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20120188 Generator 02272013 KOHLER WP0INER_SYSTEMS � � • • Section Sub Section Literature Quote Model 80REOZJF Spec Sheets Modei KSS-DCTA-0400S Spec Sheets Alternator Data Alternator Data Sheet 4R9X Sound Data Sound Data Sheet Sound Data Emissions Data Emissions Data Emissions Data EPA Certificate EPA Certificate SCAQMD Permit SCAQMD Permit Dimensional Drawings Generator ADV-8181 Accessories ADV-7648 Controller ADV-7935 Enclosure ADV-7647 Subbase Tank ADV-7880 Transfer Switch ADV-7193 Wiring Schematic Diagrams Controller Schematic Diagram ADV-8041 Controller Wiring Diagram GM79690 Interconnection Diagram GM78246 Remote Serial Annunciator ADV-6990 Transfer Switch GM46266 Transfer Switch GM46288 Misc Battery 244578 Battery Charger GM28341 Block Heater 326220 Block Heater GM75557 Circuit Breaker ADV-5912 Circuit Breaker X-6304 Circuit Breaker Mounting ADV-7371 Emergency Stop A222654 Warranty Warranty TP-5373 Warranty TP-5374 Certification IS09001 Certificate G15-152 Prototype Test Certificate G18-56 Pre-Startup Checklist Pre-Startup Checklist PreStartUpCheckList ��, 1 �V V �� tYt� BILL OF MATERIALS FOR PROJECT: Palisades Kohier 80KW standby generator model number: 80REOZJF This generator set equipped with a 4R9X'alternator operating at 120/208 volts is rated for 83 kW/104 kVA. Output amperage: 288 Generator Confiauration: 80REOZJF Generator Set, 12V, 60hz Nameplate Rating, Standby 130 Degree Voitage,60Hz,120/208V,3Ph,4W,0.8PF Decal, UL2200 Listing (Diesel) Cooling, Unit Mounted Radiator Air Intake, Standard Duty Altemator 8� Mtg. 4R9X Controll�r: Controller, DEC3000 400A, 3Ph Run Relay, 12V Electrical Svstem: Block Heater, 1500W, 120V Battery,1/12V,650CCA,Wet Batt Chgr, Float, 90-120V, 12V-6A LCB, 300A, LAP, Therm Mag, 80% Mtg, LCB, L-Frame, 300-400A. 4S Enclosure and Fuel: Enclosure, Sound, Crit Sil,Cap Skid/State Tank, 24Hr, 12V Flexible Fuel Lines 5 Gal Spill w/Fill Pipe Ext, Tnk Hgt 15" Normal Vent 12' Kit/W Spill Fill Misc: Air Cleaner Restriction Ind Coolant in Genset 5 gals. Warranty, 1 Year Standby Remote Emergency Stop Switch Rodent Guards Lit Kit, General Maint, 80REOZJF Power Factor Test,0.8,3Ph Only Kohler automatic transfer switch model: KSS-DCTA-0400S 3 Pole, 4 Wire, Solid Neutral, 0400 Amps, Kohler Series rated automatic transfer switch, Model KSS- DCTA-0400S, rated 208V, 60 Hz, complete with all standard equipment and housed in a NEMA Type 1 enclosure. Warranty, 1 Year Standard Lit Kit, ATS Production, KSS/KSP Exceptions and clari�cations: 1. Off-loading at the job site is excluded. 2. All fuel, fuel piping, and connections excluded. 3. No retainage is allowed. 4. Start-up testing and warranty validation includes one trip to the job site during normal working hours. If the generator is not ready for start-up when we arrive at the job site, there may be additional charges for a return trip. 5. Generator training to be performed at start-up or subject to additional charges. 6. Kohler factory recommended field testing provided. NETA ATS testing not included. 7. Additional O &M's will be$50.00 net each. 8. All piping, wiring, anchoring, and permits are by others. 9. Compliance with National Electrical Code, NFPA, IFC, and state and local fire codes is the responsibility of the installing contractor. Special fuel tank labeling and venting/filling equipment may be required, but is excluded unless otherwise noted. 10. Equipment is shipped FOB factory, with freight prepaid and allowed to the job site unless otherwise noted. 11. Breaker coordination studies excluded. 12. Local Codes may require outdoor generators to have a Service Rated disconnect. We are not providing a Service Rated disconnect unless it is specifically noted in this quotation. 13.TVSS devices for the generator or transfer switch(es) are excluded unless otherwise noted. 14. IBC seismic certification excluded unless otherwise noted. 15. Prices do not include any applicable taxes. ___.. _.... _......_. _......._................................................ K41�LER PQWER_SYSTENIS � - - - ..8OREO�JF Diesel ��l�.�� P`��E� .��'�TE1�� _ ��r/�� Standard Features �. 4 xf�;r�� r�;4,:� • Kohler Co. provides one-source responsibility for the r��c��R��a��sr��ta� generating system and accessories. ��ll.n ,..�,,..�.. . _ _ • The generator set and its components are prototype- � � tested,factory-built, and production-tested. • The 60 Hz generator set offers a UL 2200 listing. ____.._____..._. • The generator set accepts rated load in one step. ' �� • The 60 Hz generator set meets NFPA 110, Level 1, � .. � � when equipped with the necessary accessories and ` ' installed per NFPA standards. • A one-year limited warranty covers all systems and components. Two-,five-,and ten-year extended warranties are also available. � �wd �� • Alternator Features: � ° � o The unique Fast-Response X excitation system delivers excellent voltage response and short circuit capability using a rare-earth, permanent magnet (PM)-excited alternator. o The brushless, rotating-field alternator has broad range reconnectability. • Other Features: o Controllers are available for all applications. See controller features inside. o The low coolant level shutdown prevents overheating (standard on radiator models only). o Integral vibration isolation eliminates the need for under-unit vibration spring isolators. _ o Multiple circuit breaker configurations. �er��ra#,��=�:S`_►�� F��i��': Standby130C Ratings Altemator Voltage Ph Hz kW/kVA Amps 4R9X 120/208 3 60 83/104 288 RATINGS:All three-phase units are rated at 0.8 power fador.All single-phasa units are reted at 1.0 power factor.Standby Ratings:The standby rating is applicable to varying loads for the duration of a power outage.There is no overload capability for this reting.Prime Power Ratings:At varying load,the number of generetor sel operating hours is unlimited.A 10%overbad capacity is available for one hour in twelve. Ratings are in accordance with ISO-8528-1 and IS430461.For limited running time and continuous ratings,consult the factory.Obtain technical infortnation bulletin(TIB-101)for re6ngs guidelines,complete ratings definitions,and site condition derates.The generetor set manufacturer reserves the right to change the design or specifications without notice antl without any obligation or Iiability whatsoever. Model: 80REOZJF, continued Alternator Specifications Specifications Alternator Alternator manufacturer Kohler Type 4-Pole, Rotating-Field Exciter type Brushless, Rare-Earth Permanent-Magnet Leads, quantity 12, Reconnectable Voltage regulator Solid State,Volts/Hz Insulation NEMA MG1 Insulation: Material Class H Insulation:Temperature Rise 130°C, Standby Bearing: quantity,type 1, Sealed Coupling Flexible disc Amortisseur windings Full Voltage regulation, no-load to full-load RMS Controller Dependent One-Step Load Acceptance 100%of rating Unbalanced load capability 100%of Rated Standby Current • Sustained short-circuit current of up to 300%of the rated current for up to 10 seconds. • Sustained short-circuit current enabling down stream circuit breakers to trip without collapsing the alternator field. • Self-ventilated and dripproof construction. • Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long Ilfe. • Superior voltage waveform from a finro-thirds pitch stator and skewed rotor. Engine Engine Specifications Engine Manufacturer John Deere Engine Model 4045HF285H Engine:type 4-Cycle,Turbocharged, Charge Air-Cooled Cylinder arrangement 4 Inline Displacement, L(cu. in.) 4.5(276) Bore and stroke, mm (in.) 106 x 127(4.19 x 5.00) Compression ratio 19:1 Piston