carburetor
2. Secondary gas regulator
See the generator set specification sheets for fuel 3. Solenoid valve (quantity of two in series may be required
consumption at different loads, and contact your fuel for UL applications)
supplier for information regarding tank sizes. 4. Pressure gauge
5. Primary gas regulator (supplied by gas supplier or
installer)
System types. Single-source gas fuel systems include
LP gas vapor-withdrawal and LP gas liquid-withdrawal. Figure 6-4 Typical LP Gas Vapor-Withdrawal
System

6.3.2 LP Gas Liquid-Withdrawal 6.4 Natural Gas Systems
Systems
The utility supplies natural gas in a vapor state. A
LP liquid-withdrawal fuel systems are available for natural gas fuel system consists of the same basic
generator sets but are not recommended for automatic components and operates with the same general
standby service. With liquid-withdrawal systems, liquid sequence as LP gas vapor-withdrawal systems. See
LP at 1034--1379 kPa (150--200 psi) flows to the engine. Figure 6-6 and Figure 6-7. Note that when the heat
A combination of converters (vaporizers) and gas content of the fuel falls below 1000 Btu, as it does with
regulators then reduces the pressure to a usable level. sewage-derived and some other natural gas fuels, the
generator set will not produce its rated power. The
In Figure 6-5, a converter (a combination of a vaporizer natural gas regulator is typically installed in the upright
and primary and secondary gas regulators) changes the position (pointing upward).
liquid to vapor using heat from the engine’s cooling
system. For a period following startup, a liquid-
withdrawal system may be unable to vaporize enough 1 2 3 4 5
fuel for an engine running under load until the engine
reaches operating temperature. The engine needs time
to warm sufficiently to provide adequate heat to vaporize
the fuel.
Note: Install a gauge to test fuel

1 2 3 4 pressure during setup and replace
with a pipe plug when setup is
complete, if required. TP-5700-6
1. Primary gas regulator (supplied by gas

supplier or installer)
2. Pressure gauge
3. Solenoid valve (quantity of two in series may
be required for UL applications)
4. Secondary regulator
5. Carburetor
Figure 6-6 Natural Gas Fuel System with Pressure

Gauge
3 4 5
TP-5700-6
1
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) 2
Figure 6-5 LP Gas Liquid Withdrawal System

050604
Some codes prohibit gas fuel pressurization greater

1. Primary gas regulator (supplied by gas supplier or installer)
than 34.5 kPa (5 psi) inside buildings. This might
2. Manual shutoff valve
preclude the use of a liquid-withdrawal system. To 3. Solenoid valve (quantity of two in series may be required
ensure code compliance, converters are sometimes for UL applications)
located outside the building housing the generator set. 4. Secondary gas regulator
5. Carburetor
However, the great length of pipe between the converter
and the carburetor does not allow sufficient heat buildup
and heat retention to maintain the fuel in its vapor state, Figure 6-7 Natural Gas Fuel System without
which can cause startup problems. Pressure Gauge and with Manual Shutoff
Valve

6.5 Combination Systems The natural gas and LP gas, vapor withdrawal system
contains a separate secondary gas regulator and
Combination fuel source systems include: solenoid valve for each fuel. The LP gas regulator
typically mounts in the inverted position. A pressure
D Natural gas and LP gas
switch on the primary fuel source closes when fuel
pressure drops, which energizes a relay that closes the
6.5.1 Combination Natural Gas and LP primary fuel solenoid and opens the secondary or
Gas emergency fuel solenoid. A separate LP gas load
adjustment valve ensures the right fuel-to-air mixture in
Some applications use natural gas as the main fuel and the carburetor.
LP gas as the emergency fuel when natural gas is not
available. The load adjustment valve is located inline between the
secondary gas regulator and the carburetor. See
The natural gas and LP gas, liquid withdrawal system Figure 6-9.
uses a converter (vaporizer) to change the LP liquid to
gas vapor. A pressure switch on the primary fuel source
closes when fuel pressure drops, which energizes a 1 2 3 4 5
relay that closes the primary fuel solenoid and opens the
secondary or emergency fuel solenoid.
A separate LP gas load adjustment valve ensures the

right fuel-to-air mixture in the carburetor. The load
adjustment valve is located inline between the converter 6
(vaporizer) and the carburetor. See Figure 6-8.
4
1 2 3
TP-5700-6
8
1. Carburetor 7
5 2. Load adjustment valve
9 10 3. Secondary LP gas regulator
6 4. Solenoid valve (quantity of two in series may be
4 required for UL applications)
5. LP gas supply
6. Natural gas supply
7. Low pressure switch
8. Secondary natural gas regulator
Note: Install a gauge to test fuel Figure 6-9 Natural Gas and LP Gas System, Vapor
pressure during setup and replace
with a pipe plug when setup is Withdrawal
complete, if required.
TP-5700-6
8 7
1. Carburetor
2. Load adjustment valve
3. Converter (vaporizer)
4. Solenoid valve (quantity of two in series may be required for
UL applications)
5. LP gas filter (supplied by gas supplier or installer)
6. LP gas supply
7. Natural gas supply
8. Primary gas regulator (supplied by gas supplier or installer)
9. Secondary natural gas regulator
10. Pressure gauge
Figure 6-8 Natural Gas and LP Gas System, Liquid

Withdrawal

6.6 Pipe Size Requirements for 0.60 specific gravity and with a normal amount of
restriction from fittings. To calculate the correct pipe size
Gas Fuel Systems for a specific installation, refer to the chart and follow the
The type of fuel, the distance it must travel from gas procedure outlined below.
meter/tank to fuel shutoff solenoid, and the amount
consumed by the engine must be considered when Fuel Specific Gravity Correction Factor
determining fuel line pipe size. Sewage Gas 0.55 1.040
Natural Gas 0.65 0.962
To find the correction necessary for the different specific
Air 1.00 0.775
gravity of the particular fuel used, refer to Figure 6-10.
Propane (LP) 1.50 0.633
Figure 6-11 is based on gas pressures of 3.4 kPa Butane 2.10 0.535
(0.5 psi, 13.8 in. water column) or less and a pressure
drop of 0.12 kPa (0.018 psi, 0.5 in. water column) with a Figure 6-10 Fuel Correction Factors
Nominal Length of Pipe, m (ft.)

Iron Pipe Internal IPS 3.0 (10) 6.1 (20) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70)
Size Diameter,
(IPS), In. mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
1/4 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)
1 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)
2 52.50 (2.067) 111.9 (3950) 77.9 (2750) 62.3 (2200) 53.8 (1900) 47.6 (1680) 43.0 (1520) 39.6 (1400)
2 1/2 62.71 (2.469) 178.4 (6300) 123.2 (4350) 99.7 (3520) 85.0 (3000) 75.0 (2650) 68.0 (2400) 63.7 (2250)
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)
4 102.26 (4.026) 651.2 (23000) 447.4 (15800) 362.5 (12800) 308.7 (10900) 274.7 (9700) 249.1 (8800) 229.4 (8100)
Nominal Length of Pipe, m (ft.)

Iron Pipe Internal IPS 24.4 (80) 27.4 (90) 30.5 (100) 38.1 (125) 45.7 (150) 53.3 (175) 61.0 (200)
Size Diameter,
(IPS), In. mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
1/4 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)
1 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)
2 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)
3 77.93 (3.068) 104.8 (3700) 97.7 (3450) 92.0 (3250) 83.5 (2950) 75.0 (2650) 69.4 (2450) 64.6 (2280)
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 necessary—use this table without a correction factor.
Figure 6-11 Maximum Flow Capacity of Pipe in Cubic Meters (Cubic Feet) of Gas per Hour

1. Refer to the fuel consumption on the generator set 5. Find the value closest to pipe length in the
specification sheet. Note type of fuel used, Length of Pipe column in Figure 6-11.
generator set application rating, and the m3/hr. Example:
(ft3/hr.) consumption at 100% load.
38.1 m (125 ft.).
Example:
Example:
80 kW, propane gas, 60 Hz standby rating = At 28.9 m 3/hr. (1020 ft 3/hr.) the pipe size = 2 in. IPS.
12.0 m 3/hr. (425 ft 3/hr.).
6. Move vertically down the table in Figure 6-11
2. Refer to the Fuel Correction Factors in Figure 6-10.
from the determined value in Length of Pipe
Locate the correction factor for specific gravity of column.
the selected fuel.
Example:
When the fuel has a specific gravity of 0.7 or less no 38.1 m (125 ft.)
correction factor is necessary—use Figure 6-11
without a correction factor. Stop at the value that is equal to or greater than
corrected consumption value from step 3.
Example:
propane gas specific gravity = 1.50 Example:
fuel correction factor = 0.633. 28.9m 3/hr. (1020 ft. 3/hr.).
3. Divide the consumption value from step 1 by the 7. Move to the left column from the value in step 6
correction factor from step 2. to determine the correct pipe size.
Example:
12.0 m 3/hr. (425 ft 3/hr.) divided by 0.633 =
19.0 m 3/hr. (671 ft 3/hr.).
4. Determine the length of pipe between the gas

meter/tank and the fuel shutoff solenoid at the
generator set.
Example:
34.7 m (114 ft.).

Section 7 Electrical System
Before installing the generator set, provide for electrical

WARNING
connections through conduit to the transfer switch and
other accessories for the generator set. 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. Hazardous voltage. Moving parts.
AC circuit protection. All AC circuits must include Operate the generator set only when
circuit breaker or fuse protection. Select a circuit all guards and electrical enclosures
breaker for up to 125% of the rated generator set output are in place.
current. The circuit breaker must open all ungrounded
conductors. The circuit breaker or fuse must be Short circuits. Hazardous voltage/current can cause
mounted within 7.6 m (25 ft.) of the alternator output severe injury or death. Short circuits can cause bodily injury
terminals. 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.
WARNING
7.1 Generator Set Voltage

Reconnection
To change the voltage of 10- or 12-lead generator sets,
Accidental starting.
use the procedure shown in the operation manual
containing the respective controller setup. Adjust the
Disconnect the battery cables before governor and voltage regulator for frequency changes.
working on the generator set. Consult the generator set service manual for frequency
Remove the negative (--) lead first adjustment information.
when disconnecting the battery.
Reconnect the negative (--) lead last Voltage reconnection. Affix a notice to the generator set
when reconnecting the battery. after reconnecting the set to a voltage different from the
voltage on the nameplate. Order voltage reconnection
Disabling the generator set. Accidental starting can decal 246242 from an authorized service distributor/
cause severe injury or death. Before working on the dealer.
generator set or equipment connected to the set, disable the
generator set as follows: (1) Turn the generator set master Equipment damage. Verify that the voltage ratings of
switch and switchgear engine control switch to the OFF the transfer switch, line circuit breakers, and other
position. (2) Disconnect the power to the battery charger. accessories match the selected line voltage.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the Reconnect the generator set stator leads to change the
battery. Follow these precautions to prevent the starting of the output phase or voltage. Reference the voltage
generator set by an automatic transfer switch or a remote reconnection drawings in the Appendix.
start/stop switch.
Disabling the generator set. Accidental starting can Follow the safety precautions at the front of this manual
cause severe injury or death. Before working on the and in the text and observe National Electrical Code
generator set or connected equipment, disable the generator (NEC) guidelines.
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 1/13 Section 7 Electrical System 61

7.2 Electrical Connections For customer-supplied wiring, select the wire
temperature rating in Figure 7-1 based upon the
Several electrical connections must be made between following criteria:
the generator set and other components of the system
for proper operation. Because of the large number of D Select row 1, 2, 3, or 4 if the circuit rating is
accessories and possible combinations, this manual 110 amperes or less or requires #1 AWG (42.4 mm2)
does not address specific applications. Refer to the or smaller conductors.
submittal catalog accessory drawings and wiring
diagrams for connection and location. Most field- D Select row 3 or 4 if the circuit rating is greater than
installed accessory kits include installation instructions. 110 amperes or requires #1 AWG (42.4 mm2) or
larger conductors.
Comply with applicable national and local codes when

installing a wiring system.
Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only
1 60_C (140_F) Use No. * AWG, 60_C wire or Use 60_C wire, either No. * AWG Cu, or No. * Use 60_C wire, No. * AWG or
or use No. * AWG, 75_C wire AWG Al or use 75_C wire, either No. * AWG use 75_C wire, No. * AWG
75_C (167_F) Cu or No. * AWG Al
2 60_C (140_F) Use No. * AWG, 60_C wire Use 60_C wire, either No. * AWG Cu or No. * Use 60_C wire, No. * AWG
AWG Al
3 75_C (167_F) Use No. *[ AWG, 75_C wire Use 75_C wire, either No. *[ AWG Cu or No. Use 75_C wire, No.*[ AWG
*[ AWG Al
4 90_C (194_F) Use No. *[ AWG, 90_C wire 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 7-1 Terminal Markings for Various Temperature Ratings and Conductors
7.3 Load Lead Connections

1
Feed load leads to the generator junction box from one
of several different areas. Generator sets rated 300 kW
and below commonly use the bottom entry where
conduit is stubbed up into the junction box from the
concrete slab. Other methods include flexible conduit
roughed into the sides or top of the junction box. When
using flexible conduit, do not block the front or rear of the
2
controller. See Figure 7-2. TP-5700-7
Use a minimum of 13 mm (0.5 in.) spacing between the 1. Conduit from ceiling
conduit bushing and any uninsulated live parts in the 2. Conduit stubbed up from below
junction box. All conduit openings in the junction box
must be made such that no metal particles including drill Figure 7-2 Typical Load Lead Connection
chips contaminate the components in the junction box.
The four bus bars contained in the optional bus bar kits
Generator sets larger than 300 kW have the junction box simplify the connection process by offering a neutral bus
mounted on the rear of the generator set. Larger sets bar in addition to the three load bars. Optional bus lugs
may have oversized junction boxes supplied as an offer an array of terminal and wire connections.
option or to accommodate bus bar connections. Refer
to the generator set dimension drawing and/or the
electrical contractor prints for detailed information
including stub-up area recommendations.
62 Section 7 Electrical System TP-5700 1/13

7.4 Grounding and Grounded Generator sets are typically shipped from the factory
with the neutral attached to the alternator in the junction
Conductor (Neutral) box for safety reasons per NFPA 70. At installation, the
Connections neutral can remain grounded at the alternator or be lifted
from the grounding stud and isolated if the installation
Connect the electrical system grounding conductor to requires an ungrounded neutral connection at the
the equipment grounding connector on the alternator. generator set. The generator set will operate properly in
See Figure 7-3. Depending upon code requirements, either configuration.
the grounded conductor (neutral) connection is typically
grounded. Various regulations and site configurations including the
National Electrical Coder (NEC), local codes, and the
type of transfer switch used in the application determine
the grounding of the neutral at the generator set.
Min. Size of Recommended

Allowable Equipment Copper Compression Lug,
Ampacity, Grounding Conductor, ILISCO Part No. or
Amps AWG or kcmil Equivalent (UL Listed)
20 12 SLUH-90
EQUIPMENT
GROUND 60 10 SLUH-90
90 8 SLUH-90/125
100 8 SLUH-90/125
150 6 SLUH-90/125/225
200 6 SLUH-90/125/225
VIEWED FROM 300 4 SLUH-90/125/225
ENGINE END TP-5700-7
400 3 SLUH-90/125/225
Figure 7-3 Generator Set Equipment Grounding 500 1 SLUH-125/225
Connection 600 1 SLUH-125/225
800 1/0 SLUH-225/300/400
Ungrounded neutral connections use an insulated 1000 2/0 SLUH-225/300/400
standoff (not supplied) to isolate the neutral connection 1200 3/0 SLUH-225/300/400
from the grounding connection. For grounding lug 1600 4/0 SLUH-225/300/400/650
selection, see Figure 7-4. 2000 250 SLUH-225/300/400/650
2500 350 SLUH-300/400/650
3000 400 SLUH-400/650
simplify the connection process by offering a neutral bus
4000 500 SLUH-400/650
bar in addition to the three load bars. Optional bus lugs
offer an array of terminal and wire connections. 5000 700 SLUH-650
6000 800 SLUH-650
Figure 7-4 Grounding Lug Selection
The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.

