INSTALLATION GUIDELINES & USER MANNUAL

OVERALL SPECIFICATIONS OF KIRLOSKAR GREEN SILENT GENSETS

Liquid Cooled KGPI- Genset
Genset Model Engine Model Prime Power Overall Canopy Dimensions Approx. Weight
rating at 0.8 with silencer length x width x (with Canopy)
PF (kVA) height (mm) KG
KG30WS-5 3R1040 25/30 2355 X1090 X 1915 1260
KG40WS-1 4R1040 40/45 2655X 1210X 2410 1520
KG50WS 4R1190 50 3100X1270X2100 1500
KG82.5WS-2 4R1040T 62.5 3210X 1110 X 2590 1930
KG82.5WS-2 4R1040TA 82.5 3210X 1110 X 2590 1950
KG100WS 4K1080TA 100 3210 X 1305 X 2670 2500
KG125WS-3 6R1080TA 125 3450 X 1300 X 2480 2700
KG160WS-2 6K1080TA 140 4015X 1505 X 2670 2500
KG160WS-2 6K1080TA 160 4015X 1505 X 2670 2600
KG160WS 6SL9088TA 160 4350 X 1850 X 2050 3720
KG250WS-1 6SL1500TA – I 180 4555 X 1890X 2800 3870
KG250WS-1 6SL1500TA – II 200 4555 X 1890X 2800 3950
KG250WS-1 6SL8800TA 250 4555 X 1890X 2800 4660
KG320WS-3 DV8-I 320 5700 X 2120 X 3445 6000
KG400WS-2 DV8 400 5700 X 2120 X 3445 6000
KG500WS-3 DV10 500 6200 X 2120 X 3440 6655
KG600WS-3 DV12 600 6660 X 2120 X 3598 7500
KG600WS-3 DV12 625 6660 X 2120 X 3598 7500

Air-cooled KGPI - Genset

Genset Model Engine Model Prime Power Overall Canopy Approx.

rating at 0.8 Dimensions with silencer Weight
PF (kVA) length x width x height (with Canopy)
(mm) KG
SEKG6AS7 EA10 5 1610 X 825 X 1930 650
SEKG10AS5 EA16 7.5 2035 X 825X 1930 850
SEKG10AS5 EA16 10 2035 X 825X 1930 850
KG15AS1-C HA294 15 1750 X 1215 X 2235 1220
KG25AS-C HA394 25 1997 X 1185 X 1818 1350
KG35AS HA494 30 2805 X 1225 X 1940 1440
KG35AS HA494 35 2805 X 1225 X1940 1440
KG40AS HA494TC 45 2805 X 1225 X1940 1580
KG50AS HA694 55 3450 X 1320 X 1900 1870
KG70AS HA694TC 70 3450 X 1320 X 1900 1920
 INSTALLATION GUIDELINES & USER MANNUAL

Note :

are subject to change without prior notice. Also refer to latest product catalogue for updates.
r than standard operating conditions, consult Seller or Kirloskar’s Area
Office.

Sizing of KGPI Genset

To select the right generating set under a given set of circumstances, knowledge of generating set and
its performance under various conditions is necessary. It is also equally necessary to understand load
characteristics and to make a load analysis. Beyond that, the effect of the voltage regulation systems
plays an important role.
It is better to select a slightly larger generator capacity than the available load; the reason is that
additional uses are invariably observed after it has been installed. These are usually not predictable. By
having a margin available it is possible to power some loads which may have been overlooked during
Genset selection, or which may be added after the installation of the Genset.

Ratings

The rating of an alternator is expressed either in kilowatt (kW) or kVA. The relation between kW and
kVA rating is kW = kVA x Power Factor
Load variation between phases
kW = 1.732 x V x A x Power Factor (for 3 phase alternator) / 1000 should not be more than 10%
kW = V x A x Power Factor (for a single phase alternator) / 1000 and min 50% load should be
available at the time of
Where V = Line voltage; A = Line current commissioning.