speed, m/min. (ft./min.) 457 (1500) Main bearings:quantity,type 5, Replaceable Insert Rated rpm 1800 Max. power at rated rpm, kWm (BHP) 99(133) Cylinder head material Cast Iron Crankshaft material Forged Steel Valve (exhaust)material Intake Chromium-Silicon Steel Valve(exhaust)material Exhaust Stainless Steel Governor: type, make/model JDEC Electronic L16 Denso HP3 Frequency regulation, no-load to-full load Isochronous Frequency regulation, steady state t0.25% Frequency Fixed Air cleaner type, all models pry Modei: 80REOZJF, continued Exhaust Exhaust System Exhaust Manifold Type p�-y Exhaust flow at rated kW, m'/min. (cfm) 19.2(679) Exhaust temperature at rated kW, dry exhaust, °C 579(1074) �°F) Maximum allowable back pressure, kPa(in. Hg) 7.5 (2.2) Exh. outlet size at eng. hookup, mm (in.) 98(3.86) Engine Electrical Enqine Electrical System Battery charging alternator 12 Volt/24 Volt Battery charging alternator: Ground (negative/positive) Negative Volts(DC) 12/24 Ampere rating 65/45 Starter motor rated voltage (DC) 12/24 Battery, recommended cold cranking amps(CCA): Qty., CCA rating each One, 640/Two, 570 Battery voltage (DC) �2 Fuel Fuel System Fuel type Diesel Fuel supply line, min. ID, mm (in.) 11.0 (0.44) Fuel return line, min. ID, mm(in.) 6.0 (0.25) Max. lift, fuel pump:type, m (ft.) Engine-Driven, 1.8 (6.0) Max.fuel flow, Lph (gph) 62.5(16.5) Max. return line restriction, kPa(in. Hg) 20 (5.9) Fuel prime pump Manual Fuel Filter Secondary 2 Microns@ 98% E�ciency Fuel Filter Primary 30 Microns Fuel Filter Water Separator Yes Recommended fuel #2 Diesel Lubrication Lubrication System Type Full Pressure Oil pan capacity, L(qt.) 14.7 (15.5) Oil pan capacity with filter, L(qt.) 15.6 (16.5) Oil filter: quantity, type 1, Cartridge Oil cooler Water-Cooled Model: 80REOZJF, continued Cooling Radiator System Ambient temperature, °C (°F) 50(122) Engine jacket water capacity, L(gal.) 8.5(2.25) Radiator system capacity,including engine,L(gal.) 20.1 (5.3) Engine jacket water flow, Lpm (gpm) 155 (41) Heat rejected to cooling water at rated kW, dry 54.4(3096) exhaust, kW(Btu/min.) Heat rejected to air charge cooler at rated kW, dry 13.5(768) exhaust, kW(Btu/min.) Water pump type Centrifugal Fan diameter, including blades, mm(in.) 600(23.6) Fan, kWm (HP) 6.6 (8.8) Max. restriction of cooling air, intake and discharge 0.125(0.5) side of radiator, kPA(in. H20) ' Enclosure with internal silencer reduces ambient temperature capability by 5°C (9°F). Operation Requirements Air Requirements Radiator-cooled cooling air, m'/min. (scfm)" 142(5000) Combustion air, m3/min. (cfm) 6.9 (244) Heat rejected to ambient air:Engine, kW(Btu/min.) 22,g(1300) Heat rejected to ambient air:Alternator, kW(Btu/ g.g(560) min.) *Air density= 1.20 kg/m3(0.075 Ibm/ft') ��lt�l �±Ol��b�'�, Diesel L h h,at%load Ratin Sta d� �.u� �` . � � ��a�` ►�" ` ��.��?�{�;�p�?� �t��d��1.��' .�� -� ��ib�.�"��;��r�r,�,�:�� `� ��;��;�� Sta��iti��w�l.��i��.��HI� ��_.`�:,��.�i��i;� Prime Fuel Consumption at 100%load 23.8 Lph (6.3 gph) Prime Fuel Consumption at 75% load 19.3 Lph(5.1 gph) Prime Fuel Consumption at 50%load 14.4 Lph(3.8 gph) Prime Fuel Consumption at 25% load 7.9 Lph (2.1 gph) Model: 80REOZJF, continued Dimensions and Weights Overall Size, L x W x H, mm (in.): Wide Skid See Enclosure ADV Drawing Overall Size, L x W x H, mm(in.): Narrow Skid 2334 x 864 x 1216(91.89 x 34.02 x 47.90) Weight(radiator model), wet, kg (Ib.): 1125(2480) � Please see ADV F� ' Drawings for actual dimensions with � � tank and }.......-�..�..� �-�.� � � enclosure. NOTE:This drawing is provided for reference only and should not be used for planning installation.Contact your local distributor for mo�e detailed information. Industrial Generator Set Accessories KOHLER�P�WER SYSTEMS ��a�.o�=:�e��Cantrol�er 09001 3K�ohler�:�ecision-Mak�n+�:30� Cnntroller t/�� NATIONALIY REGISTERED General Description and Function The Decision-Maker�3000 generator set controller provides advanced control,system monitoring,and system diagnostics for optimum performance. ,�, The Decision-Maker�3000 contro►ler meets NFPA 110, Level 1 _�s: when equipped with the necessary accessories and installed per NFPA standards. � ,, The Decision-Makerm 3000 controller uses patented software logic to manage sophisticated functions,such as voltage regulation and alternator thermal overload protection, normally requiring additional hardware. Additional features include: � • A digital display and pushbutton/rotary selector dial provide easy local access to data. � ' �. • Measurements selectable in metric or English units. . The controller can communicate directly with a personal computer via a network or serial configuration using Decision-Maker�3000 SiteTech"" or Monitor III software. • The controiler supports Modbusa protocol. Use with serial bus or Ethernet networks. • Scrolling display shows critical data at a glance. • Digital display of power metering (kW and kVA). • Integrated hybrid voltage regulator providing±0.5% regulation. � Built-in alternator thermal overload protection. Modbusm is a registered trademark of Schneider Electric. G6-100 1/12b Page 1 � � Pushbutton/Rotary Selector Dial Volts L1-L2: aae.e v Emergency Stop Switch Annunciator Fault Light Red-Shutdown, Digital Display ___—— � Yellow-Waming FAULT Alarm Horn(locate j _-- OO OO OO O Alarm Silence/Lam9 inside the controller Test Button with Li ht OFF/RESET AUTO RUN AIARM SILENCEI Master Control Buttons IAMPTEST Off-ReseUAuto/Run � USB Communication with Lights � Connection � O User Interface Controls and Components User Interface Displays • Emergency stop switch The listing below has�denoting main menus and o denoting sub-menus. • Backlit LCD digital display with two lines of 12 characters • Overview (see User Interface Displays for menus) o Software version � Alarm horn indicates generator set shutdown and warning faults o Active shutdowns and warnings(if any are present) o Engine run time,total hours • Environmentally sealed membrane keypad with three master controi o Average voltage iine-to-line buttons with lights o Fre uenc o Off/Reset(red) o Average current o Auto(green) o Coolant temperature o Run(yellow) o Fuel level or pressure'� • Pushbutton/rotary selector dial for menu navigation o Oil pressure o Rotate dial to access main menus o Battery voltage o Push dial and rotate to access sub menus • Engine Metering o Press dial for 3 seconds to retum to top of main menu o Engine speed • Annunciator fault light � Oil pressure � System shutdown(red) o Coolant temperature o System warning(yellow) o Battery voltage • Alarm silence/lamp test button • Generator Metering o Alarm silence o Totai power,VA o Lamp test o Total power,W o Rated power,% • USB and RS-485 connections o Voitage,L-L and L-N for all phases o Allows software upgrades o Current,Li,L2,L3 o Provides access for diagnostics o Frequency o PC communication using SiteTech"' or Monitor III software • GenSet Information • Dedicated user inputs o Generator set model number o Remote emergency stop switch o Generator set serial number o Remote 2-wire start for transfer switch o Controiler serial number o Auxiliary shutdown • GenSet Run Time • Integrated hybrid voltage regulator o Engine run time,total hours • Auto-resettable circuit protection mounted on circuit board. o Engine loaded,hours • One relay output standard. Optional five relay output available. o Number of engine starts o Total energy,kWh • One analog and three digital inputs standard. Optional two inputs � GenSet System available. o System voltage NFPA 110 Requirements o System frequency,50 or 60 Hz In order to meet NFPA 110, Level 1 requirements, the generator set ° System phase,single or three(wye or delta) controllermonitorstheengine/generatorfunctionsandfaultsshownbelow. o Ampratnt9g,kW • Engine functions: o Power type,standby or prime o Overcrank o Measurement units,metnc or English(user selectable) o Low coolant temperature waming o Alarm silence,always or auto only(NFPA 110) o High coolant temperature warning • GenSet Calibration o High coolant temperature shutdown o Voltage,L-L and l.