7.5 Terminal Connector Torque Socket Size Across Flats, Tightening Torque,
mm (in.) Nm (in. lb.)
Use torque values shown in Figure 7-5 or Figure 7-6 for
3.2 (1/8) 5.1 (45)
terminal connectors. Refer to UL 486A--486B and
UL 486E for information on terminal connectors for 4.0 (5/32) 11.4 (100)
aluminum and/or copper conductors. See Section 7.2, 4.8 (3/16) 13.8 (120)
Electrical Connections, for information on temperature 5.6 (7/32) 17.0 (150)
rating of the customer-supplied wire. Comply with 6.4 (1/4) 22.6 (200)
applicable national and local codes when installing a 7.9 (5/16) 31.1 (275)
wiring system.
9.5 (3/8) 42.4 (375)
If a connector has a clamp screw such as a slotted, 12.7 (1/2) 56.5 (500)
hexagonal head screw with more than one means of 14.3 (9/16) 67.8 (600)
tightening, test the connector using both applicable Note: For values of slot width or length not corresponding to
torque values provided in Figure 7-6. 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.
Figure 7-5 Tightening Torque for Pressure Wire

Connectors with Internal-Drive
Socket-Head Screws
Tightening Torque, Nm (in. lb.)

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 >1.2 mm (0.047 in.) Split-Bolt Other
AWG, kcmil (mm2) Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections
18--10 (0.82--5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75)
8 (8.4) 2.8 (25) 4.5 (40) 9.0 (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.
Figure 7-6 Tightening Torque for Screw-Type Pressure Wire Connectors

7.6 Batteries Note: Some units are equipped with an insulating and
reflective heat shield sleeve on the battery cables
Battery location. When determining the battery and other wires that are fastened to the starter
placement, ensure that the location: solenoid. This sleeve is a conductive material
and must be secured approximately 25 mm
D Is clean, dry, and not exposed to extreme (1 in.) away from the exposed cable terminal.
temperatures
D Provides easy access to battery caps for checking the 7.7 Battery Chargers
electrolyte level (when using maintenance type
batteries) Engine-driven, battery-charging alternators charge the
batteries whenever the generator set operates.
D Is close to the generator set to keep cables short, Engine-driven systems are normally capable of charge
ensuring maximum output rates of 30 amps or more and can quickly restore the
charge used in a normal cranking cycle.
Refer to the submittal drawings for the generator set
when choosing a battery rack. Figure 7-7 shows a When the engine is not operating, a very low charge rate
typical battery system. from an AC-powered battery charger is usually sufficient
to maintain a full charge on the batteries. Some small
industrial generator sets have no battery-charging
1 alternators and, therefore, require a separate AC-
powered battery charger.
2 Select an automatic or manual battery charger with a
high charge rate of 2 amps and a trickle charge rate up
to 300 milliamps. The low maximum charge rate makes
the charger ill-suited to restore fully discharged batteries.
3 For full recovery capability independent of the engine-
1. Battery cables 4 TP-5700-7
driven charging system, use an automatic float battery
2. Battery secured in mounting rack charger with a high charge rate of at least 10 amps.
3. End view
4. Generator set skid Use separate, self-contained battery chargers or units
built into the automatic transfer switch. Run leads from a
Figure 7-7 Typical Battery System, Side View
transfer switch-mounted battery charger in conduit
Battery type. Starting batteries are usually the lead- separate from the conduit that holds the generator load
acid type and are sized according to the engine cables or remote engine-start circuits.
manufacturer’s recommendation for a particular
Note: Digital controllers with microprocessor circuitry
ambient temperature and required cranking time.
and vacuum fluorescent displays typically draw
NFPA 110 recommends cranking periods, including a
more than 300 milliamps, making trickle charge
single 45-second cycle for generator sets below 15 kW
battery chargers inappropriate for systems with
and three 15-second crank cycles separated by 15-
these controllers. Select only automatic float/
second rests for larger models. Refer to the respective
equalize battery chargers with a 3 amp or greater
generator set specification sheet for the required battery
rating for units with digital controllers.
cold-cranking ampere (CCA) rating.
Battery failure is the most common reason for
Nickel-cadmium batteries are sometimes used for
emergency generator set start failure. Two common
standby generator sets because of their long life
battery failure causes are a manual charge rate set too
(20 years). However, initial high cost, larger space
low to maintain the battery and a manual charge rate set
requirements, and special charging requirements can
too high, resulting in loss of battery electrolyte. To avoid
offset this benefit. Therefore, conventional lead-acid
battery failure, use an automatic float charger, which
batteries have proven satisfactory for the majority of
varies the charge rate in response to battery condition.
generator set applications.
For large engines with two starters, use either one bank
Battery cables. A UL 2200 listed generator set requires
of batteries and chargers for both starters or use
battery cables with positive (+) lead boots.
separate battery systems. The latter system is
Factory-supplied and optional battery cables include
preferable because it reduces the chance of a single
positive (+) lead boots. When battery cables are not
component failure rendering the entire system
factory-supplied, source battery cables with positive (+)
inoperative.
lead boots for UL 2200 compliance.

7.8 Optional Accessories Use 18--20 gauge wire for signal wires up to 305 m
(1000 ft.).
The generator set manufacturer offers optional
accessories that require connection to other Length, m (ft.) Wire Gauge
components in the system. These accessories enable 30.5 (100) 18--20
the generator set to meet standards for local and 152.4 (500) 14
national codes, make operation and service more 304.8 (1000) 10
convenient, or satisfy specific customer installation
requirements. Figure 7-10 Wire Length and Size, Lead N and 42B
Accessories vary with each generator set model and Match the wire terminals to the terminal strip conductor
controller. Accessories are available factory-installed screw size. Use a maximum of two wire terminals per
and/or shipped loose. See Figure 7-8 for a list of terminal strip screw unless otherwise noted on the
available kits. Some accessories are available only with respective accessory drawing or installation instruction.
the microprocessor and digital controllers. Obtain the
most current list of accessories from the respective Accessory connections. Do not direct-connect
generator set specification sheet or by contacting your accessories to the controller terminal strip. Connect
local authorized service distributor/ dealer. accessories to either a single-relay dry contact kit or
ten-relay dry contact kit. Connect the dry contact kit(s)
Kit Description to the controller (customer) connection kit. Connect all
Bus Bar Kits/Bus Lugs accessories except the emergency stop kit to the
Gas Fuel Valve connection kit terminal strip(s).
Line Circuit Breaker
Run Relay
Terminal strips and available connections vary by
controller. Refer to the respective controller operation
Wireless Monitor
manual and the accessory wiring diagrams in the wiring
Figure 7-8 Optional Accessories diagram manual for connection of kits. Field-installed
accessories include installation instructions and/or
Additional accessories and connections are shown in wiring diagrams.
the following sections based on controller specific
information. See Figure 7-9.
7.8.1 Bus Bar Kits/Bus Lugs
Controller Section
Decision-Maker 3+ 8
simplify the connection process by offering a neutral bus
Decision-Maker 550 9
bar in addition to the three load bars. Optional bus lugs
offer an array of terminal and wire connections. See
Figure 7-11.
Figure 7-9 Controller Accessories
Accessory kits generally include installation

L1
instructions. See the wiring diagrams manual for
electrical connections not shown in this section. See L2
the installation instructions and drawings supplied with L3
the kit for information on the kit mounting location.
L0
The instructions provided with the accessory kit
supersede these instructions, if different. In general,
run AC and DC wiring in separate conduit. Use
shielded cable for all analog inputs. Observe all
applicable national and local electrical codes during
accessory installation.
Accessory wiring. To determine the appropriate size TP-5700-7

for the customer-supplied wiring of the engine battery-
powered accessories, use the guidelines in Figure 7-10. Figure 7-11 Bus Bar Kits/Bus Lugs

7.8.2 Gas Fuel Valve Kit
This section provides the wiring information for an
additional gas fuel valve kit required for UL Approval.
See Figure 7-12. Refer to the respective generator set
wiring diagrams for additional information and for LP
liquid applications.
TP-5352-1
Figure 7-13 Line Circuit Breaker
7.8.4 Run Relay Kit

The run relay kit energizes only during generator set
GM72401D-D operation. The three sets of contacts typically control air
intake and/or radiator louvers. However, alarms and
Figure 7-12 Gas Fuel Valve Kit Connections other signaling devices can also connect to the contacts.
See Figure 7-14.
7.8.3 Line Circuit Breaker
The line circuit breaker interrupts generator output if an
overload or short circuit occurs. Use the line circuit
breaker to manually disconnect the generator set from
the load during generator set service. See Figure 7-13.
The circuit breaker must open all ungrounded

connectors. Refer to Service Bulletin 611 for circuit
breaker instantaneous overcurrent trip adjustment
information.
273705
Figure 7-14 Run Relay Kit

7.8.5 Wireless Monitor and able to generate messages. If a device fails to
report a nightly heartbeat for more than a day, the
The wireless monitor system has two components: a system sends a Unit Failed to Report Heartbeat alarm
wireless monitor unit and a website. The monitor unit message to the website.
transmits messages in response to signals received
from the equipment controller and notifies designated Generator set run times and the number of cycles are
recipients of selected operating conditions. The website reported. Models GM23409-KP1 and -KP3 accumulate
monitors these messages. run times over a 24-hour period and report the run times
with the heartbeat message. Model GM23409-KP2 (for
There are three monitor models: GM23409-KP1 for use the 550 controller only) reports the total accumulated
with hardwire inputs; GM23409-KP2 for use with a 550 run time and the total number of starts. Run times for
controller using Modbusr communication; and model GM23409-KP2 are also totaled using the Control
GM23409-KP3 for use with a 550 controller using Panel function and can be updated upon request.
hardwire inputs that require a customer interface board.
Upon power loss, a rechargeable battery powers the
Note: The 550 controller supports only one connection wireless monitor. The monitor continues to transmit
for Modbusr communication. If the controller’s messages for 15 minutes, then transmits a loss of power
RS-485 connection is already used for Modbusr signal and enters the sleep mode. The sleep mode can
communication with other equipment, use last up to 18 hours, until the battery completely
wireless monitor model GM23409-KP1 or -KP3 discharges or power is restored. The wireless monitor
with hardwire inputs through a customer continues to send scheduled heartbeat messages
connection board for monitoring. during the sleep mode until the battery discharges
completely.
Typical messages might include:
D Overcrank
D Low oil pressure 86
[3.4]
D Overspeed
D Common fault
At the website, the user configures which individuals will

receive messages regarding selected operating 275
[10.8]
conditions and the message delivery method. Delivery 244
[9.6]
methods include pagers (alphanumeric, numeric), fax,
XML, e-mail, PCS, or telephone (voice delivery). Each
message sent will contain the condition that generated
the transmission and also the make, model, and location
of the equipment. Up to 40 messages each day can be 181
[7.1]
delivered. Single or multiple messages can be sent to 211
95
[3.75]
[8.3]
selected recipients via multiple delivery methods. More
than one delivery method can be used for each
Dimensions are mm [in.]. All
recipient. dimensions are approximate.
The wireless monitor is powered by the equipment

51 51
power source or by the generator set and constantly [2] [2]
27
[1.06]
C
monitors the inputs. When an input is triggered, the L
G6-53
wireless monitor sends the condition over the North
American AMPS (advanced mobile phone system). An Figure 7-15 Wireless Monitor
operations center server receives the transmission and
forwards the message to the selected recipients
according to the configured delivery method.
7.9 Wiring Connections
Although equipment and connections vary, Figure 7-16
Every 24 hours, the wireless monitor also sends shows examples of the options and wire connections
information about itself and the system it is monitoring. necessary to make an industrial system operational.
This heartbeat transmission tells the Kohler center that Always refer to the wiring diagram for details of wire size,
the wireless monitor is properly functioning, powered, location, and number.
Modbusr is a registered trademark of Schneider Electric

NEGATIVE CONNECTION
Based on ADV-5795-S-E
Figure 7-16 Generator Set Connections, Typical

Notes

Section 8 Decision-Makerr 550 Controller Accessories
8.1 Accessories and Connections Kit Description

Audiovisual Alarm
Several accessories help finalize installation, add Common Failure Relay (Terminal 32A)
convenience to operation and service, and establish
Controller (Customer) Connection
state and local code compliance.
Float/Equalize Battery Charger (with alarms)
Accessories vary with each generator set model and Ground Fault Annunciation
controller. Select factory-installed and/or shipped- Idle (Speed) Mode Feature
loose accessories. See Figure 8-1 for a list of available Low Fuel (Level) Switch
kits. Obtain the most current accessory information Low Fuel (Pressure) Switch
from your local authorized service distributor/dealer. Prime Power Switch
Remote Emergency Stop
This section illustrates several accessories available at Remote Reset Feature
print time of this publication. Accessory kits generally
Remote Serial Annunciator
include installation instructions. See wiring diagrams
Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring
manual for electrical connections not shown in this
section. See the installation instructions and drawings Single-Relay Dry Contact
supplied with kit for information on kit mounting location. Ten-Relay Dry Contact
Twenty-Relay Dry Contact
Figure 8-1 Optional Accessories
supersede these instructions where there are
differences. In general, run AC and DC wiring in
Front View Side View
separate conduit. Use shielded cable for all analog
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
8.1.1 Audiovisual Alarm Kit

An audiovisual alarm warns the operator at a remote
location of fault shutdowns and prealarm conditions.
Audiovisual alarms include an alarm horn, an alarm
silence switch, and common fault lamp. See Figure 8-2 A-292887
and Figure 8-3. See Section 8.2, Accessory
Connections, for terminal identification. Figure 8-2 Audiovisual Alarm
Note: Use the audiovisual alarm with a dry contact kit.
CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX
GM13984-
Figure 8-3 Audiovisual Alarm Connections
TP-5700 1/13 Section 8 Decision-Makerr 550 Controller Accessories 71

8.1.2 Common Failure Relay Kit 8.1.4 Float/Equalize Battery Charger Kit
with Alarm Option
The common failure relay kit provides one set of
contacts to trigger user-provided warning devices if a The float/equalize battery charger with alarm option
fault occurs. The common failure relay faults are provides battery charging to the engine starting
user-defined. See the respective operation manual for battery(ies) and connects to the controller for fault
status and faults available for this function. detection. Battery chargers for 12- or 24-volt models are
available as a generator set accessory. See Figure 8-7.
Connect up to three common failure relay kits to the See Section 8.2, Accessory Connections, for terminal
controller output. See Figure 8-4 and Figure 8-5. See identification.
Section 8.2, Accessory Connections, for terminal
identification.
8.1.3 Controller (Customer) Connection