Power Factor

The power factor of electrical system depends upon the nature of characteristics of load e.g Induction
motors, Furnaces, thyristor, power electronics etc. Power Factor is lagging for inductive load. Power
Factor is leading for capacitive load. Power factor is unity for purely resistive loads. Normally, a
generator is designed for a power factor of 0.8 The table below gives power factors of non-motor
loads.

Type of load Power Factor

Incandescent lights 1.00
Heating elements, ovens 1.00
Fluorescent lights 0.90
Induction furnaces 0.60 - 0.70
Arc furnaces 0.80 - 0.90
Welding Set Transformer) 0.60
Welding Set (AC Motor-DC 0.80 - 0.90
Generator)
Transformers 0.80-0.95
 INSTALLATION GUIDELINES & USER MANNUAL

 Load variation between phases should not be more than 10%.

 KVA x 1.39 = AMP per Phase for III phase gen set & KVA X 1.39 x 3 AMP for I phase gen
set at 100% load . Minimum 50% of AMPs per phase is required at the time of commissioning.

Deration Factor
The engine’s horse power as mentioned on its name plate is the HP which an engine can deliver in
MSL at NTP conditions. HP delivered at site will vary depending on site conditions (deration due to
altitude, temperature and humidity). For details of site derations please consult Seller or Kirloskar’s
Area Office.

Input HP (Metric ) = . kW / 0.736 x Alternator Efficiency

Load Calculation

Steps to be followed while sizing the Genset.

Step 1:
Collect all necessary basic data of load. Tabulate the details such as lighting load, motor load, A/C
load, Heaters load etc with quantity and name plate details.
For motor loads, mention starting method also, i.e. Type of starter used.

Step 2 :
(Applicable For Three Phase Genset)
Convert all single phase loads to three phase loads by distributing equally on three phases.

Step 3:
Starting power (kVA) of each equipment is based on type of starting method.
For eg, In case of motors,
- Starting by DOL will pull up to 6 to 7 times the rated full load kW of a motor.
- Star/Delta will pull up to 2 to 3 times the full load kW of the motor.
- Soft Start will pull up to 1.2 to 1.5 times the full load kW of the motor.
Rectifier loads may also pull up to 50% above their rated KVA.

Step 4:
Sum up all the steady state running loads in kVA and sum up all the starting kVA’s. These two figures
will be used to size up the Genset and sequence of loading.

Step 5:
Determine the maximum allowable voltage dip which the Genset should experience when the total
starting KVA is applied on this Genset. This voltage dip percentage is usually known to the customer
based on equipment type to be powered.

Step 6:
The previously obtained figures (Running KVA, Starting KVA, Voltage, Voltage Dip, Loading
sequence) will decide Genset size.
 INSTALLATION GUIDELINES & USER MANNUAL

Installing KGPI Genset:

Location

Dust and Fumes are the greatest danger to generating set as they could lead to clogging of cooling and
air system which may affect Genset performance.

1. If KGPI Genset to be installed in free field condition, please ensure dust free location and clear
space of 2 times of height of Genset.

2. If KGPI Genset to be installed in the room, please ensure proper cross ventilation, clear space of
minimum 3 meters from all sides.

3. If KGPI Genset to be installed on Roof Top, please ensure Structural clearance, proper cross
ventilation with respect to wind direction, clear space of minimum 3 meters from all sides.

4. If KGPI Genset to be installed in basement, ensure ventilation with respect to Air requirement and
clear space for easy maintenance.

Layout

crusher plant, garment plant, cement factory, paint factory, chemical factory, etc. the Genset should be
isolated from the dust, hazardous and chemical fumes contained in the surrounding air.

cleaners (Please contact Seller or KOEL Area office for further guidelines).

arrangement for Genset, follow the local rules and regulations.

o The environment protections
 INSTALLATION GUIDELINES & USER MANNUAL

o The fire protection

alternator.

on requires proper planning and the structural design considerations for dynamic
loading.

for hot surface.

Noise
o There should be sufficient space around the Genset to avoid resonance and echo
effect which contributes to abnormal sound from Genset.
o The space should be open without any obstacles.

Ventilation

through forced ventilation with suitable air ducts.

in table are with lagged exhaust piping in the room and silencer fitted outside the room.

erature rise above ambient in Genset Enclosure at air intake of engine is 7

deg centigrade.