-N for all phases o Low oil pressure shutdown o Current,L1,L2,L3 o Low oil pressure warning o Reset calibration o High engine speed * • Voltage Regulation o Low fuel (level or pressure) o Adjust voltage,t10°/a o Low coolant levei • Oigital Inputs o EPS supplying load o In ut settin s and status o High battery voltage p g o Low battery voltage • Digital Outputs o Output settings and status � General functions: • Analo In uts o Master switch not in auto 9 P o Battery charger fault* o Input settings and status � Lamp test • Event Log o Contacts for local and remote common alarm o Event history(stores up to 1000 system events) o Audible alarm silence button • Selector Switch(requires initial activation by SiteTech'") o Remote emergency stop* * Function requires optional input sensors or kits * Functions require optional input sensors or kits G6-100 1/12b Page 2 Controller Features Waming Shutdown Function Fu�ction • AC Output Voltage Regulator Adjustment. The voltage � € adjustment provides a maximum of:10%of the system voltage. Critically high fuel level* o • Alarm Silence. The controller can be set up to silence the alarm ECM communication loss • hom only when in the AUTO mode for NFPA-110 application or ECM diagnostics • • Always for user convenience. Engine over speed •t • Alternator Protection. The controller provides generator set Engine start aid active overload and short circuit protection matched to each alternator for Engine under speed • the particular voltage/phase configuration. Fuel tank leak* o 0 • Automatic Restart. The controller automatic restart feature initiates High battery voltage • the start routine and recrank after a failed start attempt. High coolant temperature • •# • Common Failure Relay. This relay is integrated on the controiler High fuel level* o circuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at Low battery voltage • 120 VAC. Low coolant level • • Communication. Controller communication is available. Low coolant temperature • • Cyclic Cranking. The controller has programmable cyclic cranking. Low cranking voltage • Low engine oil level* o 0 • ECM Diagnostics. The controller displays engine ECM fault code Low fuel level(diesel models)* o 0 descriptions to help in engine troubleshooting. Low fuel pressure(gas models)* o • Engine Start Aid. The starting aid feature provides control for an Low oil pressure • •# optional engine starting aid. No coolant temperature signal • • Event Logging. The coMroller keeps a record(up to 1000 entries) No oil pressure signal • for warning and shutdown faults. This fault information becomes a Overcrank �# stored record of system events and can be reset. Speed sensor fault • • Historical Data Logging. Total number of generator set successful starts is recorded and displayed. Alarm horn silenced • Integrated Hybrid Voltage Regulato�. The voltage regulator Analog inputs o 0 provides t0.5%no-load to full-load regulation with three-phase sensing. Battery charger fault* • Chicago code active* • Lamp Test. Press the alarm silence/lamp test button to verify � functionality of the indicator lights. Common fault(includes�) Common warning • • LCD Display. Adjustable contrast for improving visibility. Digital inputs o 0 • Measurement Units. The controller provides selection of English or Emergency stop •� metric displays. Engine cooldown(delay)active • Power Metering. Controller digital display provides kW and kVA. Engine start delay active • Programming Access(USB). Provides software upgrades and Engine started diagnostics. Engine stopped • Remote Reset. The remote reset function resets faults and allows EPS supplying load restarting of the generator set without going to the master control Generator running switch off/reset position. Input/output communication loss • • RSA II Remote Monitoring Panel. The controller is compatible with Internal failure • the Kohlera Remote Serial Annunciator(RSA 11). Master switch not in auto • • Run Time Hourmeter. The generator set run time is displayed. NFPA 110 alarm active Remote start • Time Delay Engine Cooldown(TDEC). The TDEC provides a time System ready delay before the generator set shuts down. • Time Delay Engine Start(TDES). The TDES provides a time delay AC sensing loss • • before the generator set starts. Alternator protection • • Voltage Selection Menu. This menu provides the capability of Ground fault input* • quickly switching controller voltage calibrations. Requires initial kW overload • activation using SiteTech"' software. NOTE: Generator set output leads require voltage reconnection. Locked rotor • Overfrequency • Controller Functions Overvoltage(each phase) • Underfrequency • The following chart shows which functions cause a warning or shutdown. Undervoltage(each phase) • Ali functions are available as relay outputs. • Standard functions Warning causes the fault light to show yellow and sounds the alarm horn o Available user functions signaling an impending problem. * Functions require optional input sensors or kits # Items included with common fault shutdown Shutdown causes the fault light to show red,sounds the alarm horn,and stops the generator set. G6-100 1/12b Page 3 KOHLER CO.,Kohler,Wisconsin 53044 USA Kohler Power Systems Phone 920-457-4441,Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada,phone 1-800-544-2444 Singapore 619159 KohlerPower.com Phone(65)6264-6422,Fax(65)6264-6455 Controller Specifications Communication and PC Software Decision-Makero 3000—Software Version 3.025 or higher Available Options • Power source with circuit protection: 12-or 24-volt DC Refer to G6-76 Monitor III Software and the communication literature for • Power drain: 200 milliamps additional communication and PC software information including • Humidity range: 5°/a to 95%noncondensing Modbuse communication. • Operating temperature range: -40°C to+70°C(-40°F to+158°F) • Storage temperature range: -40°C to+85°C(-40°F to+185°F) ❑ Monitor III Software for Monitoring and Control • Standards: (�ndowse-based user intertace) o CE Directive o NFPA 99 ❑ Converter,Modbus�/Ethernet. Supports a power system using o NFPA 110,Level 1 controllers accessed via the Ethernet. Converter is supplied with an c UL 508 IP address by the site administrator. Refer to G6-79 for converter o ASTM B117(salt spray test) details. • Panei dimensions—W x H,229 x 160 mm(9.0 x 6.3 in.) ❑ Converter,RS-232/RS-085. Supports a power system using �@CISIOCI-Maker� 3000 Available Options controliers accessed via a serial(RS-232)connection. �• �LO�q�ii1��' "�._ �available with 6 or 10 amp DC volt output. The 10 amp models are available with and without Modbus�is a registered trademark of Schneider EleMric. NFPA alarm to signal a battery charger fault. wndow5m�s a re9�s�e�ed c�adema�k ot nmcrosoe co�Po�ano�. ❑ Prime Power Switch prevents battery drain during generator set non-operation periods and when the generator set battery cannot be maintained by an AC battery charger. �- .Fi81'tt�t�a;`�i8�'g�e�a�is�"�YII'�avaiiable as a wall mounted panel to remotely shut down the generator set. ❑ Remote Monitoring Panel. The Kohler�Remote Serial Annunciator(RSA II)enables the operator to monitor the status