Power Up Your Space with a 50kW Generator Installation

Power Up Your Space with a 50kW Generator Installation

Table of Contents:

1. Introduction
2. Choosing the Location
3. Inspecting the Generator
4. Installing the Generator 4.1. Placing the Generator on a Concrete Pad 4.2. Anchoring the Generator 4.3. Natural Gas or LP Installation
5. Electrical Systems 5.1. Making Electrical Connections 5.2. Wiring System and Connections 5.3. Battery Charger and Heaters 5.4. Control of the Generator Set 5.5. Ethernet Modbus Converter
6. Starting Up the Generator 6.1. Reviewing Safety Warnings 6.2. Going Through the Startup Checklist 6.3. Scheduling a Startup with a Kohler Distributor
7. Conclusion

Installing a Kohler 50 Kilowatt Diesel Generator: A Comprehensive Guide

Introduction

Kohler generators are known for their dependability and long-lasting service. In this article, we will provide a step-by-step guide to installing a Kohler 50 kilowatt diesel generator. We will discuss the factors to consider when choosing the location, how to inspect the generator upon arrival, the installation process, electrical system connections, and the startup procedures. Please note that this article is a general overview and should not replace the installation manual provided by Kohler.

Choosing the Location

The location for your generator is crucial for its optimal performance. It should be placed on a concrete pad at ground level, providing ample clearances and avoiding areas with restricted airflow or excessive dust. If the generator will be installed above ground or on a rooftop, a building engineer should assess the structure's weight-bearing capacity. It's important to review the dimensional drawings and ensure compliance with local codes and permit requirements.

Inspecting the Generator

Before proceeding with the installation, thoroughly inspect the generator for any signs of damage. Take the time to review the safety instructions provided in the installation manual. Familiarize yourself with the generator's size, weight, and specifications mentioned in the dimensional prints. Pay attention to the conduit and fuel line placement for a better understanding of the installation process.

Installing the Generator

4.1 Placing the Generator on a Concrete Pad

When placing the generator, lift the entire enclosure, generator set, and sub-base fuel tank assembly using the provided lifting eyes. Make sure not to attach hoisting equipment to the enclosure base to avoid any damage. Remove the rear panel of the stub-up area for a better view of the stub-up piping on the concrete slab. Move the unit into place and anchor it securely to the concrete using bolts cast into the pad or expansion anchor bolts. Kohler recommends a single-level concrete mounting pad for maximum stability, with a minimum six-inch border around the unit.

4.2 Anchoring the Generator

Ensure the concrete pad's weight exceeds the total weight of the generator package. This is crucial for structural stability. Follow the recommended guidelines for the specific fuel type being used, whether diesel, natural gas or LP. For LP fuel systems, install gas regulators to reduce high volume fuel pressures to levels required by the engine. Refer to the spec sheets for additional details on both vapor withdrawal and liquid withdrawal systems. Importantly, never use fuel piping or fuel line clamps to ground any electrical equipment.

4.3 Natural Gas or LP Installation

For installations using natural gas or LP fuel systems, the setup and location considerations remain similar to those of a diesel generator. Review the safety instructions, dimensional drawings, and lifting specifications accordingly. Follow the manufacturer's guidelines for installing gas regulators and ensure compliance with all codes and regulations.

Electrical Systems

5.1 Making Electrical Connections

Making proper electrical connections is essential for the generator's functionality. Refer to the submitted catalog's accessory drawings and wiring diagrams for detailed instructions. Comply with all applicable electrical codes when installing the wiring system. Follow code requirements for neutral and ground connections, making appropriate connections within the generator junction box.

5.2 Wiring System and Connections

Feed the load leads from the stub-up into the generator junction box, ensuring a minimum spacing of 13 millimeters or 1/2 inch between the conduit bushing and any uninsulated live parts. Ground leads should connect to a copper bus bar on top of the alternator. Depending on the installation requirements, the neutral can remain grounded at the alternator or be lifted from the grounding stud and isolated. Torque the connections on the terminal as per the recommended values mentioned in the installation manual.

5.3 Battery Charger and Heaters

Install and connect the battery, and mount the receptacles for the battery charger, battery heater, and block heater. Separate circuits should cater to the block heater and the battery charger/battery warmer. The engine-driven battery charging alternators charge the starting battery while the generator operates. When the engine is not running, a low charge rate from an AC-powered battery charger is usually sufficient. Consult the dimensional drawings for detailed mounting and specification requirements, especially in cold climates where a battery heater may be necessary.

5.4 Control of the Generator Set

The control of the generator set involves wiring supplied by the customer from the site. Ensure this wiring is separate from the AC power and make the necessary connections to the remote start and dry contact board. The optional Ethernet Modbus converter can also be connected using the provided Ethernet cable.

Starting Up the Generator

6.1 Reviewing Safety Warnings

Before starting up the generator set, thoroughly review the safety warnings provided. Ensure you have gone through the installation checklist and filled out page one completely. Familiarize yourself with the startup checklist provided for the generator set and transfer switch.

6.2 Going Through the Startup Checklist

During the startup process, check the cleanliness and installation of the air cleaner. Ensure unobstructed air inlets, check the fuel level, oil fill, coolant level, and exhaust system for any leaks. Prime the fuel system and place the generator set master switch in the off reset position. The fault lamp should illuminate when the alarm silence button is pressed for a lamp test. Verify battery charging indication, oil pressure, and check for oil, coolant, and exhaust leaks. If everything is in order, place the generator set master switch in the run position.

6.3 Scheduling a Startup with a Kohler Distributor

To ensure a smooth startup and proper functioning of the generator, it is advised to schedule a startup with a local Kohler distributor. They can provide expert guidance and support throughout the process.

Conclusion

Installing a Kohler 50 kilowatt diesel generator requires careful consideration and adherence to safety guidelines and local regulations. This article provided a comprehensive guide covering the location selection, generator inspection, installation process, electrical system connections, and startup procedures. Always refer to the installation manual for detailed instructions and consult a professional if needed.

Highlights:

• Step-by-step guide to installing a Kohler 50 kilowatt diesel generator
• Factors to consider when choosing the location
• Inspection and safety guidelines
• Proper installation process and anchoring
• Electrical system connections and wiring
• Startup checklist and scheduling a startup with a Kohler distributor
• Importance of complying with local codes and regulations

FAQ:

Q: Should I install the generator myself or hire a licensed contractor? A: Installing a Kohler generator should always be done by a licensed contractor to ensure proper installation and compliance with safety regulations.

Q: Can the generator be placed on any surface? A: The ideal location for the generator set is on a concrete pad at ground level. Other surfaces, such as rooftops, require assessment by a building engineer to determine weight support.

Q: How do I make the necessary electrical connections? A: Proper electrical connections should be made as per the instructions provided in the installation manual. Following the wiring diagrams and complying with electrical codes is crucial.

Q: What is the purpose of the battery charger and heaters? A: The battery charger ensures the starting battery remains charged, while the heaters help maintain optimal performance in cold climates.

Q: Do I need to schedule a startup with a Kohler distributor? A: Scheduling a startup with a Kohler distributor is recommended to ensure a smooth startup and proper functioning of the generator. They can provide expert guidance and support.