FIG. AIR COOLED GENSET FIG. WATER COOLED GENSET

 INSTALLATION GUIDELINES & USER MANNUAL

Foundation
Foundation is one of the important factor affecting the successful operation and life of a generating set.
Improper foundation may result in alignment and vibration problems which may subsequently lead to
pre-mature failure of Genset Components and Safety.
The basic functions of foundation are as below,
- To provide leveled platform to seat and seal the Genset.
- To support the weight of the entire generating set.
- Support the dynamic load of Genset while in running.
- Absorb the vibration produced by the rotating and reciprocating masses.
- Isolate the surrounding structures by absorbing the vibration of generating set while in running.

FIG. FOUNDATION OF GENSET FIG. CORRECT & INCORRECT FOUNDATION

While casting the concrete foundation, the bearing strength of the soil at site of installation should be
determined. The Table below gives the approximate safe bearing capacity of various soil.

Nature of the load bearing material Safe bearing capacity kg/sq. meter

Hard Rock Granite 2,44,100 – 9,76,400

Medium Rock Shell 97,600 – 1,46,400
Hard Pan 78,100 – 97,600
Soft Rock 48,800 – 58,600
Hard Clay 39,000 – 48,800
Gravel and Corse Sand 39,000 – 48,800
Loose, Medium coarse and Compact fine 29,300 – 39,000
sand
Medium Clay 19,500 – 39,000
Loose Fine Sand 9,750 – 39,500
Soft Clay 9,750

The length and width of foundation should be at least 300 mm more on each side than acoustic
enclosure length and width respectively.

- It is recommended to have foundation height of 150 to 200 mm above ground level to maintain
cleanliness and avoid flooding.
 INSTALLATION GUIDELINES & USER MANNUAL

- Check the foundation level diagonally as well as across the length and width for even flatness and
same should be within + 0.50 in horizontal plane in any one direction only.

- Ensure that the concrete is completely cured before positioning the enclosure.

- Ensure that the foundation to support 1.5 times of the total wet weight of the single generating set
installation and 2 times of the total wet weight for the multiple generating set installations.

- For Rooftop installations, it is necessary to have planning and structural design approval.

Do not install acoustic enclosure on loose sand or clay.

Avoid hard / sharp projections such as stone or steel parts on foundation surface, which may damage
fuel tank at the bottom. Avoid uneven foundation which may lead to improper resting of Genset on
foundation, there by leading to leakage of sound and vibration on Genset.

If Genset to be mounted on foundation having uneven surface under unavoidable circumstances, use
appropriate thickness of Rubber Matting above foundation for positive sealing of Genset with base.

All the Gensets are provided with suitable lifting arrangements.

spreader bar / spacer plate, of suitable capacity to avoid any damage of the D G set.

e acoustic enclosure (Canopy) which provides support to the equipment when it

is moved. This makes it easier to set them up on the foundation.

Exhaust System

Genset Exhaust system directs the hot flue gases into the atmosphere harmlessly.
On KGPI Genset, exhaust silencer and expansion bellow are the integral part of exhaust system. At the
time of Genset installation, please ensure, proper alignment of exhaust silencer with respect to
expansion bellow. If the canopy is required to dismantle, then utmost care is necessary at the time of
re-assembling.
 INSTALLATION GUIDELINES & USER MANNUAL

While taking exhaust gases away from Genset above stack height, please refer table below for
selecting the size of exhaust pipe.

As per Statutory regulations, exhaust pipe has to be extended above the surrounding stack as below.

H = h + 0.2 x vKVA Where H = Minimum height of exhaust stack, h = height of building

ENGINE MODEL MINIMUM PIPE MINIMUM PIPE

ENGINE MODEL
(WATER INSIDE DIAMETER INSIDE DIAMETER
(AIR COOLED)
COOLED) IN INCH IN INCH

EW-SERIES 2.5" EA 10/16 2"

RB-SERIES 2.5" HA294/ 394/494 2.5"
2R/3R/4R 2.5" HA694 3"
4RTA 3"
4K/6K 4"
6SL 5"
K 5"
DV 5"

Note : If the extension of exhaust pipe is more than 5 meters above Genset, increase pipe dia by 0.5”
for every 3 meters.