of the generator set from a remote location,which may be required for NFPA 99 and NFPA 110 installations. � ktun_Ra1a�'provides a relay indicating that the generator set is running. ❑ Shunt Trip�ring provides relay outputs to trip a shuM trip circuit breaker and to signal the common fault shutdowns. Contacts rated at 10 amps at 28 VDC or 120VAC. ❑ Two Input/Five Output Module provides a generator set mounted panel with two inputs and five relay outputs. DISTRIBUTED BY: Availability is subject to change without notice. Kohler Co.reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohlerm generator set distributor for availability. �zoos,zoio,zoiz ey rconier co., All rights reserved. G6-100 1/12b Page4 Industrial Generator Set Accessories KOH��POWER SYSTEMS 4�ne Gir�uit Breal�er��0-225o'kW 09001 �� Standard Features NATIONALLY REGISTFRED • The line circuit breaker interrupts the generator set output during a short circuit and protects the wiring when an overload occurs. Use the circuit breaker to � , O o manually disconnect the generator set from the load during generator set service. ° � • Circuit breaker kits are mounted to the generator set � and are provided with load-side lugs and neutral bus bar. Q J, o � • Kohler Co. offers a wide selection of molded-case line circuit breaker kits including single, dual, and multiple configurations for each generator set. � � O • Four types of line circuit breakers are available: (see page 2 for definitions and pages 3 and 4 for '�� g �� application details) o Magnetic trip o Thermal magnetic trip ao Electronic trip O ° o Electronic with Ground Fault Circuit Interruption , (GFCI)trip � 8 • In addition, line circuit breakers are offered with 80% and 100% ratings. o �, � io � Single line circuit breaker kits allow circuit protection - of the entire electrical system load. • Dual line circuit breaker kits allow circuit protection 0 � � of selected priority loads from the remaining electrical system load. Dual Circuit Breaker Kit with Neutral Bus Bar 20-300 kW Model Shown � Multiple line circuit breaker kits with field connection barrier allow circuit protection for special applications (350-2250 kV�. � � � Line circuit breakers comply with the following codes ❑. and standards unless otherwise stated. � -•- o UL 489 Molded Case Circuit Breakers �_� a� � a � � o UL 1077 Supplementary Protectors � ; ; i i ; ; � o U L 2 2 0 0 S t a t i o n a r y E n g i n e G e n e r a t o r A s s e m b l i e s � , � Multiple Circuit Breaker Kits with Neutral Bus Bar 350-2250 kW Model Shown (also applies to some 300 kW models) G6-88 10/11e Page 1 Line Circuit Breaker Types Magnetic Trip pickup switch sets the current level atwhich the circuit breaker will trip after the ground fault delay. Ground fault pickup values The magnetic trip features an electromagnet in series with the are based on circuit breaker sensor plug only and not on the load contacts and a moveable armature to activate the trip rating plug multiplier. Changing the rating plug multiplier has mechanism. When a sudden and excessive current such as no effect on the ground fault pickup values. a short circuit occurs,the electromagnet attracts the armature resulting in an instantaneous trip(UL 1077 circuit breakers). �Q°�q`'�2�'�@d.�tl"GU'I� BCe;a�C@r ;��a� �,,��`�� Most molded-case circuit breakers are 80%rated devices. An 80°k rated circuit breaker can only be applied at 80%of its Thermal magnetic trip contains a thermal portion with a rating for continuous loads as defined by NFPA 70. Circuit bimetallic strip that reacts to the heat produced from the load conductors used with 80°�rated circuit breakers are required current. Excessive current causes it to bend sufficiently to trip to be rated for 100%of the circuit breaker's rating. the mechanism. The trip delay is dependant on the duration The 80%rated circuit breakers are icall at a lower cost and excess of the overload current. Elements are factory- �P y caiibrated. A combination of both thermal and magnetic than the 100�o rated circuit breaker but load growth is limited. features allows a delayed trip on an overload and an 100% Rated Circuit Breaker instantaneous trip on a short circuit condition. Electronic Tri Applications where all UL and NEC restrictions are met can use p 100°�rated circuit breakers where 100°/a rated circuits can carry These line circuit breakers use electronic controls and miniature 100%of the circuit breaker and conductor current rating. current transformers to monitor electrical currents and trip when The 100%rated circuit breakers are typically at a higher cost preset limits are exceeded. than the 80%rated circuit breaker but have load growth Electronic with Ground Fault Trip possibilities. When applying 100%rated circuit breakers,compty with the The ground fault trip feature is commonly referred to as Ground various restrictions including UL Standard 489 and NEC Fault Circuit Interruption(GFCI). Models wfth GFCI compare Section 210. If any of the 100%rated circuit breaker restrictions current flow in phase and neutral lines,and trip when current are not met,the circuit breaker becomes an 80°�rated circuit unbalance exists. breaker. Ground fault trip units are an integral part of the circuit breaker and are not available as field-installable kits. The ground fauR Line Circuit Breaker Options ❑ Alarm Switch ❑ Lockout Device(padlock attachment) The alarm switch indicates that the circuit breaker is in a tripped This field-installable handle padlock attachment is available for position caused by an overload,short circuit,ground fault,the manually operated circuit breakers. The attachment can operation of the shunt trip,an undervoltage trip,or the push-to- accommodate three padlocks and will lock the circuit breaker trip pushbutton. The alarm reseis when the circuit breaker is in the OFF position only. reset. ❑ Neutral Lugs ❑ Auxiliary Contacts Various neutral lug sizes are available to accommodate multiple These switches send a signal indicating whether the main cable sizes for connection to the bus bar only. circuit breaker contacts are in the open or closed position. ❑ Overcurrent Trip Switch ❑ Breaker Separators (350-2250 kW) The overcurrent trip switch indicates that the circuit breaker has Provides adequate clearance between breaker circuits, tripped due to overload,ground fauft,or short circuit and returns ❑ Bus Bars to the deenergized state when the circuit breaker is reset. Bus bar kits offer a convenient way to connect load leads to the ❑ Shunt Trip, 12 VDC or 24 VDC generator set when a circuit breaker is not present. A shunt trip option provides a so�enoid within the circuit breaker 20-300 kW. Bus bar kits are available on alternators with leads case that,when momentarily energized from a remote source, for connection to the generator set when circuit breakers are not activates the trip mechanism, This feature allows the circuit ordered. breaker to be tripped by customer-selected faults such as 350-2250 kW. A bus bar kit is provided on the right side of the altemator overload or overspeed. The circuit breaker must unit when no circuit breaker is ordered. Bus bars are also be reset locally after being tripped. Tripping has prioriry over available in combination with breakers or other bus bars on the manual or motor operator closing. opposite side of the junction box. On medium voltage(3.3 kV and above)units,a bus bar kit is standard. ❑ Shunt Trip Wiring ❑ Field Connection Barrier Connects the shunt trip to the generator set controller. Provides installer wiring isolation from factory connections. ❑ Undervoltage Trip, 12 VDC or 24 VDC ❑ GrOUnd FBUIt AnnunClatlOn The undervoltage trips the circuit breaker when the control voltage drops below the preset threshold of 35%-70%of the A relay contact for customer connection indicates a ground rated voltage. fault condition and is part of a ground fault alarm. G6-88 10/11e Page 2 20-300 kW Line Circuit Breaker Specifications 80% Rating Circuit Breaker Circuit Breaker Lugs Per Phase (AI/Cu) � B Frame Size Ampere Range Wire Range Gen.Set Alt. Ampere Frame E 30-100 Up to two wire terminals fitting kW Model Range Trip Type Size (480 V max.) 10-32 or 1/4-20 stud Magnetic,UL 1077 HD 15-150 One#14 to 3/0 Magnetic,UL 1077 E 175 One 1/0 to 4/0 30-100 with 12 V shunt trip (4gp V �� 200-250 One 3/0 to 350 kcmii 20-80 4P/4PX/ Magnetic,UL 1077 m�� Oite;#1.