Kit
The controller connection kit allows easy connection of
controller accessories without accessing the controller
terminal strip. The supplied wiring harness connects
controller connector P23 and terminal strips TB1-3 and
TB1-4 to the controller connection kit connector P25 and
terminal strips TB6, TB7, TB8, and TB9. Connect all
accessories (except the emergency stop kit) to the
controller connection kit terminal strips. See Figure 8-6.
See Section 8.2, Accessory Connections, for terminal
identification. C-294301
Figure 8-4 Common Failure Relay Kit
GM13984-
Figure 8-5 Common Failure Relay Kit Connections
72 Section 8 Decision-Makerr 550 Controller Accessories TP-5700 1/13

GM16088A-A
Figure 8-6 Controller (Customer) Connection Kit
CHARGER MALFUNCTION
LV HV CM BATTERY CHARGER
ALARM TERMINAL STRIP
GM16088A-A
Figure 8-7 Float/Equalize Battery Charger Connections

8.1.5 Ground Fault Annunciation Ground Fault Controller Setup Procedure
A relay contact for customer connection indicates a 1. Reconnect battery, if not already done.
ground fault condition and is part of a ground fault alarm.
See Figure 8-8 for electrical connections and the 2. Place the controller master switch to the AUTO
following procedure for controller setup. Use the position.
instructions with the kit when provided to install and
3. Press the Alarm Off key to silence the alarm horn, if
setup this accessory.
necessary.
POWER SUPPLY GENERATOR
DC 12 -- TB3-9 N
4. If the programming mode LED is not flashing, go to
or 24 V + TB3-4 See assembly
drawing and the step 5. If the programming mode LED is
pick list for
neutral to
ground cable.
flashing, go to step 6.
GFA 300
5. Set Programming Mode to Local.
Generator
system
a. Press keys .
ground
connect to
ground bus.
b. Press key until Programming Mode--

TB4-6 (DCH6) Local is displayed.
TB4-27 (GND)
GFI WIRED TO DEC550 GM53026-

c. Press the YES key .
Figure 8-8 Ground Fault Connections
d. When the Enter Code displays, press the
factory default or the user password

WARNING
keys and . The programming mode LED
should be flashing.
6. Set digital input #6 to ground fault.

a. Press . Menu 9 Input Setup
Disconnect the battery cables before should be displayed.
working on the generator set.
Remove the negative (--) lead first
b. Press until Digital Input 06 Warning is
Reconnect the negative (--) lead last
when reconnecting the battery.
displayed.
Disabling the generator set. Accidental starting can c. Press once to select this input.
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
OFF position. (2) Disconnect the power to the battery d. Press until Ground Fault is displayed.
the battery. Follow these precautions to prevent starting of the e. Press to define Digital Input #06 as
generator set by an automatic transfer switch, remote ground fault. Entry Accepted is displayed.
computer.
f. Press to display Digital Input #06 Inhibit
Time.

9. Place the controller master switch to the OFF/
g. Press to enter the inhibit time. Entry RESET position.
Accepted is displayed and the inhibit time 0:00
is now displayed. 10. Disconnect the battery negative (--) lead to power
down the generator set.
h. Press to display Digital Input #06 Delay 11. After 2-3 minutes, reconnect the battery negative
TIme. (--) lead.
12. Reset the controller clock. See Menu 6—Time and

Date.
i. Press to enter delay time. Entry
Accepted is displayed. Default delay time is
5 sec. 8.1.6 Idle (Speed) Mode Feature
The idle (speed) mode feature provides the ability to
start and run the engine at idle (reduced) speed for a
j. Press .
selectable time period (0--10 minutes) during warm-up.
7. Verify Programming. The controller will override the idle speed mode if the
engine reaches the preprogrammed engine warmed-up
a. Move handle of ground fault circuit breaker at temperature before the idle mode times out. See
generator set to simulate a ground fault. Figure 8-9 for user-supplied switch connection.
b. Verify that display shows D06 Ground Fault.

The System Warning LED should be
illuminated and the alarm horn should sound. If
these indicators are not present, recheck steps
6a. through 6j.
c. Return handle of ground fault circuit breaker to

the non-ground fault position. D06 Ground
Fault display should now be cleared.
8. Set Programming Mode to Off.
GM16088A-A
a. Press .
Figure 8-9 Idle (Speed) Mode Switch
b. Press key until Programming Mode Off is

displayed.

should now be off.

8.1.7 Low Fuel (Level/Pressure) Switch
Some gaseous-fueled models offer a low fuel pressure
switch. The low fuel pressure switch connects to the
same terminal as the low fuel level switch on diesel- or
gasoline-fueled models. See Figure 8-10 and 1
PRIME POWER
Figure 8-11. See Section 8.2, Accessory Connections, SWITCH 2
for terminal identification.
Note: The main tank or the transfer/day tank includes GM20652-
the low fuel level switch. The fuel tank supplier

1. Prime power decal (293668) 2. Toggle switch (354464)
typically provides the low fuel level switch.
Figure 8-12 Prime Power Switch Installation Location
GM16088A-A
Figure 8-10 Low Fuel Switch (Level or Pressure)
Switch Rating 12 volts DC minimum, 0.5 amp minimum

Wiring Recommendation
Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500) Toggle switch shown in
the prime power mode off
10 305 (1000)
position (contacts open)
GM16088A-D
Figure 8-11 Switch Rating & Wiring Recommendation
Figure 8-13 Prime Power Switch Connections
8.1.8 Prime Power Switch Kit Stop the generator set using the stopping procedures in
The prime power switch kit prevents battery drain during the respective operation manual before placing the
generator set nonoperation periods and when the generator set in the prime power mode. Move the prime
generator set battery cannot be maintained by an AC power switch located on the back of the controller to the
battery charger. See Figure 8-12 for an illustration of the DOWN position. The controller including the digital
kit and Figure 8-13 for the electrical connections. display, LEDs, and alarm horn does not function when
the generator set is in the prime power mode.
Move the prime power switch located on the back of the

controller to the UP position and reset the controller time
and date before attempting to start the generator set.

8.1.9 Remote Emergency Stop Kit 8.1.10 Remote Reset Feature
The emergency stop kit allows immediate shutdown of The remote reset switch provides generator set
the generator set from a remote location. See resetting after a fault shutdown at a remote location.
Figure 8-14 and Figure 8-15. If the emergency stop See Figure 8-16 and Figure 8-17 for user-supplied
switch activates, the EMERGENCY STOP lamp lights switch connection.
and the unit shuts down. Before attempting to restart the
generator set, reset the emergency stop switch (by Press and hold the switch for 2--3 seconds and release
replacing the glass piece) and reset the generator set by to reset the generator set controller.
placing the master switch in the OFF/RESET position.
Use the single glass piece located inside the switch for REMOTE RESET SWITCH ≈
CONTACTS NORMALLY OPEN
replacement and order additional glass pieces as MOMENTARY CLOSED TO
service parts. See the respective operation manual for ACTIVATE
the Emergency Stop Switch Reset Procedure. See
identifications.
GM16088A-A-
A-222654
TP-5352-1 Figure 8-16 Remote Reset Switch Connections
Figure 8-14 Emergency Stop Kit
Switch Rating 12 volts DC minimum, 1 amp minimum
Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 8-17 Switch Rating and Wiring

Recommendations
GM16088A-A
Figure 8-15 Remote Emergency Stop Kit

Connections

8.1.11 Remote Serial Annunciator
RSA II is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA is a remote serial annunciator Figure 8-18 and
Figure 8-19 that monitors the condition of the generator
set and/or ATS from a remote location. The RSA alerts
the operator through visual and audible signals using
LED indication and a horn. An alarm silence and lamp /Aux.
test switch are included.

The RSA meets NFPA 110, Level 1 (2005) applications
that require remote controls and alarms be powered by
a storage battery such as the engine starting battery. AC
adaptor kit GM62466-KP1 is available when NFPA is not
required.
The front panel decals include areas that can be used to
identify user-selected fault inputs and identify
associated power system equipment.
An RSA annunciator can be used for a single generator
set or with a combination of a generator set and
automatic transfer switch. In systems using more than a
single RSA, one must be designated as the master Figure 8-18 Remote Serial Annunciator (RSA II)
device to broadcast to additional RSA annunciators,
designated as slave devices. Up to five RSA slave
devices can be used with an RSA master device. All
RSA annunciators factory default to the master device,
but can be changed with RSA II setup software that can
be connected to the RSA front panel via a universal
serial bus (USB) connection.
The RSA 1000 can be connected with the RSA II
provided that the master remote annunciator is an
RSA II.
RSA II setup software is required to make the RSA II
functional. Use your SecurID to access KOHLERnet,
click on the TechTools button, and follow the instructions
to download the files. See RSA II Setup Software at the
end of this document.
The RSA kits include components for surface mounting
or flush mounting.
Figure 8-20 shows the status of the system ready LED,
generator set running LED, communication status LED,
common fault LED, common fault output, and horn for
each fault or status condition. See Appendix for RSA
wiring connections. Figure 8-19 RSA II with ATS Controls
If the RSA II is used with an Ethernet communication

network, order Modbusr Ethernet converter
GM41143-KP2 and refer to TT-1405 Converters,
Connections, and Controller Setup for Network
Communication for system installation.
Modbusr is a registered trademark of Schneider Electric.

System Monitoring LEDs and Functions
Generator Common
Fault System Running Communication Common Fault
Fault and Status Condition LED Ready LED LED Status LED Fault LED Output Horn
Overcrank Shutdown Red Red SF Off Green Red SF On On
High Engine Temperature Warning * Yellow Red SF Green Green Red SF On On
High Engine Temperature Shutdown Red Red SF Off Green Red SF On On
Low Oil Pressure Warning * Yellow Red SF Green Green Red SF On On
Low Oil Pressure Shutdown Red Red SF Off Green Red SF On On
Overspeed Shutdown Red Red SF Off Green Red SF On On
Emergency Stop * Red Red SF Off Green Off On On
Low Coolant Level/Auxiliary Shutdown * Red Red SF Off Green Red SF On On
Low Coolant Temperature * Yellow Red SF Off Green Red SF On On
Low Fuel—Level or Pressure * Yellow Red SF Off Green Red SF On On
EPS Supplying Load (RSA II) Green Green Green or Off Green Off Off Off
System Ready Green Green Green or Off Green Off Off Off
System Not Ready Red Red SF Green or Off Green Off On On
Low Cranking Voltage Yellow Red SF Off Green Red SF On On
(Loss of) Communication Status Red Off Off Red FF Off On On
(Master RSA II)
(Loss of) Communication Status (Slave RSA II) Red Off Off Red SF Off On On
Not-In-Auto Red Red SF Green or Off Green Red SF On On
Battery Charger Fault * Yellow Green Green or Off Green Off On On
High Battery Voltage * Yellow Green Green or Off Green Off On On
Low Battery Voltage * Yellow Green Green or Off Green Off Off Off
User Input #1 (RSA II) Warning Yellow Green Green or Off Green Off On On
User Input #1 (RSA II) Shutdown Red Green Green or Off Green Off On On
Common Fault Warning Yellow Green Green or Off Green Red SF On Off
Common Fault Shutdown Red Green Green or Off Green Red SF On On
ATS Position N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Available N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Available E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Yellow Yellow Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
SF = Slow Flash (1 second intervals), FF = Fast Flash (200 ms intervals)
* May require optional kit or user-provided device to enable function and LED indication.
Figure 8-20 System Monitoring LEDs and Functions

8.1.12 Shunt-Trip Line Circuit Breaker 8.1.13 Single-Relay Dry Contact Kit
A shunt-trip line circuit breaker provides a 12- or 24-DC The single-relay dry contact kit provides normally open
volt solenoid within the line circuit breaker case that can and normally closed contacts in a form C configuration
energize the trip mechanism. This feature allows the to activate warning devices and other user- provided
circuit breaker to be tripped by a customer-selected fault accessories allowing remote monitoring of the
such as alternator overload, overspeed, overvoltage, or generator set. Typically, lamps, audible alarms, or other
defined common fault. Connection requires a shunt-trip devices signal faults or status conditions. Connect any
wiring kit and a dry contact kit. See Figure 8-21. controller fault output to the single-relay dry contact kit.
A total of three dry contact kits may connect to a single

controller output. See Figure 8-22 and Figure 8-23. See
identifications.
Typical Connection:
TB6--RDO1 Overspeed (39),
TB8--RDO18 Defined Common Fault (32A), A-273945
TB8--RDO20 Overvoltage (26), or GM16088A-H

Figure 8-22 Single-Relay Dry Contact Kit, Typical
TB9--RDO30 Load Shed kW Overload
Figure 8-21 Shunt-Trip Line Circuit Breaker and

Shunt-Trip Wiring Kit Connections
GM16088A-A
Figure 8-23 Single-Relay Dry Contact Kit Connections

8.1.14 Ten-Relay Dry Contact Kit ten-relay dry contact kit. Typically, lamps, audible
alarms, or other devices signal the fault conditions.
The ten-relay dry contact kit provides normally open and
normally closed contacts in a form C configuration to Refer to Figure 8-24 for an internal view of the contact
activate warning devices and other user-provided kit. See Figure 8-25 for electrical connections. See
accessories allowing remote monitoring of the Section 8.2, Accessory Connections, for terminal
generator set. Connect any controller fault output to the identifications.
A-273936
Figure 8-24 Ten-Relay Dry Contact Kit
GM13984-/354246B-
Figure 8-25 Ten-Relay Dry Contact Kit Connections

8.1.15 Twenty-Relay Dry Contact Kit
The twenty-relay dry contact kit provides normally open
and normally closed contacts in a form C configuration
to activate warning devices and other user-provided
accessories allowing remote monitoring of the
generator set. Typically, lamps, audible alarms, or other
devices signal faults or status conditions. Connect any
generator set fault output to the dry contact kit.
Refer to Figure 8-26 for an internal view of the contact

kit. See Figure 8-27 for electrical connections. See
identifications.
D-294303-D
Figure 8-26 Twenty-Relay Dry Contact Kits
GM16759D-C
Figure 8-27 Twenty-Relay Dry Contact Relay Kit Connections