Exhaust bend

M S Bends used in exhaust piping should have a long smooth bend as shown in figure to ensure
smooth flow of exhaust gases.
Exhaust Outlet should have 30® cut at the tail end with Coarse wire mesh.

Note :
- If No of bends are more than 4, increase the diameter of Exhaust Pipe and Bend by 0.5” for
addition of each bend.
- The exhaust outlet should be in the direction of prevailing wind.
 INSTALLATION GUIDELINES & USER MANNUAL

Rain Cap

FIG. RAIN CAP WITH RAIN CAP FIG. CORASE WIREMESH

If horizontal exhaust outlet as recommended above is not possible, provide a rain cap over exhaust
pipe end as per the figure. The distance between exhaust pipe and rain cap should be higher than
diameter of pipe (minimum 2.5D) with coarse wire mesh.

t is also recommended that horizontal run of exhaust piping should slope downwards away from
engine to the condensate trap. Silencer should be installed with drain plug at bottom.

Exhaust Support

FIG. EXHAUSE PIPE SUPPORT

Proper support is required for the extended exhaust pipe above Genset to ensure no self weight is
transferred on to the Genset.
 INSTALLATION GUIDELINES & USER MANNUAL

Type of Exhaust Pipe

Use black MS Pipe, Galvanised Iron Pipes should not be used.

FIG. CORRECT & INCORRECT EXHAUST PIPE

Exhaust Pipes should be joined through flanges.

Exhaust pipe throughout should be cladded by mineral wool with aluminium sheet. Minimum
thickness of cladding should be 50 mm.

Cooling System

Liquid Cooled Engine

Kirloskar Liquid Cooled Engines use solid cooling system for removal of heat generated in the engine
due to internal combustion and to maintain optimum operating temperature for efficient engine
operation.
KGPI Genset – Liquid Cooled are delivered with initial fill of Pre-mixed Coolant “K-Cool Super
Plus”.
 INSTALLATION GUIDELINES & USER MANNUAL

Ensure NO addition of Water in Coolant.

-Cool Super Plus” coolant.

Air Cooled Engine

Kirloskar Air Cooled Engines use Air as a cooling media for removal of heat generated in the engine
through cooling passages and to maintain optimum operating temperature for efficient engine
operation.

Lub Oil System

Kirloskar engines utilize the pressure lubrication system with the lub oil filter adequately designed to
handle the flow of lubricating oil at the designed pressure and temperature for Lubrication, Cooling
and Cleaning of internal components.

KGPI Gensets are delivered with initial fill of Lub Oil “K-Oil Super Plus”.

-Oil
Super Plus” only.

K-Oil Super SAE 15W 40 is a specially blended engine oil which ensures:

-ups.

Use of the wrong grade of oil could lead to :

- Overheating of the engine.

- Sluggish performance.

- Excessive Fuel Consumption

- Increase Wear of Bearings and Other moving components.

 INSTALLATION GUIDELINES & USER MANNUAL

Fuel System

The fuel (High Speed Diesel) should comply with the following International Standards.

DIN 51601
IS : 1460 1995
ASTM D 975-81 : 1D & 2D

- Ensure fuel filling point is accessible and clean all the time.
- Ensure all fuel piping is leak free.
- Avoid fuel spillage.
- Ensure fuel dilution does not occur.
- Care should be taken while filling of tank to prevent ingress of dust & moisture inside diesel tank.
- It is recommended to fill fuel after stopping of the Genset to avoid condensation.

It is recommended not to fill Fuel during running of Genset.

Electrical System

Earthing

Any leakages in current will be earthed through the shortest route in the link.
KGPI Genset should be connected to earth in accordance to local regulations.
The size of the link used for the main earth connection should be of adequate size as shown below
table.

The generating set and all associated equipment must be earthed before the set is put into operation.
4 numbers of earth pits are required as per Indian Electricity rules / local electricity regulations.
- 2 earthing pits for Genset / control panel body

- 2 earthing pits for neutral.