#0'GOQ kcmil,qr 4Q/4QX with 24 V shunt trip � ��`� (2);#1 tc�25Q kcmil 15-150 Thermal magnetic HD One#2 to 500 kcmil AI only 150-400 One#2 to 600 kcmil Cu onl 175-250 Thermal magnetic JD DG Y Magnetic,UL 1077 Two 2/0 to 500 kcmil AI only 600 Two 2/0 to 350 kcmil Cu only Magnetic,UL 1077 E 30-100 with 12 V shunt trip �4gp V MG 700-800 Three 3/0 to 500 kcmil Magnetic,U L 1077 m�•� 600-800 Three 3/0 to 500 kcmil with 24 V shunt trip PG 1000-1200 Four 3/0 to 500 kcmil 15-150 Thermal magnetic HD :�'4S/ 175-250 Thermal ma netic JD �� asw 9 _ Interrupting Ratings 4TX/4V �� :�. Electronic Circuit Breaker 240 Volt, 480 Volt, 600 Volt, 600 DG Frame Size kA kA kA Electronic GFCI 700-800 Thermal magnetic MG HD 25 18 14 800 Electronic JD 25 18 14 800 Electronic GFCI PG � � � �� DG 65 35 18 15-150 Thermal magnetic HD MG 65 35 18 175-250 Thermal magnetic JD pG 65 35 18 300-400 Thermal magnetic LA Electronic 200-300 4UA � Electronic GFCI DG 700-800 Thermal magnetic MG 1000-1200 Thermal magnetic PG 800-1200 Electronic PG 800-1200 Electronic GFCI PG 100% Rating Circuit Breaker c.s. Alt. Ampere Frame Gen.Set kW Model Range Trip Type Size 20-80 4P/4PX/ 1� � Electronic DG 4Q/4QX Electronic GFCI Electronic 4RX/4S/ 1�-� Electronic GFCI DG 60-200 4SX/ Electronic 4TX/4V s� � Electronic GFCI PG Electronic 150-400 Electronic GFCI DG 200-300 4UA Electronic 600-�200 Electronic GFCI PG G6-88 70/17e Page 3 KOHLEFi CO.,Kohler,Wisconsin 53044 USA Kohler Power Systems Phone 920-457-4441,Fax 920-459-1645 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada,phone 1-800-544-2444 Singapore 619159 KohlerPower.com Phone(65)6264-6422,Fax(65)6264-6455 ��;�,��'��l�'�c��B��ake,��►�pl;i��i�ra�; �ir1g[��I�e��'�'��h�� Dual Circuit Breaker installations A generator set with a single circuit breaker installed typically A generator set with duai circuit breakers installed is used to feeds a single transfer switch and then a distribution panel. separate critical loads. Typically,one circuit breaker will feed This allows protection of the entire system. a main transfer switch with noncritical loads and the other circuit breaker will feed a second transfer switch that feeds critical Line C.e. � loads. First Second � O� � Line C.B. Line C.B. �o � ° �. � � ° �� .� �� _ � .� 0 0 0 0 0 _ _ ATS O O o o O ATS ATS Distribution Distribution Panel Panel Distribution Distribution Panel Panel � � � � d To Remaining To Priority Load(s) � � � � Building Loads To Remaining To Priority Load(s) Single line circuit breaker configuration where circuit breaker can Building Loads trip causing all power to building loads including priority load to Dual line circuit breaker configuration where first circuit breaker be disrupted. can trip allowing second circuit breaker to continue supplying power to priority load(s). Dual Circuit Breaker Combinations First Second First Second Alternator C.B.Frame C.B.Frame Alternator C.B.Frame C.B.Frame Modet Size Size Comments Model Size Size Comments 100�o rating,standard or HD,JD,LA, DG — GFCI MC' or DG �00%rating,no GFCI 4P/4PX/4Q/ 4RX/4S/ 4QX/4RX/4S/ H� — 4SX/4TX/4V PG HD,JD,LA, 100%rating,no GFCI 4SX/4TX/4V/ JD — or DG 4UA HD HD HD,JD,IA, MG or OG DG available as GFCI JD HD or JD � _ 4UA PG HD,JD,LA, PG and/or DG available as or DG GFCI MG — PG PG 100%rating,no GFCI 4RX/4S/4SX/ PG 100%rating,standard or 4TX/4V/4UA — GFCI LA HD,JD,or � DISTRIBUTED BY: 4P/4PX/4Q/ HD,JD,LA, 4QX/4RX/4S/ DG or DG 100°�rating,no GFCI 4SX/4TX/4V HD,JD,LA, Primary or sec.available 4UA DG or DG �100%rating,std.or GFCI Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever.Contact your local Kohler�generator set distributor for availability. �zoo�,zo�o,2011 by KohlerCo. All rights reserved. G6-88 10/11e Page 6 MUITiPLES CsP RATEO CllRR€NT � °- " .. ., � :^ x a � .� s�� . .ns= �u, _ . . -'°"� �" -�°�� LAJLN FAM�LY PdD4flE6 CkSE CIRCUIT BREAKERS �' - -{ �� - --�awo CFiARACTERISTiC TREP CURVE NQ 6603 _ , � --;w ` � _ �., . .��_ __..._.._._ _ __.. _f _ _..___.. .. .__�.-�. ; ' t � ClRfU�TBREAKEAfHfORMATEtrtL xr.a _�,_ . -.-. ..,.._ . ,,,.. w _..,� ; �s�in ; . .._ _....., � �_ ....... . .:..... . ... . ._ . : . , �.._a . 8� . 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Sp9 , . , m..,di7i_ . _ > . . . .,..... . , _ ' "_' " ' wx - .. k .. � ., � . � _ . � � � � a ,.:aR � � � � � � ��,�� .^'f �� (} �� 4��N ��{�E �� MULTIPLES OF RA7Ed CURREN7 ^�F °=: c,ue,,�.,>c c.nw«.r � a��^i, ,.:g ..._ . 1 • - • - � • • LA, LH and Q4 Circuit Breakers Description 400-ampere frame circuit breakers with LA and LH circuit breakers rated 125 through 400 amperes and Q4 circuit breakers rated 250 through 400 amperes with the following features: �" �� ■ 2-and 3-pole construction � �� '� �A' These circuit breakers have 2-and 3-pole construction built in a 3-pole module. ■ Push-to-trip Yeliow push-to-trip button mechanically trips the circuit breaker. ■ Trip indication The handle moves to the center position when the circuit breaker trips. ■ ON/OFF indication LA CirCUit Breaker ON/OFF inarkings are on the face of the circuit breaker along with the international I/O markings. ■ Endurance(switching operations) 1,000 full-load operations 5,000 no-load operations ■ Thermal trip element ��"' �F�:,,f Thermal trip elements are factory calibrated for 40°C per the UL 489 =� Standard.Calibration for 50°C is also available without the UL Listing. ■ Magnetic trip element The magnetic trip element on the LA,LH and Q4 circuit breakers is set by a single adjustment on the circuit breaker cover. ■ Mounting All LA,LH and Q4 circuit breakers can be mounted and operated in any position,and are not limited to vertical or horizontal mounting. Q4 Circuit Breakers Continued on ne�page Ampere Interrupting Ratings(AIR) Catalog Number UL Listed Ampere Interrupting Ratings(AIR) IEC Ultimate Prefix Continuous RMS Symmetrical Amperes DC Volts Federal Rating 415/240V No.of Am ere SPe�� 50/60 Hz Poles P AC Volts,50/60 Hz W-C-375B! Unit-mount I-LINE° Rating 120 240 277 4277� 480 600 125 250 500 GEN 157-1 947-2 LAL LA 2,3 125-400 42K 42K — 30K 30K 22K 10K 10K — 21a 30K — LHL• LH• 2,3 125-400 65K 65K — 35K 35K 25K 10K 10K — 23a 36K — LHL-DC' — 2,3 — — — — — — — — — 20K — — — Q4L Q4 2,3 250-400 25K 25K — — — — — — — 14b — — 'Separate UL ratings available for 240Vand 480V grounded B single-phase systems. •UL Listed for 500 Vdc nom.600 Vdc max.rating.The circuit breakers are suitable only for use with UPS(uninterruptible power supplies)and ungrounded systems. D SQUARE D GROLIPE SCHNEIDER Classes 660 and 735 Thermal-Magnetic Molded Case Circuit Breakers ■ I-LINE�construction DesCl'iptlon—Continued All LA,LH and Q4 circuit breakers are available in I-LINE�plug-on construction. ■ Molded case switches Automatic molded case switches are available in LH 2-and 3-pole construction.Molded case switches provide no overcurrent protection. ■ MAG-GARD� circuit breakers The LA MAG-GARD�circuit breakers comply with requirements for Accessories instantaneous trip circuit breakers. Factory � Marine applications Field Installed LA and LH 2-and 3-pole circuit breakers are available for use on Accessory Installable Only* vessels over 65 feet in length. Shunt Trip• LA,LH,Q4 ■ Mining applications Undervoltage Trip• LA,lH,Q4 LA 2-and 3-pole circuit breakers are available. 