8.2 Accessory Connections For specific information on accessory connections, refer
to the accessory wiring diagrams in the wiring diagram
The 550 controller contains circuit boards equipped with manual and the instruction sheet accompanying the kit.
terminal strip(s) for use in connecting a controller See Figure 8-28 and Figure 8-29 for controller
connection kit. Do not connect accessories directly to interconnection circuit board connections. See
the controller terminal strip(s). Connect accessories to Figure 8-30 and Figure 8-31 for controller (customer)
either a controller connection kit or a dry contact kit. connection kit connections. See Figure 8-32,
Connect the dry contact kit(s) to the controller Figure 8-33, and Figure 8-34 for accessory connection
connection kit. Connect alarms, battery chargers, wiring diagrams.
remote switches, and other accessories to the dry
contact kit relay(s).
TOP OF CONTROLLER BACK PANEL
2
4
GM16088A-A/GM10193B-A
1. TB1 terminal strip 4. TB4 terminal strip
2. TB2 terminal strip 5. P23 Connector
3. TB3 terminal strip
Figure 8-28 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
Term. Description
Term. Description 1 DCH1 Battery charger fault
1 Emergency stop ground 2 DCH2 Low fuel
1A Emergency stop 3 DCH3 Low coolant temp. with ECM models or
3 Remote start warning default with non-ECM models
4 Remote start 4 DCH4 Field overvoltage with M4/M5/M7
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7 alternators
5 DCH5 Breaker Closed, Paralleling Applications
Term. Description 6 DCH6 Enable Synch, Paralleling Applications
1 ACH1 (CTS) Signal (non-ECM including Waukesha) 7 DCH7 Warning
2 ACH1 (CTS) Supply (non-ECM including Waukesha)
8 DCH8 Warning
3 ACH2 (OPS) Signal (non-ECM including Waukesha)
9 DCH9 Warning
4 ACH2 (OPS) Supply (non-ECM including Waukesha
10 DCH10 Warning
5 ACH3 Signal (air intake temp. for Waukesha)
11 DCH11 AFM Shutdown, Waukesha engine
6 ACH3 Supply (air intake temp. for Waukesha)
12 DCH12 Detonation Warning, Waukesha engine
7 ACH4 Signal (oil temp. for Waukesha)
13 DCH13 Detonation Shutdown,
8 ACH4 Supply (oil temp. for Waukesha)
Waukesha engine
9 ACH5 Signal
14 DCH14 Warning
10 ACH5 Supply
15 DCH15 Remote shutdown
11 ACH6 Signal
16 DCH16 Remote reset
12 ACH6 Supply (VSG for Volvo, GM, Doosan)
13 ACH7 Signal (optional analog voltage adjust signal) 17 DCH17 VAR PF mode
14 ACH7 Supply 18 DCH18 Voltage lower
15 N/C 19 DCH19 Voltage raise
16 ACH1 (CTS) Return (non-ECM) 20 DCH20 Air damper
17 ACH1 (CTS) Shield ground (non-ECM) 21 DCH21 Idle mode functional with
18 ACH2 (OPS or OPS2) Return (non-ECM) ECM-equipped engines only
19 ACH2 (OPS) Shield ground (non-ECM) 22 DCH1 Return
20 ACH3 (IAT or OPS1) Return 23 DCH2 Return
21 ACH3 Shield ground 24 DCH3 Return
22 ACH4 (Oil Temp) Return 25 DCH4 Return
24 ACH5 Return 27 DCH6 Return
30 N/C 33 DCH12 Return
34 DCH13 Return
35 DCH14 Return
TB3 Terminal Strip—Accessory Power Output 36 DCH15 Return
Connections 37 DCH16 Return
Term. Description 38 DCH17 Return
1 +12 VDC (OEM use only) 39 DCH18 Return
4 Fused battery (+) (42A) (5 amp) 42 DCH21 Return
5 Fused battery (+) (42A) (5 amp)
7 Battery (--) Note: TB4-1 through TB4-21 are user definable with
8 Battery (--) factory defaults listed. Terminals TB4-3, TB4-4,
9 Battery (--) TB4-14, and TB4-21 have different functions
10 Battery (--) depending upon the generator set configuration.
11 Battery (--) See comments above.
12 Panel lamp output See Menu 9—Input Setup for changing inputs.
Figure 8-29 Controller Terminal Strip Identification

GM13984-
Figure 8-30 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box
TB6 Terminal Strip—RDOs 1--7 TB9 Terminal Strip—RDOs 24--31

Term. Description Term. Description
42A Battery (+) RDO24 Speed sensor fault
GND Battery (--) RDO25 Loss of AC sensing
N/C RDO26 ECM loss of communication
RDO1 Overspeed (lead 39) RDO27 Undervoltage
RDO2 Overcrank (lead 12) RDO28 Overfrequency
RDO3 High coolant temperature shutdown (lead 36) RDO29 Underfrequency
RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload
RDO5 Low coolant temperature (lead 35) RDO31 Load shed underfrequency
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low oil pressure warning (lead 41) 4 Remote start
TB7 Terminal Strip—RDOs 8--17
Term. Description Note:Lead numbers shown in parentheses are the factory
RDO8 Low fuel (lead 63) default wire designations.
RDO9 Master switch not in auto ( lead 80)
RDO10 NFPA 110 common alarm (lead 32)* Note:RDO-1 though RDO-31 are user definable with the
RDO11 Battery charger fault (lead 61) following factory defaults: emergency stop, high coolant
RDO12 Low battery voltage (lead 62) temperature, low oil pressure, overcrank, and overspeed
RDO13 High battery voltage
RDO14 Emergency stop (lead 48)
*NFPA-110 common alarm faults include:
RDO15 Generator set running (lead 70R)
RDO16 Time delay engine cooldown (TDEC) (lead 70C) Air damper indicator (RDO--23)
RDO17 System ready (lead 60) Battery charger fault (RDO--11)
EPS supplying load (RDO--22)
TB8 Terminal Strip—RDOs 18--23 High battery voltage (RDO--13)
Term. Description High coolant temperature warning (RDO--06)
42A Battery (+) High coolant temperature shutdown (RDO--03)
42A Battery (+) Low battery voltage (RDO--012)
GND Battery (--) Low coolant level (RDO--19)
GND Battery (--) Low coolant temperature warning (RDO--05)
RDO18 Defined common fault (lead 32A) Low fuel (level or pressure) (RDO--08)
RDO19 Low coolant level Low oil pressure warning (RDO--07)
RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO--04)
RDO21 Idle mode Master switch not in auto (RDO--09)
RDO22 EPS supplying load Overcrank (RDO--02)
RDO23 Air damper indicator (lead 56) Overspeed (RDO--01)
Figure 8-31 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)

Figure 8-32 Accessory Connections GM78247A-D
Figure 8-33 Accessory Connections GM78247C-D
Figure 8-34 Accessory Connections GM78247D-D
Section 9 Decision-Makerr 3000 Accessories
9.1 Accessories and Connections The optional common fault relay shown in Figure 9-3 as
DCB2 has contacts rated at 10 amps at 28 VDC or
Several accessories help finalize installation, add 120 VAC and can be connected to user-supplied
convenience to operation and service, and establish accessories.
state and local code compliance.
The optional common fault relay shown in Figure 9-3 as
Accessories vary with each generator set model and DCB1 has contacts rated at 10 amps at 28 VDC or
controller. Select factory-installed and/or shipped- 120 VAC and is used to trigger the shunt-trip line circuit
loose accessories. See Figure 9-1 for a list of available breaker kit (mentioned later in this section).
kits. Obtain the most current accessory information
from your local authorized service distributor/dealer.
This section illustrates several accessories available at

print time of this publication. Accessory kits generally
include installation instructions. See wiring diagrams
manual for electrical connections not shown in this
section. See the installation instructions and drawings
supplied with kit for information on kit mounting location.

supersede these instructions where there are GM67191-B
differences. In general, run AC and DC wiring in
separate conduit. Use shielded cable for all analog Figure 9-2 Common Fault Relay Wiring (Standard)

identification.
Kit Description
Common Fault/Failure (32A) Connections
Input/Output Module Board
Low Fuel (Level) Switch
Low Fuel (Pressure) Switch
Prime Power Switch
Remote Reset Feature
Remote Serial Annunciator
Shunt-Trip Line Circuit Breaker
Figure 9-1 Optional Accessories
9.1.1 Common Fault/Failure (32A) Relay

The common fault relay is standard on the controller GM67191-B
circuit board and located at the TB2 terminal strip
connections. Contacts are rated at 2 amps at 32 VDC Figure 9-3 Common Fault Relay Kit and Shunt-Trip
or 0.5 amps at 120 VAC max. See Figure 9-2 and Relay Kit Wiring
Figure 9-3.
TP-5700 1/13 Section 9 Decision-Makerr 3000 Accessories 89

9.1.2 Float/Equalize Battery Charger Kit
with Alarm Option
The float/equalize battery charger with alarm option
provides battery charging to the engine starting
battery(ies) and connects to the controller for fault
detection. Battery chargers for 12- or 24-volt models are
available as a generator set accessory. See Figure 9-4
and Figure 9-5 for battery connections.
CONNECT TO TB1
CHARGER
MALFUNCTION GM67191-B
Figure 9-5 Battery Charger to Controller

Connections
LV HV CM
BATTERY CHARGER 9.1.3 Input/Output (I/O) Module Board
ALARM TERMINAL
STRIP The I/O module board provides a generator set mounted
GM16088A-A/TP--6694
panel with two analog or digital inputs and five digital
outputs. See Figure 9-6 for circuit board components
Figure 9-4 Float/Equalize Battery Charger and electrical connections to the controller. See
Connections Figure 9-7 for connections of analog inputs. Refer to
Figure 9-24 for accessory connections.

identification.
1 2
6 3
GM64493
4
1. P29/P30/P31 K1/K2/K3 2-amp relay outputs 5. P25 RJ45 In (DEC 3000 P23)
2. P32 K4/K5 10-amp relay outputs 6. P26 RJ45 Out
3. SW1 switch 7. P27 CAN terminator
4. P28 In1/In2 analog or digital inputs
Figure 9-6 Input/Output (I/O) Module Board Kit
90 Section 9 Decision-Makerr 3000 Accessories TP-5700 1/13

P28 Optional 5 V P28 Optional 5 V P28
power power
+5 +5 +5
(50 mA max.) (50 mA max.)
VPx VPx + VPx
Output
Analog Analog
VNx VNx -- VNx
Device Device
GND GND GND
GND
GND
100 ohm min. or 50 mA max. current
TP-6694-6
0--5 Volt Ratiometric Sensor 0--5 Volt Analog Device +/-- 3 Volt Analog Device
Figure 9-7 Analog Input Connections P28

9.1.4 Low Fuel (Level/Pressure) Switch Switch Rating 12 volts DC minimum, 0.5 amp minimum
Some gas-fueled models offer a low fuel pressure Wiring Recommendation

switch. The low fuel pressure switch connects to the Gauge mm (ft.)
same controller terminal as the low fuel level switch on 18--20 30.5 (100)
diesel-fueled models. See Figure 9-8, Figure 9-9, and 14 153 (500)
Figure 9-10. 10 305 (1000)
Figure 9-10 Switch Rating & Wiring

Note: The main tank or the transfer/day tank includes
Recommendation
9.1.5 Prime Power Switch Kit
The prime power switch kit prevents battery drain during
CONNECT TO TB1 generator set non--operation periods and when the
(for warning) or generator set battery cannot be maintained by an AC
TB3 (for shutdown) battery charger. See Figure 9-11 for an illustration of the
kit and Figure 9-12 for the electrical connections.
Stop the generator set using the stopping procedures in

GM16088A-A/TP-6694
respective operation manual before placing the
generator set in the prime power mode. Move the prime
Figure 9-8 Low Fuel Switch (Level or Pressure) power switch located on the junction box to the DOWN
position. The controller including the digital display,
LEDs, and alarm horn does not function when the
generator set is in the prime power mode.
Move the prime power switch located on the junction box

to the UP position. The generator set is now ready for
starting.
1
PRIME POWER
SWITCH 2
GM67191-B GM20652-/
TP-6694
Figure 9-9 Low Fuel Switch Connection to 1. Prime power decal (293668) 2. Toggle switch (354464)
Controller Connection
Figure 9-11 Prime Power Switch

GM67191-B
Figure 9-14 Remote Emergency Stop Kit

Connections
9.1.7 Remote Reset Feature

The remote reset switch provides generator set
Toggle switch shown in controller resetting after a fault shutdown at a remote
the prime power mode off location. See Figure 9-15 and Figure 9-16 for
position (contacts open) GM64345-/TP-6694
user-supplied switch connection.
Press and hold the switch for 2--3 seconds and release
to reset the generator set controller.
9.1.6 Remote Emergency Stop Kit
The emergency stop kit allows immediate shutdown of
identifications.
the generator set from a remote location. See
Figure 9-13 and Figure 9-14. If the emergency stop
switch activates, the EMERGENCY STOP lamp lights
and the unit shuts down. Before attempting to restart the ≈
REMOTE RESET SWITCH
generator set, reset the emergency stop switch (by CONTACTS NORMALLY OPEN
replacing the glass piece) and reset the generator set by MOMENTARY CLOSED TO
pressing the master control switch OFF/RESET button. ACTIVATE
Use the single glass piece located inside the switch for
replacement and order additional glass pieces as
service parts. See the respective operation manual for CONNECT TO TB1
Emergency Stop Switch Resetting. as a Digital Input
GM16088A-A-/TP--6694
identifications. Figure 9-15 Remote Reset Switch Connections

Gauge m (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)

Recommendations
A-222654
TP-5352-1

RSA II is an annunciator panel offered in several kit
RSA II is a remote serial annunciator Figure 9-17 and
Figure 9-18 that monitors the condition of the generator
set and/or ATS from a remote location. The RSA II alerts
the operator through visual and audible signals using
LED indication and a horn. An alarm silence and lamp /Aux.
test switch are included.

The RSA II meets NFPA 110, Level 1 applications that
require remote controls and alarms be powered by a
storage battery such as the engine starting battery. An
AC adaptor kit is available when NFPA is not required.
An RSA II annunciator can be used for a single
generator set or with a combination of a generator set
and automatic transfer switch. In systems using more
than a single RSA II, one must be designated as the
master device to broadcast to additional RSA II Figure 9-17 Remote Serial Annunciator (RSA II)
annunciators, designated as slave devices. Up to five
RSA II slave devices can be used with an RSA II master
device. All RSA II annunciators are factory set as the
master device, but can be changed to a slave device
using a PC and SiteTecht software that connects to the
RSA II front panel via a universal serial bus (USB)
connection.
RSA II.
Refer to TT-1485 Remote Serial Annunciator (RSA II)
Kits for operation and installation instructions.
A PC with SiteTecht software is required to make
the RSA II functional. Use your SecurID to access
KOHLERnet, click on the TechTools button, and follow
the instructions to download the files. Refer to the
SiteTecht Software Operation Manual for more
information.
The RSA II kits include components for surface
mounting or flush mounting.
Figure 9-19 shows the status of the system ready LED, Figure 9-18 RSA II with ATS Controls
common fault LED, common fault output, and horn for See Section 9.2, Accessory Connections, for terminal
each fault or status condition. See Appendix for RSA identifications.
wiring connections.
If the RSA II is used with an Ethernet communication
network, order Modbusr Ethernet converter
Connections, and Controller Setup for Network
Communication for system installation.