Resistance between 2 earth pits should be more than 5 Ω.

EARTHING WIRE & Recommended Earth

STRIP SIZE KVA Strip/ Cable

5 -82.5 KVA 8SWG-COPPER / 25 x 3mm

GI

100-250 KVA 25 X 3mm COPPER / 25 X

6mm GI

320 – 625 KVA 50 X 6mm COPPER

INSTALLATION GUIDELINES & USER MANNUAL

FIG. EARTH PIT

 INSTALLATION GUIDELINES & USER MANNUAL

FIG. 4 NOS EARTHING ARRANGEMENT

Power Cable

Cabling from Alternator to Panel should be done with proper size of cable and lugs. Typical cable
sizes are provided in the tables which are indicative. Please refer to cable manufactures for details.

eating and burning of the cable and terminals.

terminal box and control panel terminations.

les at both the ends of Alternator and

Control Panel.

of control and monitoring cables should be sheathed and should be within 5 meters length
for accurate performance.

provided from the ground separately through cable tray.

 INSTALLATION GUIDELINES & USER MANNUAL

Typical cable sizes for KGPI Genset

3-Phase Genset 1-Phase Genset

AMP AMP
GENS
GENS RATI RATI
ET
ET NG CABLE SIZES IN SQ MM NG CABLE SIZES IN SQ MM
RATI
RATI @0.8 @0.8
NG
NG PF PF
COPPER COPPER
ALLUMINI ALLUMINI
(App.) MULTISTR MULTISTR
UM UM
AND AND
5 7 4 6 5 20.83 6 10
10 14 4 6 10 41.66 10 16
15 21 4 6 15 62.5 16 25
20 28 6 10 20 83.33 35 50
25 35 10 16 25 104.16 35 50
30 42 10 16 30 125 50 70
40 56 16 25 40 166.66 70 95
45 63 16 25 50 208.33 95 150
50 70 25 35
62.5 87 35 50
82.5 115 50 70
100 139 70 95
125 174 95 150
140 195 95 185
160 223 120 240
180 250 120 240
200 278 150 300
250 348 150 300
320 445 120+95 240+185
400 556 150+150 300+300
500 695.62 185 x2 240 x 3
625 869.52 400 300 x 3
 INSTALLATION GUIDELINES & USER MANNUAL

BATTERY

WATER COOLED GENSET

SL. BATTERY RATING IN

KVA RATING ENGINE MODEL
NO. AMPS.
1 5,6 EA10 88
2 7.5/10 EA16 88
3 20 2R 88
4 25 3R 88
5 30 3R 88
6 45 4R 88
7 50 4R 120
8 62.5 4RT 135
9 75/82.5 4RTA 135
10 100/125 4K 135
11 125 6RTA 180
12 140/160 6K 180
13 180/200/250 6SL 180x2
14 275/320/400 DV 180x2
15 500/600/625 DV 180x2

AIR COOLED GENSET

SL. BATTERY RATING IN

KVA RATING ENGINE MODEL
NO. AMPS.
1 12.5/15 HA294 88
2 20/25 HA394 88
3 30/35 HA494 120
4 40/45 HA494TC 120
5 50/55 HA694 180
6 63/70 HA694TC 180

Ensure that the polarity of the battery connections are correct before switching on the DC controls.

charged or replaced and then try to start.

 INSTALLATION GUIDELINES & USER MANNUAL

Before Starting the New KGPI Genset

-belt tension as per specifications.

Lubrication :
- Check Lub oil level with help of Dipstick and if require Topup up to H-Mark with “K-Oil Super”.

Fuel :
- Ensure fuel tank is clean from inside.
- Fill fuel tank with clean High Speed Diesel.
- Bleed the fuel system as shown in maintenance manual.

Cooling :
Liquid cooled engine.
- Check Coolant level inside Radiator and Compensatory tank. If required Topup with “K-Cool Super
Plus”.

Air Cooled Enignes.

- Check Blower Fan belt tension.
- Check hot air exhaust fan is working properly.