1A1 B Auxiliary Switches' LA,LH,Q4 ■ DC applications N.o.or N.C.Be11 Alarm•• �q,�H,Qq LAL and LHL 125-400 ampere circuit breakers are suitable for use on 125 and 250 Vdc systems. Handle Tie LA,LH,C14 LHL-DC 3-pole 250-400 ampere circuit breakers are suitable only for Handle Extension LA,LH,Q4 use with uninterruptible power supplies and ungrounded systems rated Handle Padlock Attachment LA,LH,Q4 500 Vdc nominal,600 Vdc maximum. See AIR�able on page 1 for ralings. Electrical Motor Operator LA,LH,Q4 � Ratings Walking Beam LA,�H AIR-See table on page I. Cylinder Lock LA,LH,Q4 ■ Standards/Files •UL Listed accessory. Circuit breakers •Right pole. UL 489/E10027 *For LA and LH top-feed I-LINE�circuit breakers CSA C22.2 No 5.1/LR7551 Qaws on OFF end)all accessories must be factory installed. IEC 157-1 Molded Case Switches UL 1087/E33117 CSA C22.2 No.5.2/LR32390 MAG-GARD�UL Recognized Component UL 489/E 10027 CSA C22.2 No.5.1/LR32390 Marine circuit breakers UL489/E85161 ■ Rerating Circuit breakers can be rerated for: • Ambient temperatures below 25°C or above 40°C • DC magnetic trip level • 400 Hz applications For more information see application guide SD361R1,"Determining Current Carrying Capacity in Special Applications." 2 Classes 660 and 735 Thermal-Magnetic Molded Case Circuit Breakers Terminations Circuit breakers and molded case switches are provided with mechanical lugs for copper or aluminum conductors.Optional lugs are also available. ■ Reverse connection All LA,LH and Q4 circuit breakers are UL Listed,CSA Certified and IEC Rated for reverse connection without restrictions. �� Mechanical Lug Kit Information Kit Catalog Circuit Breaker Application Conductor Size and Type � �� Number (one wire per lug) (One lug per kit) Circuit Standard AWG/kcmil(mmz) � Breaker Ampere Rating AL400LA LA,LH,Q4 125-400 �1)#1-600(50-300)AI/Cu � (2)#1-250(50-120)AI/Cu CU400LA LA,LH,Q4 125-400 ��)#1-600(50-300)Cu (2)#1-250(50-120)Cu AL400LA AL400LH7 CU400LA AL400LH7 LA,LH,Q4 125�00 350-750(185-400)AI/Cu (optional) � � Power Distribution Lugs �Q �� Kit Catalog �Q D��Q Number Circuit Breaker Applications Conductor Size and Type �0 �DO� (One lug per kit) AWG/kcmil(mm) 0 PDC6LA20• LA,LH,Q4 (6)#12-#2/0(2.5-70)Cu PDC6LA20 PDC12LA4 PDC12LA4• LA,LH,Q4 (12)#14-#4(2.5-25)Cu � PDC4LA250• LA,LH,Q4 (3)#14-#2(2.5-35)Cu O (1)#2-250(35-120)Cu O •For use in UL580 Industrial Control applications only. Must be used on the OFF end only when the OFF end is the load end. PDC4LA250 Crimp Lugs Kit Catalog Circuit Breaker Conductor Size and Type Number Applications AWG/kcmil(mmz) VC400LA35 LA,LH,Q4 250-350(120-185)AI/Cu Q (Two Lugs Per Kit) p VC400LA3 (Two Lugs Per Kit) LA,LH,Q4 #4-300(25-150)Al/Cu VC400LA5 LA,LH,Q4 #2/0-500(70-240)AI/Cu (One Lug Per Kit) CVC400LA5 VC400LA3 VC400LA7 LA,LH,Q4 500-750(240-400)AI (One Lug Per Kit) 500(240)Cu CVC400LA3 LA,LH,Q4 #2/0-300(70-150)Cu (Two Lugs Per Kit) CVC400LA5 LA,LH,Q4 250-500(120-240)Cu (One Lug Per Kit) 3 Classes 660 and 735 Thermal-Magnetic Molded Case Circuit Breakers Dimensions Electrical Clearance/Wire Bending Space -------------------------- 1 � 14.00 [356] 3.87 5.98 [98] 1.58 2.81 [152j 2.86 0.25 �40� n�� [73] �6l + � - - - i 4 2� 0.44 � [109] �� I �N i ON 11.00 � [279] 9.25 � � � 3 73 TRIPPED [235] I � I951 OFF � OFF RESET � O O 4.48 i [114] 0.88�— 4.02 �22� 2.00 2.00 [102] [51] [51 j 4.56 [116] 5.81 2.00 2.00 (147] I511 [51] 0.98 � [25] 2.05 I I I 0.32 �52� Dual Dimensions:�NCHES �8� [Millimeters] � � � 0.34 [9] 1.26 [32J LA1046A.1 Square D,�,and MAGGARD and I-LINE are Registered 7rademarks of Square D Company. Order No.0660H09601 � SC3UARE D Square D Company 3700 Si�h Street SW GROLIPE SCHNEIDER 4 Cedar Rapids,IA 52406 Industrial Generator Set Accessories Cp �/ �Systeir�,Batteries ��""��.�� f V L.f'�. � I �� ,�� Standard Features �j� �.,�, ��,#,,�;, • Kohler Co.selects batteries to meet the engine �,��c��:�c:�aE�,sr�� manufacturer's specifications and to comply with Ty�i��1 G►verat[ Qim�nsie�ns . NFPA requirements for engine-cranking cycles. Heavy-duty starting batteries are the most cost- effective means of engine cranking and provide excellent reliability in generator set applications. I�—�'---�I • Batteries are rated according to SAE standard J-537. All batteries are 12-volt and have lead-calcium or lead- antimony plates with sulfuric acid electrolyte. • Most generator set battery kits offer dry-charged or wet-charged batteries. � • Tough polypropylene cases protect against life- � • shortening vibration and impact damage. �, Removable cell covers allow checking of electrolyte specific gravity. �— �—�. Battery SAE Dimension,mm in. Charge Voltage Fuel Battery Battery BCI L W H Cold Cranking Reserve Battery Post Type* Part Qty.per Group Amps at-18°C Capacity Layout and Number Kit Size (0°F)Min. Minutes at Style 27°C(80°F) Min. Wet 256984 1 24 273.0 173.0 228.6 650 130 C/1 (10.8) (6.8) (9.0) Batt�ry Specific�tior�s Sattery�ost L.dyou't�A–�C�snd Style�#-� Q �y � j � � F�oss�v$.'.i.48 dia. j � Ne�#•,te,'I�.8� dia. � � 3� � _� 1a��t�es�ht Poat 1:�;an� G <'�+� `� � � f3 _ — 1�.7-1�,I hei�# 3r8-1 S UtW^�-��4 k'nre�l Ntt7EEes: �ime�suar>�are in rnaa�:�,4 zzrtn equala 1�oh. ��f s�rs.�n�u�ers sF�wn a�t�a�ya. �r•Jer sEur9 aci!2..��7 tsa�.�nr�rtfrsm�ty�l��'tu�fi�iie 1. Industrial Generator Set Accessories ��o�t�Eqe�al iz� ��.�� lf V �� 1 �� a#ferj�; ��arg=e�r` �� Standard Features � ; , �. ��;=,,y�;, • 12 VDC output."Use two battery chargers for 24-volt �,��,�,�,k��k��,�s�� electrical systems - Automatic 3-stage float/equalize battery charger ' r � 5�� • Charges both lead-acid and gel-cell type batteries ',°��:.s ,F,F,�, • Indicator lamps: red and green LEDs indicate bulk �a , ��., charge, absorption, and float charge stages �°�� "�� • Durable potted assembly for full waterproofing and � shockproofing ,, - � • Reverse-polarity protection � � � 9� � • Short-circuit protection � �� j� � �_ .>" • UL 1236 listed � �. • UL 2200 compliant � '_ • UL 991 compliant for vibration and shock �� `° • UL listed to Canadian safety standards � � �Y • UL rated inline fuse ��, �� ; � �� #� ' • FCC Class B-compliant for EMI/RFI (Date code y � 8/26/04 or later) z� � ��`��-�� '� :� �� ,�F � �' � � �� °�'"�'�� . 1-year warranty ��,� ��r, u� .� '� { �?+.. v.� � �„ ,, .. • Easy installation: • Integral mounting flanges • Ring terminals for battery connection • Standard US style 3-prong AC plug S ecifications Batte Char er Kit GM78298-KA1 In ut Volta e 90-135 VAC In ut Fre uenc 50/60 Hz DC Out ut: Bulk 11.8-14.0 VDC 5.0-6.0 am s DC Out ut:Absor tion 14.0-14.5 VDC 1.5-5.0 am s DC Out ut: Float 13.3-14.5 VDC 0.1-1.5 am s Stead Full-Load Out ut Current am s Current Limit 7 am s Out ut Power Limit 70+2/-5 watts DC Volta e Re ulation 0.01 Isolation, In ut to Out ut 500 V Dimensions(L x W x D 164 x 87 x 53 mm 6.4 x 3.5 x 2.1 in) eight 1.6 k 3.5 Ib.) em erature Ran e, O eratin and Storage 40°C to 70°C -40°F to 158°F Humidity 0 to 100% (condensin Float/Equalize Battery Charger, continued �.�_.��.��.��r,�.� ��_.___________� ' ��.� --�--- ' ; ��s.�- �� •-"��.� —� � �.._ a�c:��.� -�„�' � � � '� - , , , � ��- �� ,_�, -��--�--�- I t � � II � I€ _ � ��, � _ � :,� �«<-�°��:.� � � �� ..r��..��. ` _.i I, =-�- �,. ce ..�, ,�,,�t :-��-- I � �f �.��. . x.�. � , .��_._� � � .