Generator Common
(Master RSA II)

9.1.9 Shunt-Trip Line Circuit Breaker 9.2 Accessory Connections
A shunt-trip line circuit breaker provides a 12- or 24-DC The controller contains a circuit board equipped with
volt solenoid within the line circuit breaker case that can terminal strip(s) for use in connecting external optional
energize the trip mechanism. This feature allows the accessories including alarms, battery chargers, and
circuit breaker to be tripped by the common fault (32A). remote switches. The optional I/O board provides an
Connection requires a shunt-trip wiring kit and a dry additional two analog or digital inputs and five digital
contact kit. See Figure 9-20 and Figure 9-21. outputs.
The optional common fault relay shown in Figure 9-21 For specific information on accessory connections, refer
as DCB1 has contacts rated at 10 amps at 28 VDC or to the accessory wiring diagrams in the wiring diagram
120 VAC and is used to trigger the shunt-trip line circuit manual and the instruction sheet accompanying the kit.
breaker kit. See Figure 9-22, Figure 9-23, and Figure 9-25 for
controller circuit board connections.
9
2
3
GM67191-B
8
Figure 9-20 Shunt-Trip Wiring (Standard)
GM64345-C
7 6 5
1. (4) push-on terminal connectors
2. TB2 4-position terminal block
4. P2 6-pin connector
8. P23 8-pin connector (RJ45)
Figure 9-22 Controller Circuit Board Connections
GM67191-B
Figure 9-21 Shunt-Trip Relay Kit and Line Circuit

Breaker Wiring (Shown with Common
Fault/Failure Relay Kit)

TB1 Terminal Strip P1 24-Pin Connector
Analog and Digital Input Connections Engine Wiring Harness
Terminal Description Connection Terminal Description Connection
TB1--DI 1 DCH1 No Function P1--12 14P +12VDC Prime Power Switch
TB1--DI 2 DCH2 Aux. Warning Switch P21 6-Pin Connector
TB1--DI 3 DCH3 Battery Charger Fault RS-485 (RSA II)
TB1--AI 1 ACH1 No Function Terminal Description Connection
TB1--AI 2 ACH2 No Function P21--1 GND Shield
TB1--GND Ground Common A/D Ground P21--2 (+) Red
TB2 Terminal Strip P21--3 (--) Black
KI Relay Outputs P21--4 GND Shield
Terminal Description Connection P21--5 (+) Red
TB2--COM Common User--Defined P21--6 (--) Black
TB2--COM Common Common Fault (2) TB1 Terminal Strip Designations
TB2--NO Normally Open Common Fault (32A) Analog and Digital Input Connections
TB2--NC Normally Terminals Controller SiteTech
User--Defined
Closed on Board Designation Designation
TB3 Terminal Strip TB1--DI 1 DIn A1 A1
Accessory Power Output Connections TB1--DI 2 DIn A2 A2
Terminal Description Connection TB1--DI 3 DIn A3 A3
TB3--1 E--Stop E--Stop Ground TB1--AI 1 AIn A1 —
TB3--1A E--Stop E--Stop TB1--AI 2 AIn A2 A1
TB3--3 Remote Start Remote Start TB1--GND — —
TB3--4 Remote Start Remote Start
TB3--AUX Auxiliary Aux. Shutdown Sw.
TB3--AUXR Auxiliary--R Aux. Shutdown Sw.
Figure 9-23 Controller Connections

P25 Connector P30 Connector
RJ45 Remote I/O In 2 Amp. K2 Relay Output (2.2) Connections
Connects to DEC 3000 P23 Terminal Description
P26 Connector P30--NC Normally Closed
RJ45 Remote I/O Out P30--COM Common
Open P30--NO Normally Open
P27 Connector P31 Connector
CAN Terminator 2 Amp. K3 Relay Output (2.3) Connections
Place the P27 jumper on the IN pins Terminal Description
Single-Ended (0--5 V) Analog Input Connections P31--COM Common
Terminal Description P31--NO Normally Open
P28--GND AGND Analog Return P32 Connector
P28--VN1 NO Connection 10 Amp. K4 Relay Output (2.4) Connections
P28--VP1 ACH1 Signal Terminal Description
P28--+5V Supply (.05 amp max.) P32--NC Normally Closed
P28--GND AGND Analog Return P32--COM Common
P28--VN2 NO Connection P32--NO Normally Open
P28--VP2 ACH2 Signal 10 Amp. K5 Relay Output (2.5) Connections
P28--+5V Supply (0.05 amp max.) Terminal Description
Differential (+/--3 V) Analog Input Connections P32--COM Common
Terminal Description P32--NO Normally Open
P28--GND AGND Analog Reference
P28 Connector Designations
P28--VN1 ACH1 Negative Differential Signal
Terminals Controller SiteTech
P28--VP1 ACH1 Positive Differential Signal
on Board Designation Designation
P28--+5V Supply (.05 amp max.)
P28--GND
P28--GND AGND Analog Reference
P28--VN1
P28--VN2 ACH2 Negative Differential Signal DIn B1 B1
P28--VP1
P28--VP2 ACH2 Positive Differential Signal
P28--+5V
P28--+5V Supply (0.05 amp max.)
P28--GND
P29 Connector
P28--VN2
2 Amp. K1 Relay Output (2.1) Connections Din B2 B2
P28--VP2
Terminal Description
P28--+5V
P29--NC Normally Closed
P29--COM Common
P29--NO Normally Open
Figure 9-24 Input/Output Module Board Connections

Figure 9-25 Decision-Makerr 3000 Wiring Connections GM67191-B
Section 10 Decision-Makerr 6000 Accessories
10.1 Accessories and Connections Note: Use the audiovisual alarm with a dry contact kit.
Several accessories help finalize installation, add Kit Description

convenience to operation and service, and establish Audiovisual Alarm
state and local code compliance. Common Failure Relay (Terminal 32A)
Accessories vary with each generator set model and Ground Fault Annunciation
controller. Select factory-installed and/or shipped- Idle (Speed) Mode Feature
loose accessories. See Figure 10-1 for a list of Low Fuel (Level) Switch
available kits. Obtain the most current accessory Low Fuel (Pressure) Switch
information from your local authorized service Prime Power Switch
distributor/dealer.
This section illustrates several accessories available at Remote Reset Feature

print time of this publication. Accessory kits generally Remote Serial Annunciator
include installation instructions. See wiring diagrams Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring
manual for electrical connections not shown in this Single-Relay Dry Contact
section. See the installation instructions and drawings Ten-Relay Dry Contact
supplied with kit for information on kit mounting location. Twenty-Relay Dry Contact
The instructions provided with the accessory kit Figure 10-1 Available Accessories
supersede these instructions where there are
differences. In general, run AC and DC wiring in Front View Side View
separate conduit. Use shielded cable for all analog
10.1.1 Audiovisual Alarm Kit

An audiovisual alarm warns the operator at a remote
location of fault shutdowns and prealarm conditions.
Audiovisual alarms include an alarm horn, an alarm
silence switch, and common fault lamp. See Figure 10-2 A-292887
and Figure 10-3. See Section 10.2, Accessory

Figure 10-2 Audiovisual Alarm
Connections, for terminal identification.
CONTROLLER CUSTOMER CONNECTION TERMINAL STRIP
GM13984-
Figure 10-3 Audiovisual Alarm Connections

10.1.2 Common Failure Relay Kit
The common failure relay kit provides one set of
contacts to trigger user-provided warning devices if a
fault occurs. The common failure relay faults are
user-defined. See Section 2, Operation, Menu 10—
Output Setup, for status and faults available for this
function.
Connect up to three common failure relay kits to the

controller output. See Figure 10-4 and Figure 10-5.
identification.
10.1.3 Float/Equalize Battery Charger Kit C-294301
with Alarm Option Figure 10-4 Common Failure Relay Kit

The float/equalize battery charger with alarm option
provides battery charging to the engine starting
battery(ies) and connects to the controller for fault
detection. Battery chargers for 12- or 24-volt models are
available as a generator set accessory. See
Figure 10-6. See Section 10.2, Accessory
GM13984-
Figure 10-5 Common Failure Relay Kit Connections
CHARGER MALFUNCTION
LV HV CM BATTERY CHARGER
ALARM TERMINAL STRIP
GM16088A-A
Figure 10-6 Float/Equalize Battery Charger Connections

10.1.4 Ground Fault Annunciation Ground Fault Controller Setup Procedure
A relay contact for customer connection indicates a 1. Reconnect battery, if not already done.
ground fault condition and is part of a ground fault alarm.
See Figure 10-7 for electrical connections and the 2. Press the controller master switch AUTO button.
following procedure for controller setup. Use the
3. Press the Alarm Off key to silence the alarm horn, if
instructions with the kit when provided to install and
necessary.
setup this accessory.
4. If the programming mode LED is not flashing, go to
POWER SUPPLY GENERATOR
DC 12 -- TB3-9 N
the step 5. If the programming mode LED is
or 24 V + TB3-4 See assembly
drawing and flashing, go to step 6.
pick list for
neutral to
ground cable.
GFA 300 5. Set Programming Mode to Local.
a. Press keys .
Generator
system
ground
connect to
ground bus. b. Press key until Programming Mode--
Local is displayed.
TB4-6 (DCH6)
TB4-27 (GND)
GFI WIRED TO THE CONTROLLER GM53026- c. Press the YES key .
Figure 10-7 Ground Fault Connections d. When the Enter Code displays, press the
WARNING keys and . The programming mode LED

should be flashing.
6. Set digital input #6 to ground fault.
a. Press . Menu 9 Input Setup
should be displayed.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first b. Press until Digital Input 06 Warning is
displayed.
Reconnect the negative (--) lead last
when reconnecting the battery.
c. Press once to select this input.

Disabling the generator set. Accidental starting can
generator set or equipment connected to the set, disable the
d. Press until Ground Fault is displayed.
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative e. Press to define Digital Input #06 as
(--) lead last when reconnecting the battery. Follow these ground fault. Entry Accepted is displayed.
precautions to prevent the starting of the generator set by the
remote start/stop switch.
f. Press to display Digital Input #06 Inhibit
Time.
g. Press to enter the inhibit time. Entry

Accepted is displayed and the inhibit time 0:00
is now displayed.

10.1.5 Idle (Speed) Mode Feature
h. Press to display Digital Input #06 Delay
TIme. The idle (speed) mode feature provides the ability to
start and run the engine at idle (reduced) speed for a
selectable time period (0--10 minutes) during warm-up.
The controller will override the idle speed mode if the
i. Press to enter delay time. Entry
engine reaches the preprogrammed engine warmed-up
Accepted is displayed. Default delay time is
temperature before the idle mode times out. See
5 sec.
Figure 10-8 for user-supplied switch connection.
j. Press .
7. Verify Programming.
a. Move handle of ground fault circuit breaker at

generator set to simulate a ground fault.
b. Verify that display shows D06 Ground Fault.

The System Warning LED should be
illuminated and the alarm horn should sound. If
these indicators are not present, recheck steps
6a. through 6j. GM16088A-A
c. Return handle of ground fault circuit breaker to Figure 10-8 Idle (Speed) Mode Switch
the non-ground fault position. D06 Ground
Fault display should now be cleared. 10.1.6 Low Fuel (Level/Pressure) Switch
8. Set Programming Mode to Off. Some gaseous-fueled models offer a low fuel pressure
switch. The low fuel pressure switch connects to the
same terminal as the low fuel level switch on diesel- or
a. Press . gasoline-fueled models. See Figure 10-9 and
Figure 10-10. See Section 10.2, Accessory
b. Press key until Programming Mode Off is
displayed. Note: The main tank or the transfer/day tank includes

should now be off.
9. Press the controller master switch OFF button.
10. Disconnect the battery negative (--) lead to power GM16088A-A

down the generator set.
Figure 10-9 Low Fuel Switch (Level or Pressure)
11. After 2-3 minutes, reconnect the battery negative
Switch Rating 12 volts DC minimum, 0.5 amp minimum
(--) lead.
12. Reset the controller clock. See Menu 6—Time and Gauge mm (ft.)
Date. 18--20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 10-10Switch Rating & Wiring Recommendation

10.1.7 Prime Power Switch Kit 10.1.8 Remote Emergency Stop Kit
The prime power switch kit prevents battery drain during The emergency stop kit allows immediate shutdown of
generator set nonoperation periods and when the the generator set from a remote location. See
generator set battery cannot be maintained by an AC Figure 10-13 and Figure 10-14. If the emergency stop
battery charger. See Figure 10-11 for an illustration of switch activates, the EMERGENCY STOP lamp lights
the kit and Figure 10-12 for the electrical connections. and the unit shuts down. Before attempting to restart the
generator set, reset the emergency stop switch (by
replacing the glass piece) and reset the generator set by
placing the master switch in the OFF/RESET position.
Use the single glass piece located inside the switch for
1 replacement and order additional glass pieces as
PRIME POWER service parts. See the respective operation manual for
SWITCH 2
the Emergency Stop Switch Reset Procedure. See
GM20652- identifications.
1. Prime power decal (293668) 2. Toggle switch (354464)
Figure 10-11 Prime Power Switch Installation

Location
A-222654
TP-5352-1
Toggle switch shown in

the prime power mode off
position (contacts open)
GM16088A-D
Stop the generator set using the stopping procedures in

the respective operation manual before placing the
generator set in the prime power mode. Move the prime GM16088A-A
power switch located on the back of the controller to the Figure 10-14 Remote Emergency Stop Kit
DOWN position. The controller including the digital Connections
display, LEDs, and alarm horn does not function when
the generator set is in the prime power mode.
Move the prime power switch located on the back of the

controller to the UP position and reset the controller time
and date before attempting to start the generator set.

10.1.9 Remote Reset Feature
The remote reset switch provides generator set
resetting after a fault shutdown at a remote location.
See Figure 10-15 and Figure 10-16 for user-supplied
switch connection.
Press and hold the switch for 2--3 seconds and release
to reset the generator set controller. /Aux.
REMOTE RESET SWITCH ≈

CONTACTS NORMALLY OPEN
MOMENTARY CLOSED TO
ACTIVATE
Figure 10-17 Remote Serial Annunciator (RSA II)
GM16088A-A-
Figure 10-15 Remote Reset Switch Connections

Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)

Recommendations

RSA II is an annunciator panel offered in several kit Figure 10-18 RSA II with ATS Controls
RSA is a remote serial annunciator Figure 10-17 and The RSA meets NFPA 110, Level 1 (2005) applications
Figure 10-18 that monitors the condition of the that require remote controls and alarms be powered by
generator set and/or ATS from a remote location. The a storage battery such as the engine starting battery. AC
RSA alerts the operator through visual and audible adaptor kit GM62466-KP1 is available when NFPA is not
signals using LED indication and a horn. An alarm required.
silence and lamp test switch are included.