Electrical:
- Check Battery Polarity.
- Check Battery cables are correctly connected and secured.
- Check all other electrical connections and intactness.
- Ensure Emergency Push Button in released condition.
- Ensure Load Change over Switch / Breaker in off condition.

Starting and Stopping of KGPI Genset

Procedure: Starting KGPI Genset

Before Starting
- Clean the Genset with dry cloth.
- Check the lub oil, coolant and fuel levels – Top up if required as per recommendation given.
- Check for V-belt, Hoses and external leakage if any.
- Ensure Load change over switch / Breaker in Off condition.
 INSTALLATION GUIDELINES & USER MANNUAL

Starting
- For Key Starting

Do not crank engine for more than 5 second. As soon as engine fires, release the start key. Leave
ignition switch in “ON” position.
- For Push Button Starting

Gently press starts button once and release.

- If engine fails to start, wait for a minute and try again.
- Check for leakages if any.
- Allow the engine to idle for 3 minutes and then start loading the Genset gradually in steps.
- Check for Engine parameters like Oil Pressure, Coolant Temp and Battery charging rate at regular
intervals while the Genset in operation and maintain log book.
- Check for Exhaust Smoke.
- Check for Abnormal Noise if any.
- Check for A C Alternator parameters like Voltage, Ampere, KW, PF on all phases.
- Ensure load is balanced in all phases as per recommendation and within rated output of Genset.
- Check for all gauges and meters provided in Control Panel are working.

Procedure: Stopping KGPI Genset

Before Stopping
- Remove the load from Genset and let it run for about 3 minutes.
- For Key Start

Put Ignition key in “Off” condition.

- For Push Button Start

Push Stop button gently once and release.

After Stopping
- Put Load Change Over Switch in “OFF” position.
- Check for leakages if any.
- Top Up the Fuel Tank.
- Ensure Proper closing of Genset Enclosure.

Maintenance Tips

First oil change @ 50 hrs or 3 months of commissioning. For details refer user manual.

Cleaning and Preservation of KGPI Genset

Remove dust deposit from the Cylinder heads, Liners fins, lub oil cooler fins, Radiator and A C
Alternator with compressed air. Cleaning with diesel fuel or kerosene may cause dust to deposit again
on the cleaned parts.
Open the Air duct while cleaning of Air Cooled Engine.
Cleaning should be done from the opposite side of the system air flow.
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When deposits are hard, scrape and clean with a water jet. Run the engine after such cleaning till all
the water evaporates.
When the Genset is kept idle for more than 6 months, it is advisable to protect it from atmospheric
moisture, condensates, internal corrosions and rodents

Recommended Engine lub oil and Engine cooling Unpainted ferrous

Preservatives: Fuel system system for liquid metal parts
Manufacturer cooled

Bharat petroleum Bharat Preserve oil 30 Bharat Sherol B Bharat Rustrol 152
Emulsion with water
ratio 1:20
Hindustan petroleum Autoprun T120 Koolkit Rustop 274
40.5%Emulsion with
water
Indian oil corporation Servo Servo Cut S 20% Servo RP 125
Preserve 30 OR Emulsion with water
Servo 'Run-N' Oil 30
Castrol India - - Russtilo DW 904 OR
DW901
Veedol tide water oil Veedol 30/40 Veedol Amulkut 4 Veedol Rustop IT
co. Emulsion with water
in ratio 1:15

Alternatively 'Surprabha VCL 302' of Suprabha products can be used in engine cooling System.
For preservation and re-commissioning contact seller.

After Sales Service Guidelines

- The after sales service to KGPI Genset is provided through KOEL’s Country-wide network of
authorized spare and service dealers. For information about KOEL’s Authorized Dealers, please
contact either the supplier of KGPI Genset or nearest KOEL Area office.
- Before commissioning the KGPI Genset, please go through the contents of the warranty booklet.
-

YOU ARE ENTITLED TO RECEIVE THE FOLLOWING ENGINE RELATED DOCUMENTS

FROM KGPI GENSET SUPPLIER.
- Warranty Booklet
- User manual- Hard copy/ Soft copy
- Maintenance manual- Hard copy/ Soft copy