�.� , � � _� F s� ' �° �'Jutp�st i�ed IBStg�i�1.2�rt t4 ft.� �; ` = ' ��4 ,, �� [ , i�� ; /��`,�3�?��$t$if4915�i�'k��811'1��.� � � �',�f ai � � �� a �� ' �� s 9� . � F ' � d � � '�' � € �t � �;"`e: �..�.�' �� &�� L�!'f�@3t'3iGit��!�iitlT63TX. �* 'n�s i t Battery Connections Lead �ength 1.2 m (4 ft.) Battery Connections 9.5 mm(3/8 in.)ring terminals AC Power Connections Lead Length 1.8 m (6 ft.) Connection Standard US style 3-prong AC plug Shipping Information Carton Size 254 x 152 x 89 mm (10 x 6 x 3.5 in.) Shipping Weight 1.8 kg (4 Ib.) C��r�g �t�rv�� — , � � � � � � ' � � � ; � � � � � � � fi $ � � � �".""�k��, � � � �� $r � S� � k �Li�t tdTti �,r O �� °�,: � � .... B S'S S A�.- i o.S 3 S8 2 '.# .. G�'. 6.3 a�a�a Industrial Generator Set Accessories �+�,ur��d�c�osure ��rr�� '�..�/�l Y �� i � I L�� i�ti ��e� T'ank ��a+ckage: �� Sound Enclosure Standard Features . �,.�� k��;��,�.,r,; • Intemal-mounted critical silencer and flexible exhaust ��,,,�.�,��:;x ��,�� connector. _ • Lift base-mounted or tank mounted steel construction �. . _.� .......,. _...._ ��....�_ ...... ..�.o.�.��.��_.�. with hinged doors. • Fade-, scratch-, and corrosion-resistant Kohler� cream beige and black powder-baked finish. • Lockable,flush-mounted door latches. � � • Vertical air inlet and outlet discharge to redirect air and reduce noise. • Lift base or tank-mounted, steel construction with hinged doors. � • Accoustic insu�ation that meets UL 94 HF1 flammability classification and repels moisture absorption. � � • Sound attentuated enclosure that uses up to 51 mm (2 in.)of acoustic insulation. Subbase Fuel Tank Features • The above-ground rectangular secondary containment tank mounts directly to the generator set, below the generator set skid (subbase). • Both the inner and outer tanks have emergency relief vents. • Flexible fuel lines are provided with subbase fuel tank selection. • The secondary containment generator set base tank meets UL 142 tank requirements.The inner(primary) tank is sealed inside the outer(secondary)tank.The outer tank contains the fuel if the inner tank leaks or ruptures. Sound Enclosure with Fuel Tank Package, continued ��-,se�at�^,-.�s,d rl�c�s �ac&at�e,t��h- ��,:��se�,�se�sse2r t6��..�� cc�-r�c,n-sesisiasa7 #ca�ase ai' ¢nc�a3attea3 doar�tres iv �-p��ueci safi�y� a�scn��U:g;-� �YeL'�_R—'Je'#�t�'�'7��337 5EN9G�t(� �'i,�+'.C+��:'ft 13.+i't.��?'�� t"..GS£!d�9YJFY ,� 2it1 3�I r1Jg8!gr:i5�35 f ', � \ I f t f� � d f� e � � �_�m�_ _._.._.�W__....._____....._.._. ` e • w �_._.. ..________-__�.....�._�,'.__�� _.8.tl _....._.._ ,.._....._.__._... e .�,xcc> .�a �F� LQI,'�JJ`�l��al'l7t.S • � 1� ~ � � � { �`�. �"5� ' a �y � �i/�.�;.._..�� € i E � i �1 �� - . . . . , .. � ' .. . . � 4 ! Y r�-�-.,..em.+��. ] / .`'_ � l ��-___.._ .__-__�__� ._...._�� ,a�v.rs� t � f �, ` r 1� � � �r �� ,�tE�a'��* �e�A£,�ua*�5 a��t�t Essc�a� tJ�c�� k�tt5f��a€�,n aar_ess e�t��ev� fi�akis�a-n°J �t��as��t ar�+�t1�.5�kfi=t �; �sr�rte�ar�a�a�=g ��a c�a�� n�€r�y cz��x� Nrstfs: 1�A��CiR�t�Z,��srts�ef��.+m,,ad�rract�a.rr��#�r��. I�f��it�r€�s�a�Ti;rr�,4DV dr��+i��f�detai�s. Sound Enclosure Features • Available in steel (14 gauge)formed panel, solid construction. Preassembled package offering dent resilient structure mounting directly to lift base or fuel tank. • Powder-baked paint. Superior finish, durability, and appearance. • Internal critical exhaust silencer offering maximum component life and operator safety. • Interchangeable modular panel construction.Allows complete serviceability or replacement without compromising enclosure design. • Cooling/combustion air intake with a horizontal air inlet. Sized for maximum cooling airFlow. • Service access. Multi-personnel doors for easy access to generator set control and servicing of the fuel fill,fuel gauge, oil fill and battery. • Cooling air discharge.Weather protective design featuring vertical air discharge. Redircts cooling air up and above the enclosure to reduce ambient noise. • Attenuated design.Acoustic insulation UL 94 HF1 listed for flame resistance offering up to 51 mm (2 in.)mechanically restrained acoustic insulation. • Cooling air discharge.The sound enclosures include acoustic insulation with urethane film. • Note: Installing an additional lenth of exhaust tail pipe may increase backpressure levels. Please refer to the generator set spec sheet for the maximum backpressure value. Sound Enclosure with Fuel Tank Package, continued E��i�ca� R��r�va4� �a€,�arcy !Jrrrwa? ;_a�H J'+�ids�ta�#:�3-y st�.ti�:�;,a� °s��e s�'•'?S'' ��r3z'k�bs ves$t �e�}��i t€�t�1�.�� cq�t�#�flc�baat €�SI:�? s�ia�1ErEi � 5'N�^�.st �cc=6�y � � l f 't, i r ' / �� k� _ ��.....__ � _„fi,�__,, ! j�_—.� ..�...� ..�._._.,.. _�. ..�.___°_._. ��._. e a a � s / �� ' 3 '�A 3. .-� i.. ..'� . .' r� � ' 4 % � R i f�` >, . 4 ` q / # ' `� )� � j! � F�. s � � � E ��5� i � ft � f: � �:) `�-'' "1� � f f � '+�-` '� t 'E E �4. � r � � ; � :4 # � ,��: .� is� � � 4 f �i r � { � � � & ' ,� ,,� ��, .��.�.,«.w 4 5_?.-....,..� �.._ 0�..•4,�,�. .T.�.,�,�.».,.... ,,. .... � .-+<-i>. y.�....,.�� 43 , .u� � . . .»� .... ..., , ...�,... � ....., o 1 � �� F��c £fer:ia,e�e fue3 k�sa�c�a� �ua��aa'i �y a�sle' �� stt��ci sv�itc�� ra3:�r,c�itc�ae zd3�wa��8�j a"�s aaix�+ 3�rk a?�4�.�e�R a�i � � 5,.�+. � . � �t f �t � � # t Q ``�� Ei 1 p � � �t� MF � � t I�i � � �f � � [ } 2 a �� 1 j�� y �S �i s � y� ?, ; � '; N�sta�: �=6E�R�G��f�s��us,rstfit�r mad�a�s�ttN�a'. �f�s f�i�t +�A�}b'drsr�+ing,#�at d�i9�. ��r;z��. Subbase Fuel Tank • Extended operation. Usable tank capacities offers full load standby operation of up to 72 hours. • UL listed. Secondary containment generator set base tank meeting UL 142 tank requirements. • NFPA compliant. Designed to comply with the installation standards of NFPA 30 and NFPA 37. • Integral external lift lugs. Enables crane with spreader-bar lifting of the complete package(empty tank, mounted generator set, and enclosure)to ensure safety. • Emergency pressure relief vents.Meets UL requirements;ensures adequate venting of inner and outer tank under extreme pressure and/or emergency conditions. • Normal vent with cap. Vent is raised above lockable fuel fill. • Low fuel level switch.Annunciates a 50% low fuel level condition at generator set control. • Leak detection switch.Annunciates a contained primary tank fuel leak condition at generator set control. • Electrical stub-up. • State tank designed to comply with the installation standards of the Florida Dept. of Environmental Protection (FDEP)File No. EQ-634. Fuel Tank Est. Max. Max. Enclosure Enclosure Enclosure Enclosure Fuel Sound Max. Weight, Capacity,L Fuel Length, Width, and Fuel and Fuel and Fuel and Fuel Tank Pressure Height, kg (Ib.) (gal.) Supply mm (in.) mm Tank Tank Tank Tank Height at 7m mm Hours at (in.) Length,mm Width, mm Weight, kg Height, mm (H), mm (23ft.), (in.) 60 Hz (in.) (in.) (Ib.) (in.) (in.) dB(A) with Full Load 815(215) 24/31 3400 1156(45.5) 1996 1855(73) 432(17) (133.9) (4400) industrial Generator Set Accessories �'��g�,��ul�tc�rs: �C��IE�� P"��'�E� ��'�TEC��1� �� Voltage Regulators � The following information provides general features, � ��' "'"�� specifications, and functions of available voltage ��;sc��a,a��r R�c�sr�� regulators. Integral Voltage Regulator with Kohler�Decision- Maker�3000 Controller(20-300 kW Generator Set Models) This information generally applies to a single generator set and multiple generator sets with paralleling applications. „ -z ,;;�,11A�,,;;,�� Refer to the respective generator set specification sheet "" �" and see your authorized distributor for information �.� �� regarding specific voltage regulator applications and ` � availability. .. �� .