Generator Common
(Master RSA II)

An RSA annunciator can be used for a single generator 10.1.11 Shunt-Trip Line Circuit Breaker
set or with a combination of a generator set and
automatic transfer switch. In systems using more than a A shunt-trip line circuit breaker provides a 12- or 24-DC
single RSA, one must be designated as the master volt solenoid within the line circuit breaker case that can
device to broadcast to additional RSA annunciators, energize the trip mechanism. This feature allows the
designated as slave devices. Up to five RSA slave circuit breaker to be tripped by a customer-selected fault
devices can be used with an RSA master device. All such as alternator overload, overspeed, overvoltage, or
RSA annunciators factory default to the master device, defined common fault. Connection requires a shunt-trip
but can be changed with RSA II setup software that can wiring kit and a dry contact kit. See Figure 10-20.
be connected to the RSA front panel via a universal
serial bus (USB) connection.
RSA II.
SiteTecht setup software is required to make the
RSA II functional. Use your SecurID to access
KOHLERnet, click on the TechTools button, and follow
the instructions to download the files. See RSA II Setup
Software at the end of this document.
The RSA kits include components for surface mounting
or flush mounting.
Figure 10-19 shows the status of the system ready LED,
common fault LED, common fault output, and horn for
each fault or status condition. See Appendix for RSA
wiring connections.
If the RSA II is used with an Ethernet communication Typical Connection:
network, order Modbusr Ethernet converter TB6--RDO1 Overspeed (39),
TB8--RDO18 Defined Common Fault (32A),
Connections, and Controller Setup for Network TB8--RDO20 Overvoltage (26), or GM16088A-H
Communication for system installation. TB9--RDO30 Load Shed kW Overload
Figure 10-20 Shunt-Trip Line Circuit Breaker and

Shunt-Trip Wiring Kit Connections

10.1.12 Single-Relay Dry Contact Kit Refer to Figure 10-23 for an internal view of the contact
The single-relay dry contact kit provides normally open Section 10.2, Accessory Connections, for terminal
and normally closed contacts in a form C configuration identifications.
to activate warning devices and other user- provided
controller fault output to the single-relay dry contact kit.
A total of three dry contact kits may connect to a single

controller output. See Figure 10-21 and Figure 10-22.
identifications.
10.1.13 Ten-Relay Dry Contact Kit

The ten-relay dry contact kit provides normally open and
normally closed contacts in a form C configuration to
activate warning devices and other user-provided
A-273945
generator set. Connect any controller fault output to the
ten-relay dry contact kit. Typically, lamps, audible Figure 10-21 Single-Relay Dry Contact Kit, Typical
alarms, or other devices signal the fault conditions.
GM16088A-A
Figure 10-22 Single-Relay Dry Contact Kit Connections

A-273936
Figure 10-23 Ten-Relay Dry Contact Kit
GM13984-/354246B-
Figure 10-24 Ten-Relay Dry Contact Kit Connections

10.1.14 Twenty-Relay Dry Contact Kit
The twenty-relay dry contact kit provides normally open
and normally closed contacts in a form C configuration
to activate warning devices and other user-provided
generator set fault output to the dry contact kit.
Refer to Figure 10-25 for an internal view of the contact

identifications.
D-294303-D
Figure 10-25 Twenty-Relay Dry Contact Kits
GM16759D-C
Figure 10-26 Twenty-Relay Dry Contact Relay Kit Connections

10.2 Accessory Connections For specific information on accessory connections, refer
to the accessory wiring diagrams in the wiring diagram
The controller contains circuit boards equipped with manual and the instruction sheet accompanying the kit.
terminal strip(s) for use in connecting accessories. See Figure 10-27 and Figure 10-28 for controller
Connect accessories to either the controller customer interconnection circuit board connections. See
connection terminal strip or a dry contact kit. Connect Figure 10-29 and Figure 10-30 for controller (customer)
the dry contact kit(s) to the controller customer connection terminal strip connections. See
connection terminal strip. Connect alarms, battery Figure 10-31 and Figure 10-32 for accessory
chargers, remote switches, and other accessories to the connection wiring diagrams.
dry contact kit relay(s).
TOP OF CONTROLLER BACK PANEL
2
4
GM16088A-A/GM10193B-A
1. TB1 terminal strip 4. TB4 terminal strip
2. TB2 terminal strip 5. P23 Connector
3. TB3 terminal strip
Figure 10-27 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
Term. Description
Term. Description
1 DCH1 Battery charger fault
1 Remote start (3)
2 Remote start (4) 2 DCH2 Low fuel
3 Emergency stop ground (1) 3 DCH3 Low coolant temp. with ECM models or
4 Emergency stop (1A) warning default with non-ECM models
4 DCH4 Field over voltage with M4/M5/M7/M10
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7/M10 alternators
Term. Description 5 DCH5 Breaker closed, paralleling applications
1 ACH1 Signal 6 DCH6 VAR/PF
2 ACH1 Supply 7 DCH7 Base load mode
3 ACH2 Signal 8 DCH8 I/E mode
4 ACH2 Supply 9 DCH9 Low fuel shutdown (GM only)
5 ACH3 Signal 10 DCH10 Load enable
6 ACH3 Supply 11 DCH11 Synch auto, paralleling applications
7 ACH4 Signal
12 DCH12 Synch permissive, paralleling applications
8 ACH4 Supply
13 DCH13 Synch check test
9 ACH5 Signal
10 ACH5 Supply 14 DCH14 Low coolant level
11 ACH6 Signal 15 DCH15 Remote shutdown
12 ACH6 Supply 16 DCH16 Remote reset
13 ACH7 Signal (optional analog voltage adjust signal) 17 DCH17 Voltage lower
14 ACH7 Supply 18 DCH18 Voltage raise
15 N/C 19 DCH19 Speed lower
16 ACH1 Return 20 DCH20 Speed raise
17 ACH1 Shield ground 21 DCH21 Breaker tripped
23 ACH4 Shield ground
27 DCH6 Return
24 ACH5 Return
30 N/C 33 DCH12 Return
34 DCH13 Return
35 DCH14 Return
TB3 Terminal Strip—Accessory Power Output
36 DCH15 Return
Connections
37 DCH16 Return
Term. Description 38 DCH17 Return
4 Fused battery (+) (42A) (5 amp) 42 DCH21 Return
7 Battery (--)
8 Battery (--) Note: TB4-1 through TB4-21 are user definable with
9 Battery (--) factory defaults listed. Terminals TB4-3 and TB4-4
10 Battery (--) have different functions depending upon the
11 Battery (--) generator set configuration. See comments above.
12 Panel lamp output See Menu 9—Input Setup for changing inputs.
Figure 10-28 Controller Terminal Strip Identification

GM13984-
Figure 10-29 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Customer Connection Terminal Strip
TB6 Terminal Strip—RDOs 1--7 TB9 Terminal Strip—RDOs 24--31

Term. Description Term. Description
42A Battery (+) RDO24 Defined common warning
GND Battery (--) RDO25 Common load shed
N/C RDO26 Missing PGEN node
RDO1 System ready (lead 60) RDO27 In synch
RDO2 Emergency stop (lead 48) RDO28 Circuit breaker common fault
RDO3 Defined common fault (lead 32A) RDO29 Common protective relay output
RDO4 Time delay engine cooldown (TDEC) (lead 70C) RDO30 Close breaker
RDO5 Low fuel (lead 63) RDO31 Breaker trip
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low coolant temperature warning (lead 35) 4 Remote start
TB7 Terminal Strip—RDOs 8--17

Term. Description Note:Lead numbers shown in parentheses are the factory
RDO8 Low coolant level default wire designations.
RDO9 Low oil pressure warning (lead 41)
RDO10 NFPA 110 common alarm faults (lead 32)* Note:RDO-1 though RDO-31 are user definable with the
RDO11 Low battery voltage (lead 62) following factory defaults: emergency stop, high coolant
RDO12 Battery charger fault (lead 61)
temperature, low oil pressure, overcrank, and overspeed
RDO13 Maintenance due
RDO14 Over current
RDO15 Delay engine start *NFPA-110 common alarm faults typically include:
RDO16 Starting aid Air damper indicator
RDO17 Ground fault Battery charger fault (RDO--12)
EPS supplying load (RDO--18)
TB8 Terminal Strip—RDOs 18--23 High battery voltage
Term. Description High coolant temperature warning (RDO--06)
42A Battery (+) High coolant temperature shutdown
42A Battery (+) Low battery voltage (RDO--11)
GND Battery (--) Low coolant level (RDO--08)
GND Battery (--) Low coolant temperature warning (RDO--07)
RDO18 EPS supplying load Low fuel (level or pressure) (RDO--05)
RDO19 Alternator protection shutdown Low oil pressure warning (RDO--09)
RDO20 Engine derate active Low oil pressure shutdown
RDO21 Key switch locked Master switch not in auto (RDO--23)
RDO22 Generator running (lead 70R) Overcrank
RDO23 Master switch not in auto ( lead 80) Overspeed
Figure 10-30 Controller Customer Connection Terminal Strip Identification with Relay Driver Outputs (RDOs)

Figure 10-31 Accessory Connections GM78247B-D
Figure 10-32 Accessory Connections GM78247C-D
Section 11 Remote Adjustment/Control Systems
This section provides information about changes and

WARNING
adjustments when the system involves remote
starting/control systems, voltage regulation, and
paralleling generator set applications. Use the
respective switchgear literature as supplied with the
unit. Some of the items mentioned are available
generator set accessories. Hazardous voltage. Moving parts.
Before installing the generator set, provide for electrical Operate the generator set only when
connections through conduit to the transfer switch and all guards and electrical enclosures
other accessories for the generator set. Carefully install are in place.
the selected generator set accessories. Route wiring to
the generator set through flexible connections. Comply Short circuits. Hazardous voltage/current can cause
with all applicable codes when installing a wiring severe injury or death. Short circuits can cause bodily injury
system. and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
See Section 7, Electrical System for additional wiring repairs. Remove all jewelry before servicing the equipment.
information.
11.1 Automatic Transfer Switches
WARNING
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
Accidental starting. normal power source and then signals the generator set
Can cause severe injury or death. to stop.
Disconnect the battery cables before
working on the generator set. The transfer switch uses a set of contacts to signal the
Remove the negative (--) lead first engine/generator to start. When the normal source fails
when disconnecting the battery. and the generator set master switch is in the AUTO
Reconnect the negative (--) lead last position, the transfer switch contacts close to start the
when reconnecting the battery. generator set.
Disabling the generator set. Accidental starting can The engine start terminals are usually located near the
cause severe injury or death. Before working on the transfer switch contactor with an engine start decal
generator set or equipment connected to the set, disable the identifying the terminals. Refer to the transfer switch
generator set as follows: (1) Turn the generator set master decal, operation/installation manual, or wiring diagram
switch and switchgear engine control switch to the OFF manual to identify the engine start terminals prior to
position. (2) Disconnect the power to the battery charger. making connections.
(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
generator set or connected equipment, disable the generator
OFF position. (2) Disconnect the power to the battery
the battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
computer.
TP-5700 1/13 Section 11 Remote Adjustment/Control Systems 115

Make connections to the transfer switch engine-start 11.5 Reactive Droop Compensator
terminals and remote manual engine-start switch using
wire run through conduit. Use separate conduits for The reactive droop compensator is used to distribute the
engine-start leads, generator set load cables, battery load evenly when two generator sets are used in
charger leads, and remote annunciator wiring. parallel. A qualified electrician or technician should
install these kits. See Figure 11-1 and Figure 11-2.
Use a minimum of 13 mm (0.5 in.) spacing between the Additional generator set connections are shown in
conduit bushing and any uninsulated live parts in the Figure 11-17 through Figure 11-20.
ATS enclosure. All conduit openings in the ATS
enclosure must be made such that no metal particles
including drill chips contaminate the components in the
ATS enclosure.
11.2 Decision-Makerr 550

Controller, Voltage Regulator
and Paralleling Applications
The controller has a voltage regulation function that is
internal to the processor.
See the Decision-Makerr 550 Controller Operation

Manual for further details regarding voltage adjustment
and paralleling operation setup.
11.3 Decision-Makerr 3000

Controller Voltage Regulator
The controller has a voltage regulation function that is
See the Decision-Makerr 3000 Controller and

SiteTecht Operation Manuals for further details Notes: Current transformer dot or “HI”
toward generator except as noted for
regarding voltage adjustment setup. optional droop C.T. 1 phase connections.
The 380 volt, 480 volt, and 600 volt
generator sets require two turns of output
leads through current transformer. All
11.4 Decision-Makerr 6000 others require one turn of output leads
through current transformer.
Controller Voltage Regulator Phase Rotation:

A B C
L1 L2 L3
and Paralleling Applications DC-273000-U
The controller has a voltage regulation function that is Figure 11-1 Generator Set Connections
See the Decision-Makerr 6000 Controller,

Decision-Makerr Paralleling (DPS), and SiteTecht
Operation Manuals for further details regarding voltage
adjustment and paralleling operation setup.
116 Section 11 Remote Adjustment/Control Systems TP-5700 1/13

X-467-4 (Rheostat)
283869 (Nameplate)
Note: Position locating ring
or rheostat so terminals are
in the 6 o’clock position as
Wiring Instructions: shown. Nameplate is located
1. Remove lead connecting TB4-V8 & (black) on front of rheostat.
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
GM39328-A
Figure 11-2 Wiring Diagram
Test Procedure b. Observe the voltmeter on unit #1 with the

reactive droop rheostat set at minimum. As the
To test and adjust the reactive droop compensator, rheostat is turned clockwise, the voltmeter
proceed as follows. Read the entire procedure before should show a decrease in voltage. If a larger
beginning. voltage is obtained when the reactive droop
rheostat is turned clockwise, shut down the
1. With the reactive droop rheostat set at minimum
system and reverse the direction of the
(full counterclockwise position), record the rpm or
generator load line through the current
frequency and voltage at 1/4 load steps to full load
transformer, or reverse the transformer leads.
on unit #1. Repeat Step 1 for unit #2.
Recheck the droop.
2. Compare the readings and make final adjustments
c. Adjust the reactive droop rheostat to a value at
so that the voltage is within 1 volt at each load step
approximately 4% below rated voltage at full
and the speed is within 3 rpm or the frequency is
load. As an example, the voltage will droop
within 0.1 Hz for each unit. Adjust the voltage using
(decrease) 19.2 volts on a 480-volt system at
the local or remote voltage adjusting potentiometer.
full load or 9.6 volts at 1/2 load. To determine
Adjust the speed at the governor or at the remote
voltage droop at other than full load, use the
speed adjusting potentiometer.
following formula:
3. Check the droop compensation on each unit as
Rated Voltage x 0.04 x Actual Load
follows:
(expressed as a percent of full load)
a. With unit #1 operating at the correct speed and = Voltage Droop
voltage, apply a lagging power factor load. This
Note: With full load 0.8 power factor, a droop
load should preferably be 1/2 to full load and
of 3%-5% should be adequate for
must be inductive, as resistance loads cannot
paralleling.
be used.

d. Repeat Steps 3 a., b., and c. for unit #2 and be reduce the current of the unit(s) that has the
certain the amount of voltage droop is equal at highest reading. Adjust the rheostat to
the same load point as on unit #1. increase current on the unit(s) with the lower
reading. Continue making minor adjustments
e. With this procedure, the two units will share until each unit supplies current proportional to
reactive currents proportionately. its capacity as a proportion of the total system
capacity.
4. In addition to Steps 1-3, it is desirable to use the
following procedure to check that the units are c. As a result of performing Steps 4 a. and b., the
sharing the reactive load correctly. governors have been adjusted to balance the
load and the reactive droop rheostat has been
a. Parallel the units at 1/2 to full load. Check the adjusted to balance the current. These settings
wattmeters to determine that each unit is would be optimum for parallel operation.
carrying equal kW load or a load proportional to
its capacity. If the loads are incorrect, adjust Note: The voltage must droop on lagging
and recheck the governor throttle control to power factor loads (inductive loads). A
correctly balance loading. Engine speed will little change in voltage is acceptable on
determine load sharing ability. unity power factor loads (resistive
loads).
Note: Use wattmeters, not ammeters, to verify
load balance.
11.6 Remote Speed Adjustment
b. With the load balanced, check the ammeters to
see that equal current is being produced or the This kit provides remote engine speed adjustments with
current is proportional according to capacity of an approximate range of ±5% at 1800 rpm. This kit
each generator set. If the currents are requires a generator set with an electronic governor.
incorrect, adjust the reactive droop rheostat to See Figure 11-3 and Figure 11-4.
USE GM30860 BRACKET USE GM30860 BRACKET EXISTING

USE GM30860 BRACKET
Note: Dimensions shown in mm AS TEMPLATE FOR DRILLING AS TEMPLATE FOR AS TEMPLATE FOR TERMINAL BLOCK
2X 6.40 HOLES DRILLING DRILLING
2X 6.40 HOLES
2X 6.40 HOLES
C.T. TERMINAL
254.0 REF. BLOCK
(INSIDE OF J--BOX) VOLTAGE
SEE DETAIL D
102.0 REF.
REGULATOR
SEE DETAIL D
305.0 REF.
76.2 REF.
EXISTING TERMINAL 123456

BLOCK
(INSIDE OF J--BOX)
GM30862 DECAL,
SPEED ADJUST
76.2 REF. EXISTING TERMINAL
SEE DETAIL D BLOCK 76.2 REF.
GM30860
VIEW B--B
38.0 REF.
VIEW A--A VIEW C--C

GM31213
JUNCTION A
BOX B
RELAY PANEL
C C
A LO
M933--06014--60 (2) EXP

M6923--06--80 (2) EXP
B
DETAIL D
(INSIDE OF BOX)
230--300 KW 350--400 KW 450--2000 KW

GM30859-A
Figure 11-3 Remote Speed Potentiometer Installation

To program the 550 controller, MDEC-equipped DDC/
MTU engines only, use the following instructions. See
the 550 controller operation manual for further
2 1
information, if necessary.
1
WHT
3
RED
BLK
1. Go to Menu 14—PROGRAMMING MODE to
enable LOCAL programming.
2. Go to Menu 7—GENERATOR SYSTEM.

WHT
WHT
RED
RED
BLK
BLK
3. Press MENU Down # Key to access ENABLE VSG
(variable governor speed) data.
1 2 3 4 5 6 1 2 3 4 5 6
4. Press the YES Key.
953
916
510
952
510
952
7
*
2 2 5. Press the ENTER z Key to confirm entry.
6. Verify ENABLE VSG code YES appears on the

See Notes
display.
3 3
7. Go to Menu 14—PROGRAMMING MODE to
DDEC MDEC
CONNECTIONS CONNECTIONS change to programming mode OFF.
Notes: GM30859-A
• 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.
1. GM31213 potentiometer assembly ref.

2. Existing terminal block
3. Existing engine wiring harness
Figure 11-4 Remote Speed Adjusting Control Wiring

Diagram

11.7 Remote Speed Adjustment 11.8 Remote Voltage Adjustment
Potentiometer Kit (Non-ECM This kit provides the ability to fine adjust the generator
Models) output voltage from a remote location. Use this kit on
20--300 kW 16-light controller models. The maximum
The remote speed adjustment potentiometer kit recommended wire length from the potentiometer to the
provides controller-mounted engine speed adjustment. generator set is 15 ft. (4.6 m); 18-gauge twisted pair
The adjustment range is approximately ±5%. Some wire is recommended. Use a remote voltage regulator
applications locate this potentiometer with the kit if further distance is required. See Figure 11-6 and
switchgear. This kit requires an electronic governor on Figure 11-7.
the generator set. See Figure 11-5. See Section 8.2,
Accessory Connections, for terminal identifications.
1
2
3
4
4
6
5
TT-919
3.51 mm (1.38 in.)
1.27 mm (0.50 in.)
∅1.03 mm (0.046 in.)
∅0.48 mm (0.188 in.)
1 ∅0.40 mm (0.156 in.)
BR-273000-C
1. Optional Remote Speed Pot
Figure 11-5 Remote Speed Adjustment

3.35 mm (1.32 in.)
Potentiometer Connection, Typical
6.67 mm (2.625 in.)
TT-941
1. Potentiometer 5. Knob
2. Panel 6. Screw
3. Nameplate 7. Washer
4. Nut
Figure 11-6 Potentiometer Installation

327097-A
Figure 11-7 Disconnection of Controller Voltage Adjusting Potentiometer

11.9 Remote Wiring potentiometer and the voltage regulator is 4.3 m (15 ft.).
See Figure 11-10, Figure 11-11, and Figure 11-12 for
Figure 11-8 is the assembly drawing for the 16-light 20--300 kW models. See Figure 11-13 for 350 kW and
controller and Figure 11-9 is the accessory above models.
interconnection diagram showing the remote wiring for
the 550 controller. Note: A remote voltage adjustment potentiometer kit is
required when relocating the voltage regulator.
11.10 Remote Voltage Regulator Kit

The remote mount voltage regulator kit is recommended
whenever the voltage adjustment potentiometer is
located beyond 4.3 m (15 ft.) from the generator set.
Maximum distance between the generator set and
voltage regulator is 287.4 m (1000 ft.). Maximum GM28631C-B
recommended distance between the voltage adjustment Figure 11-8 16-Light Controller Remote Wiring
GM16088A-F
Figure 11-9 550 Controller Remote Wiring
3
1
141312 1110 9 8 7 6 5 4 3 2 1
7N
14 13 1211 10 9 8 7 6 5 4 3 2
V8
NO. 2 ON MARKER
3B
STRIP MUST BE IN
LINE WITH 7N
5B LEAD ON
V7 TERMINAL BLOCK.
1B
68
67
1. Remote Regulator Mounting Plate Assembly (A-263266) BS-272000-D
2. Regulator Assembly
3. Wiring Harness (273941)
Figure 11-10 Remote Voltage Regulator Kit Installation, 20--300 kW

CONNECTIONS BETWEEN TERMINAL BLOCKS AND TO REMOTE
VOLTAGE ADJUST POTENTIOMETER ARE CUSTOMER SUPPLIED
REMOTE VOLTAGE
SWITCHGEAR ADJUST POTENTIOMETER GENERATOR SET
(BACK VIEW) JUNCTION BOX
1 1
7N 2 2 7N
3 3
3 2 1 V8 4
4 V8
6 5 4
5 5
9 8 7 3 2 1
3B 6 6 3B
12 11 10 6 5 4
7 7
9 8 7 CONNECT TO
8 8 AC HARNESS
12 11 10
5B 9 9 5B
V7 10 10 V7
1B 11 11 1B
12 12
68 13 13
VOLTAGE 67 14 14
REGULATOR
TG2
REMOTE REGULATOR KIT

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
Figure 11-11 Wiring Diagram, 20--300 kW
BS-272000-D
Figure 11-12 Schematic Diagram, 20--300 kW

View C
Connect Between Terminal Block and Voltage Regulator
See View C
See View C
View A View B
GM129340-B
Figure 11-13 Remote Voltage Regulator Kit Installation, 350 kW and Above
11.11 Voltage Regulator

DVR 2000EC/Remote Voltage BF
CADE
Regulator Kit, 350 kW and

Above GND
The DVR 2000E is used with nonparalleling

applications and the DVR 2000EC is used when 1
paralleling is required.
If the voltage configuration is changed, make

adjustments to the DVR 2000 voltage regulator at the
voltage regulator. Remove the junction box cover to
adjust the DVR 2000 voltage regulator. See
Figure 11-14, Figure 11-15, and TP-5579, Operation
GM16780-A
Manual, DVR 2000 Voltage Regulator, for more
information.
1. DVR 2000 voltage regulator
Use Figure 11-15 for installation and troubleshooting of
the electrical wiring system. Figure 11-14 DVR 2000 Voltage Regulator Mounting
Location
DVR 2000t is a trademark of Marathon Electric Mfg. Corp.

Junction Box Legend
PMG -- Permanent Magnet Generator
STAT -- Stator
TB5 -- Controller AC Fuse Block
QCON(#) -- Quick Connect
Generator
GM20500-
Figure 11-15 DVR 2000 Voltage Regulator/Alternator Interconnection Wiring Diagram

11.12 Voltage Regulator, PMG Volt/Hz Potentiometer Adjustment Procedure
If the voltage configuration is changed, use the following This adjustment determines engine speed (Hz) at which
procedure to make adjustments to the voltage regulator alternator output voltage will begin to drop.
used on PMG alternators.
1. Turn generator set master switch to OFF/RESET.
The AVR monitors output voltage magnitude and
2. Turn stability potentiometer fully counterclockwise.
frequency to supply current to the stationary LED board.
The AVR circuit board includes volts/Hz and stability 3. Connect a 100-watt light bulb across terminals V0
adjustment potentiometers. The volts/Hz adjustment is and V7 on controller terminal strip or across
factory-set and normally requires no further adjustment. terminals on controller frequency meter.
If operating the generator set under extreme loads
results in voltage instability, adjust the potentiometers 4. Start generator set. With generator running at no
according to the following procedure. See Figure 11-16. load, observe light bulb flicker. Excessive light bulb
flicker indicates poor stability.
5. Adjust stability potentiometer until minimum flicker

is obtained.
1 6. Use controller voltage adjustment potentiometer
(or remote voltage adjustment potentiometer) to
2
make adjustments to the generator set while
running under normal load (if required).
3
7. Adjust the engine speed to the desired cut-in
frequency (factory setting is 57.5--58.0 Hz for 60 Hz
models or 47.5--48.0 Hz for 50 Hz models) as
measured on frequency meter. See the governor
manual for information on engine adjustment.
8. Rotate the volts/Hz adjustment potentiometer

clockwise until voltage level begins to drop (as
C-255670-B
measured on voltmeter). When set to these
1. 60 Hz voltage adjustment 3. Stability adjustment specifications, the generator set will attempt to
2. 50 Hz voltage adjustment
maintain normal output until engine speed drops
Figure 11-16 AVR Adjustment below the frequency set in the previous step (as
load is applied).
Stability Potentiometer. Fine tunes voltage regulator
to reduce light flicker. 9. Adjust the engine speed to obtain a full load engine
speed of 1800 rpm (60 Hz) or 1500 rpm (50 Hz).
Volt/Hz Potentiometer. This adjustment determines Confirm and adjust the output voltage as needed.
engine speed (Hz) at which generator output voltage will
begin to drop. 10. Use controller voltage adjustment potentiometer
(or remote voltage adjustment potentiometer) to
make final adjustments to the generator set while
running under normal load.
11. Readjust stability potentiometer (if necessary).

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity exh. exhaust
ABDC after bottom dead center CID cubic inch displacement ext. external
AC alternating current CL centerline F Fahrenheit, female
A/D analog to digital cm centimeter fglass. fiberglass
ADC advanced digital control; CMOS complementary metal oxide FHM flat head machine (screw)
analog to digital converter substrate (semiconductor) fl. oz. fluid ounce
adj. adjust, adjustment cogen. cogeneration flex. flexible
ADV advertising dimensional com communications (port) freq. frequency
drawing coml commercial FS full scale
Ah amp-hour Coml/Rec Commercial/Recreational ft. foot, feet
AHWT anticipatory high water conn. connection ft. lb. foot pounds (torque)
temperature cont. continued ft./min. feet per minute
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride ftp file transfer protocol
Institute crit. critical g gram
ALOP anticipatory low oil pressure CRT cathode ray tube ga. gauge (meters, wire size)
alt. alternator CSA Canadian Standards gal. gallon
Al aluminum Association gen. generator
ANSI American National Standards CT current transformer
Institute (formerly American genset generator set
Cu copper GFI ground fault interrupter
Standards Association, ASA)
cUL Canadian Underwriter’s
AO anticipatory only Laboratories GND, ground
APDC Air Pollution Control District CUL Canadian Underwriter’s gov. governor
API American Petroleum Institute Laboratories gph gallons per hour
approx. approximate, approximately cu. in. cubic inch gpm gallons per minute
AQMD Air Quality Management cw. clockwise gr. grade, gross
District CWC city water-cooled GRD equipment ground
AR as required, as requested cyl. cylinder gr. wt. gross weight
AS as supplied, as stated, as D/A digital to analog HxWxD height by width by depth
suggested HC hex cap
DAC digital to analog converter
ASE American Society of Engineers HCHT high cylinder head
dB decibel
ASME American Society of temperature
Mechanical Engineers dB(A) decibel (A weighted)
DC direct current HD heavy duty
assy. assembly HET high exhaust temp., high
ASTM American Society for Testing DCR direct current resistance
engine temp.
Materials deg., ° degree
dept. department hex hexagon
ATDC after top dead center Hg mercury (element)
ATS automatic transfer switch DFMEA Design Failure Mode and
Effects Analysis HH hex head
auto. automatic HHC hex head cap
aux. auxiliary dia. diameter
DI/EO dual inlet/end outlet HP horsepower
avg. average hr. hour
AVR automatic voltage regulator DIN Deutsches Institut fur
Normung e. V. (also Deutsche HS heat shrink
AWG American Wire Gauge Industrie Normenausschuss) hsg. housing
AWM appliance wiring material DIP dual inline package HVAC heating, ventilation, and air
bat. battery DPDT double-pole, double-throw conditioning
BBDC before bottom dead center DPST double-pole, single-throw HWT high water temperature
BC battery charger, battery DS disconnect switch Hz hertz (cycles per second)
charging IC integrated circuit
DVR digital voltage regulator
BCA battery charging alternator ID inside diameter, identification
E, emer. emergency (power source)
BCI Battery Council International IEC International Electrotechnical
ECM electronic control module,
BDC before dead center engine control module Commission
BHP brake horsepower EDI electronic data interchange IEEE Institute of Electrical and
blk. black (paint color), block EFR emergency frequency relay Electronics Engineers
(engine) IMS improved motor starting
e.g. for example (exempli gratia)
blk. htr. block heater in. inch
EG electronic governor
BMEP brake mean effective pressure in. H2O inches of water
EGSA Electrical Generating Systems
bps bits per second Association in. Hg inches of mercury
br. brass EIA Electronic Industries in. lb. inch pounds
BTDC before top dead center Association Inc. incorporated
Btu British thermal unit EI/EO end inlet/end outlet ind. industrial
Btu/min. British thermal units per minute EMI electromagnetic interference int. internal
C Celsius, centigrade emiss. emission int./ext. internal/external
cal. calorie eng. engine I/O input/output
CAN controller area network EPA Environmental Protection IP iron pipe
CARB California Air Resources Board Agency ISO International Organization for
CB circuit breaker EPS emergency power system Standardization
cc cubic centimeter ER emergency relay J joule
CCA cold cranking amps ES engineering special, JIS Japanese Industry Standard
ccw. counterclockwise engineered special k kilo (1000)
CEC Canadian Electrical Code ESD electrostatic discharge K kelvin
cert. certificate, certification, est. estimated kA kiloampere
certified E-Stop emergency stop KB kilobyte (210 bytes)
cfh cubic feet per hour etc. et cetera (and so forth)
cfm cubic feet per minute
TP-5700 1/13 Appendix 127

KBus Kohler communication MW megawatt rnd. round
protocol mW milliwatt ROM read only memory
kg kilogram μF microfarad rot. rotate, rotating
kg/cm2 kilograms per square N, norm. normal (power source) rpm revolutions per minute
centimeter NA not available, not applicable RS right side
kgm kilogram-meter nat. gas natural gas RTU remote terminal unit
kg/m 3 kilograms per cubic meter NBS National Bureau of Standards RTV room temperature
kHz kilohertz NC normally closed vulcanization
kJ kilojoule NEC National Electrical Code RW read/write
km kilometer NEMA National Electrical SAE Society of Automotive
kOhm, kΩ kilo-ohm Manufacturers Association Engineers
kPa kilopascal NFPA National Fire Protection scfm standard cubic feet per minute
kph kilometers per hour Association SCR silicon controlled rectifier
kV kilovolt Nm newton meter s, sec. second
kVA kilovolt ampere NO normally open SI Systeme international d’unites,
kVAR kilovolt ampere reactive no., nos. number, numbers International System of Units
kW kilowatt NPS National Pipe, Straight SI/EO side in/end out
kWh kilowatt-hour NPSC National Pipe, sil. silencer
kWm kilowatt mechanical Straight-coupling SN serial number
kWth kilowatt-thermal NPT National Standard taper pipe SNMP simple network management
L liter thread per general use protocol
LAN local area network NPTF National Pipe, Taper-Fine SPDT single-pole, double-throw
L x W x H length by width by height NR not required, normal relay SPST single-pole, single-throw
lb. pound, pounds ns nanosecond spec specification
lbm/ft3 pounds mass per cubic feet OC overcrank specs specification(s)
LCB line circuit breaker OD outside diameter sq. square
LCD liquid crystal display OEM original equipment sq. cm square centimeter
ld. shd. load shed manufacturer sq. in. square inch
LED light emitting diode OF overfrequency SS stainless steel
Lph liters per hour opt. option, optional std. standard
Lpm liters per minute OS oversize, overspeed stl. steel
LOP low oil pressure OSHA Occupational Safety and tach. tachometer
Health Administration TD time delay
LP liquefied petroleum
OV overvoltage TDC top dead center
LPG liquefied petroleum gas
oz. ounce TDEC time delay engine cooldown
LS left side
p., pp. page, pages TDEN time delay emergency to
Lwa sound power level, A weighted
PC personal computer normal
LWL low water level
PCB printed circuit board TDES time delay engine start
LWT low water temperature
pF picofarad TDNE time delay normal to
m meter, milli (1/1000)
PF power factor emergency
M mega (106 when used with
SI units), male ph., ∅ phase TDOE time delay off to emergency
m3 cubic meter PHC Phillipsr head Crimptiter TDON time delay off to normal
(screw) temp. temperature
m3/hr. cubic meters per hour
PHH Phillipsr hex head (screw) term. terminal
m3/min. cubic meters per minute
PHM pan head machine (screw) THD total harmonic distortion
mA milliampere
PLC programmable logic control TIF telephone influence factor
man. manual
PMG permanent magnet generator TIR total indicator reading
max. maximum
pot potentiometer, potential tol. tolerance
MB megabyte (220 bytes)
ppm parts per million turbo. turbocharger
MCCB molded-case circuit breaker
PROM programmable read-only typ. typical (same in multiple
MCM one thousand circular mils memory locations)
meggar megohmmeter psi pounds per square inch UF underfrequency
MHz megahertz psig pounds per square inch gauge UHF ultrahigh frequency
mi. mile pt. pint UL Underwriter’s Laboratories,
mil one one-thousandth of an inch PTC positive temperature Inc.
min. minimum, minute coefficient UNC unified coarse thread (was NC)
misc. miscellaneous PTO power takeoff UNF unified fine thread (was NF)
MJ megajoule PVC polyvinyl chloride univ. universal
mJ millijoule qt. quart, quarts US undersize, underspeed
mm millimeter qty. quantity UV ultraviolet, undervoltage
mOhm, mΩ milliohm R replacement (emergency) V volt
MOhm, MΩmegohm power source VAC volts alternating current
MOV metal oxide varistor rad. radiator, radius VAR voltampere reactive
MPa megapascal RAM random access memory VDC volts direct current
mpg miles per gallon RDO relay driver output VFD vacuum fluorescent display
mph miles per hour ref. reference VGA video graphics adapter
MS military standard rem. remote VHF very high frequency
ms millisecond Res/Coml Residential/Commercial W watt
m/sec. meters per second RFI radio frequency interference WCR withstand and closing rating
MTBF mean time between failure RH round head w/ with
MTBO mean time between overhauls RHM round head machine (screw) w/o without
mtg. mounting rly. relay wt. weight
MTU Motoren-und Turbinen-Union rms root mean square xfmr transformer
128 Appendix TP-5700 1/13

Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.
Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.
See Appendix C, General Torque Specifications, and 3. Follow these SAE washer rules after determining
other torque specifications in the service literature. exit hole type:
a. Always use a washer between hardware and a

Preferred Nut/Bolt Clearance slot.
1 2 b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female

thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3 2
1
3
G-585
1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
5
4
6
G-585
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications

Assembled into
Assembled into Cast Iron or Steel
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
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 (18) 38 (28) 53 (39)
3/8-24 Nm (ft. lb.) 27 (20) 42 (31) 60 (44)
7/16-14 Nm (ft. lb.) 39 (29) 60 (44) 85 (63)
7/16-20 Nm (ft. lb.) 43 (32) 68 (50) 95 (70) See Note 3
1/2-13 Nm (ft. lb.) 60 (44) 92 (68) 130 (96)
1/2-20 Nm (ft. lb.) 66 (49) 103 (76) 146 (108)
9/16-12 Nm (ft. lb.) 81 (60) 133 (98) 187 (138)
9/16-18 Nm (ft. lb.) 91 (67) 148 (109) 209 (154)
5/8-11 Nm (ft. lb.) 113 (83) 183 (135) 259 (191)
5/8-18 Nm (ft. lb.) 128 (94) 208 (153) 293 (216)
3/4-10 Nm (ft. lb.) 199 (147) 325 (240) 458 (338)
3/4-16 Nm (ft. lb.) 222 (164) 363 (268) 513 (378)
1-8 Nm (ft. lb.) 259 (191) 721 (532) 1109 (818)
1-12 Nm (ft. lb.) 283 (209) 789 (582) 1214 (895)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into
Assembled into Cast Iron or Steel
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15 (11) 23 (17) 33 (24)
M8 x 1.00 16 (11) 24 (18) 34 (25)
M10 x 1.50 30 (22) 45 (34) 65 (48)
M10 x 1.25 31 (23) 47 (35) 68 (50)
M12 x 1.75 53 (39) 80 (59) 115 (85)
M12 x 1.50 56 (41) 85 (63) 122 (90)
M14 x 2.00 83 (61) 126 (93) 180 (133)
M14 x 1.50 87 (64) 133 (98) 190 (140)
M16 x 2.00 127 (94) 194 (143) 278 (205)
M16 x 1.50 132 (97) 201 (148) 287 (212)
M18 x 2.50 179 (132) 273 (201) 390 (288) See Note 3
M18 x 1.50 189 (140) 289 (213) 413 (305)
M20 x 2.50 245 (181) 374 (276) 535 (395)
M20 x 1.50 264 (195) 402 (297) 576 (425)
M22 x 2.50 332 (245) 507 (374) 725 (535)
M22 x 1.50 351 (259) 535 (395) 766 (565)
M24 x 3.00 425 (314) 649 (479) 928 (685)
M24 x 2.00 447 (330) 682 (503) 976 (720)
M27 x 3.00 — 937 (692) 1341 (990)
M27 x 2.00 — 985 (727) 1409 (1040)
M30 x 3.50 — 1278 (943) 1829 (1350)
M30 x 2.00 — 1349 (996) 1931 (1425)
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.

Appendix D Fuel Physical Properties
Physical Property Manufactured

@ 15°C (60°F) Butane Propane Natural Gas or Sewage Gas Gasoline Diesel Fuel
Normal atmospheric
state Gas Gas Gas Gas Liquid Liquid
Boiling point,
Initial, °C (°F) — — — — 36 (97) 177 (350)
End, °C (°F) 0 (32) 42 (--44 ) --162 (--259) — 216 (420) 357 (675)
Heating value, Btu
/gal. (net, LHV*) 94670 83340 63310 — 116400 130300
/gal. (gross) 102032 91500 — — 124600 139000
/ft3 (gas) 3264 2516 1000 600--700 6390 —
Density,
Ft3 of gas/gal. 31.26 36.39 57.75 — 19.5 —
Wt./gal. liquid, lb. 4.81 4.24 2.65 — 6.16 7.08
Octane Number
Research 94 110+ 110+ — 80--100 —
Motor 90 97 — — 75--90 —
* Lower Heating Value
Figure 3 Engine Fuels, Physical Properties
Characteristic, LP Gas* Butane Propane

Formula C4H10 C3H8
Boiling point, °C (°F) 0 (32) --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.3 of vapor at 16°C (60°F)/lb. 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: 31.02 23.86
Ft3 air required to burn 1 ft.3 of gas N/A --104 (--156)
Flash point, °C (°F) 482--538 493--549
Ignition temperature in air, °C (°F) (900--1000) (920--1020)
Max. flame temperature in air, °C (°F) 1991 (3615) 1979 (3595)
Limits of inflammability, percentage of gas in air mixture:
At lower limit, % 1.9 2.4
At upper limit, % 8.6 9.6
Octane Number (ISO-Octane = 100) 92 Over 100
* Commercial quality. Figures shown in this chart represent average values.
Figure 4 Additional LP Gas Characteristics

Appendix E Gas Fuel Vapor Pressures
14.06 kg/cm2 (200 psi)
12.65 kg/cm2 (180 psi)
11.25 kg/cm2 (160 psi)
9.84 kg/cm2 (140 psi)
8.44 kg/cm2 (120 psi)

Pressure
7.03 kg/cm2 (100 psi)
5.62 kg/cm2 (80 psi)
4.22 kg/cm2 (60 psi)
2.81 kg/cm2 (40 psi)
1.41 kg/cm2 (20 psi)
0 kg/cm2 (0 psi)
--40°C --28°C --18°C --7°C 4°C 15°C 27°C 38°C
(--40°F) (--20°F) (0°F) (20°F) (40°F) (60°F) (80°F) (100°F)
Temperature
Figure 1 Vapor Pressures of LP Gases Graph
Approximate Pressure, kg/cm2 (PSIG)

Temperature, 50/50
°C (°F) Propane Mixture Butane
--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 Vapor Pressures of LP Gases Table

Appendix F Gas Fuel System Installation Planning
Determining Propane Cylinder Determining Propane Vaporization

Quantity Capacity
Guide for Installing 100 lb. Cylinders Guide for ASME LP Gas Storage
Containers
For continuous draws where temperatures may reach
--18°C (0°F). Assume the vaporization rate of 100 lb.
cylinder as approximately 50000 Btu/hr. % of Propane* Vaporization
Container K Capacity at --18°C (0°F) in
Number of cylinders/side = Total load in Btu Filled Equals Btu/Hr.[
50000 60 100 D x L x 100
50 90 D x L x 90
Example:
40 80 D x L x 80
Assume total load = 20000 Btu/hour. 30 70 D x L x 70
20 60 D x L x 60
Cylinders/side = 20000 = 4 cylinders/side
50000 10 45 D x L x 45
* These formulae allow for the temperature of the liquid to
The chart in Figure 1 shows the vaporization rate of refrigerate to --29°C (--20°F), producing a temperature
differential of --7°C (20°F) for the transfer of heat from the air
containers in terms of the temperature of the liquid and
to the container’s wetted surface and then into the liquid. The
the wet surface area of the container. When the vapor space area of the vessel is not considered since its
temperature is lower or if the container contains less effect is negligible.
liquid, the vaporization rate of the container is a lower [ D=outside diameter in inches
L=overall length in inches
value. K=constant for percent volume of liquid in container.
Figure 2 Propane Vaporization Capacity

Maximum Continuous Draw In Btu/Hour At
Various Temperatures In °C (°F)
Lb. of
Propane --18°C --7°C 4°C 16°C 21°C Vaporizing Capacities for Other Air
in Cyl. (0°F) (20°F) (40°F) (60°F) (70°F) Temperatures
100 113000 167000 214000 277000 300000
Multiply the results obtained with the formulae in
90 104000 152000 200000 247000 277000 Figure 2 by one of the factors in the following table for
80 94000 137000 180000 214000 236000 the prevailing air temperature.
70 83000 122000 160000 199000 214000
60 75000 109000 140000 176000 192000 Prevailing Air
50 64000 94000 125000 154000 167000 Temperature Multiplier
40 55000 79000 105000 131000 141000 --26°C (--15°F) 0.25
30 45000 66000 85000 107000 118000 --23°C (--10°F) 0.50
20 36000 51000 68000 83000 92000 --21°C (--5°F) 0.75
10 28000 38000 49000 60000 66000 --18°C (0°F) 1.00
--15°C (5°F) 1.25
Figure 1 Vaporization Rate, 100 lb. Propane
Cylinders, Approximate --12°C (10°F) 1.50
--26°C (15°F) 1.75
--7°C (20°F) 2.00
Figure 3 Propane Vaporization Temperature

Appendix G Wiring Diagrams
Description Wiring Diagram

Voltage Reconnection ADV-5875A-M
ADV-5875B-M
ADV-5875C-M
ADV-5875D-M
Remote Serial Annunciator (RSA II) GM62554A-G
GM62554B-G
GM62554C-G
GM62554D-G
GM62554E-G

Figure 11-17 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-M

Figure 11-18 20--300 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-M

Figure 11-19 60 (with Oversize Alternator)--300 kW Wound Field Alternators, ADV-5875C-M

Figure 11-20 350--3250 kW Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-M

Figure 11-21 RSA Wiring Connections GM62554A-G
Figure 11-22 RSA Wiring Connections GM62554B-G
Figure 11-23 RSA Wiring Connections GM62554C-G
Figure 11-24 RSA Wiring Connections GM62554D-G
Figure 11-25 RSA Wiring Connections GM62554E-G
Notes

Notes
TP-5700 1/13 145

Notes
146 TP-5700 1/13

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, 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
TP-5700 1/13p 7 Jurong Pier Road
Singapore 619159
E 2001, 2006, 2007, 2008, 2011, 2012, 2013 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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Installation

Industrial Generator Sets

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Model Designation Manufacturer

Accessory Number Accessory Description

TP-5700 1/13 Table of Contents 3

4 Table of Contents TP-5700 1/13

TP-5700 1/13 Table of Contents 5

6 Table of Contents TP-5700 1/13

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-5700 1/13 Safety Precautions and Instructions 7

Fire. The exhaust system must be

8 Safety Precautions and Instructions TP-5700 1/13

TP-5700 1/13 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-5700 1/13

Hot engine and exhaust system. NOTICE

TP-5700 1/13 Safety Precautions and Instructions 11

12 Safety Precautions and Instructions TP-5700 1/13

Information in this publication represents data available

For professional advice on generator set power China

TP-5700 1/13 Introduction 13

14 Service Assistance TP-5700 1/13

1. Exhaust thimble (for wall or ceiling) 6. Mounting base

Figure 1-1 Typical Stationary-Duty Generator Set Installation

TP-5700 1/13 Section 1 General 15

D UL 2200 Stationary Engine Generator Assemblies

16 Section 1 General TP-5700 1/13

The loading and transporting processes expose the

D Check the alignment of the radiator and supports to

TP-5700 1/13 Section 2 Loading and Transporting 17

Single Spreader Bar and Hook Method

Double Spreader Bar and Hook Method

Single Spreader Bar and Skid Lifting Bar Method

Refer to Figure 2-4.

Figure 2-3 Double Spreader Bar and Hook Method

Figure 2-2 Single Spreader Bar and Hook Method

Figure 2-4 Single Spreader Bar and Skid Lifting Bar

18 Section 2 Loading and Transporting TP-5700 1/13

Figure 2-6 Fuel Tank with Single Spreader Bar

2.1.4 Lifting the Subbase Fuel Tank

D The subbase fuel tank must have lifting eyes in order

D The subbase fuel tank must be empty. Do not lift a

D Remove any vent piping longer than 1 m (3.3 ft.) from

Fuel Tank with Double Spreader Bar Method

Refer to Figure 2-7.

TP-5700 1/13 Section 2 Loading and Transporting 19

Enclosure Attached Directly to the Generator Set

Do not attach hoisting equipment to the enclosure.

Generator Set Skid Skid Lifting Eyes

Do not attach hoisting equipment to the enclosure.

Enclosure Attached to the Enclosure Base and

Figure 2-10 Typical Enclosure Attached to the

20 Section 2 Loading and Transporting TP-5700 1/13

Hoisting using Four Eye Lifting Method

Apply the same lifting methods using single or double

Hoisting using Six Eye Lifting Method

D Check and remove any slack that has developed in

Figure 2-13 Eight Eyes, Two Spreader Bars, and

Figure 2-11 Six Eyes, Single Spreader Bar, and Two