� .�. -�.� ��s�rrr��i�tcer�3�00�Contirc�er v�r�t&�tsgr�k V�rPE�c.�FEe+��t�atnr The voltage regulator is integral to the controller and uses microprocessor logic providing±0.5%no-load to full-load regulation using root-mean-square (RMS)voltage sensing. The voltage regulator features three-phase sensing and is available for 12-or 24-volt engine electrical systems. Integral Voltage Regulator with Decision-Maker�3000 Controller A€#�ustmertt d�gftaE Dts�sla� R��g�S�ttirsg [)efauit Se�ction Ve�tag�AEi��rt�r[ lA�C/s�:l`. _i4�k.cfS �t�cn'1�t�� Sy��s� � Ua��a�te��n�}�t3r�'u�r f'r�Y S�rtp�-ri �?is��2 tix 2.S Mz�i�w Sys�ars�r�qa�t�t�yr Fre�}tr�cy� Ust��tf��ert��r#,1nJ�ad flaps � �f-3�k��f Sy�t�tt�#age(Vs�7ts�r Cyd�) 5 V�ts�r�}t�e Voltage Regulators, continued Specification Integral with DEC 3000 Integral Voltage Regulators with Decision- Controller MakerO 3000 Controller Generator Set Availability 20-300 kW Models • A digital display and pushbutton/rotary dial provide access to data.A Type Microprocessor based �aline LCD display provides complete and concise information. Status and Shutdown LEDs and Digital Display • The controller provides ISO 8528-5,Class G3,compliance for Indicators transient response on some 20-300 kW generator set models. See Operating Temperature -40°C to 70°C(-40°F to the respective generator set spec sheet for specific applications • See G6-100 Decision-Maker�3000 for more information. 158°F) Storage Temperature -40°C to 85°C (-40°F to Generator Set Calibration Menu 185°F) • L1-L2 Volts • L2-L3 Volts(3-phase) Humidity 5-95% Non-Condensing • L3-L1 Volts(3-phase) Circuit Protection Solid-State, Redundant • �1-N Volts Softward and Fuses • L2-N Volts • L3-N Volts(3-phase) Sensing, Nominal 100-240 Volts(L-N),50-60 Hz Sensing Mode RMS, Single-or 3-Phase Voltage Regulation Menu Input Requirements 8-36 VDC • Adjust voltage,t10% Continuous Output 100 mA at 12 VDC Maximum Output 100 mA at 12 VDC Transition Frequency 50-70 Hz Exciter Field Resistance NA No-Load to Full-Load ±0.5% Voltage Regulation Thermal Drift less than 0.5%(-40 C to 70 C) [-40 F to 158 F] Range Response Time Less Than 5�S Voltage Adjustment(of ±10% system voltage) Voltage Adjustment Controller Menu Knob Remote Voltage NA Adjustment Paralleling Capability NA VAR/PF Control Input NA DVR�is a registered trademark of Marathon Electric Mfg.Corp. NA-Data not available at time of print. .�fl:o d��;,�;��[��'.�-Q 40 0 S. �C��I�.ER ��'`�E F� ��'�TEI�I�� C��'� MPACO 1500 Controller � �rrr� ,��=.r �.��,�,.�:�x Standard Features �v��a�r��.��v R��:,�r�a�¢ • Microprocessor-based controller i �.� e • Environmentally sealed user interface v ' � � I�," " • LCD display,4 lines x 20 characters,backlit ,« G� i • Dynamic function keypad with tactile feedback pushbuttons y�l�� '�i�� allows complete programming and viewing capability at the door k` , y • LED indicators:Source available,transfer switch position, service required(fault),and"not in auto" • Broadrange voltage sensing(208-600 VAC)on all phases • Phase-to-phase sensing and monitoring with 0.5%accuracy on both sources • Frequency sensing with 0.5%accuracy on both sources • Anti-single phasing protection !� ; V� ' • Phase rotation sensing for three-phase systems � ,,u. �+ '��'' "ii , • Real-time clock with battery backup and automatic adjust for daylight saving time and leap year • Time-stamped event log � Fail-safe transfer for loaded test and exercise functions . • DIP switches:password disable and maintenance • Modbus�RTU and Modbus�TCP/IP protocols • (Modbus�register map available) • RJ45 connector for 10/100 ethernet connection ;�� • USB port with read/write compatibility �� • Isolated RS-485 ports „�� ` ' • One-year limited warranty Programmable Features Transfer Switch Standard Features • Programming and monitoring methods: • UL 1008 listed at 480 VAC o Monitoring and password-protected programming at the file#E58962(automatic),#E86894(nonautomatic) door using the keypad and display • CSA certification available o Program and monitor using a PC with Monitor II I integrated • Available with either automatic or non-automatic control generator set and ATS monitoring software • Available in 2, 3,or 4 pole configurations o Transfer files through the USB port • High withstand/closing ratings,for use with specific breakers only ' System voltage and frequency • Electrically operated, mechanically held mechanism • Voltage unbalance • Double-throw, mechanically interlocked design(break-before- ' Over/undervoltage and over/underfrequency for all phases ofthe make power contacts) normal and emergency sources • Enclosed arc chambers with arc chutes • Adjustable time delays • Standard-transition model KSS and programmed-transition KSP � Load/no load/auto-load test and load/no-load exercise functions model available • Programmable inputs and outputs • Silver tungsten alloy contacts on 400-600 amp models(Model ' Time-based and current-based*load control KSS) • Load bank control for exercise or test • Silver alloy main contacts(Model KSP) • Pre/post-transfer, nine individual time delays for selected loads • Front-accessible contacts for easy inspection • ABC/BAC/none phase rotation selection with error detection • Programmed-transition operation provides a center OFF position � Resettable historical data that allows residual voltages in the load circuits to decay(Model ' In-phase monitor KSP) • Password protection,three security levels • Main shaft auxiliary position-indicating contacts,one set Normal {Requires current sensing kit. and one set Emergency KSS-DCTA-0400S, continued User Intertace LED Indicators Communications • Contactor position:source N and souroe E • USB port with read/write capability • Source available:source N and source E • Isolated RS-485 ports • Service required(fault indication) • RJ-45 connector for 10/100 ethernet connection • Not in automatic mode • Modbus�RTU and Modbus�TCP/IP protocols(Modbus� register map available) LCD Display • USB Port.Upload or download files from a PC or a memory • System status device through the USB port. • Line-to-line voitage o Application software • Line-to-neutral voltage o Event history files • Active time delays o Language files • Source frequency o Parameter settings • Preferred source selection o Usage reports • System settings o Feature configuration • Common alarms • Load current,each phaset USB Data Logge� • Inputs and outputs • Time-stamped voltage and frequency readings • Faults • Minimum and maximum current and voltage readings for a • Time/date selected time period • Address • Event history Programmable Features • Maintenance records • System voltage,208-600 VAC* • Exerciser schedule • System frequency,50/60 Hz* • Exerciser mode • Single/three-phase operation* • Time remaining on active exercise • Standard/programmed-transition operation* • Preferred source selection Dynamic Function Tactile Keypad Operations • Phase rotation:ABC/BAC/none selection with error detection • Scroll up/down/forwardlback • Voltage and frequency pickup and dropout settings • Increase/decrease/save settings • Voltage unbalance,enable/disable • End time delay • In-phase monitor:enable/disable and phase angle • Start/end test or exercise • Transfer commiUno commit • Reset fault • Source/source mode:utility/gen,gen/gen, utility/utility,or utility/ • Lamp test gen/gen for 3-source systems • Passwords, system and test DIP SwitChes • Time,date,automatic daylight saving time enable/disable • Maintenance mode • Time delays(see table) • Password disable • Exerciser:calendar mode,loaded/unloaded up to 21 events • Test:load/unloaded/auto load(1-60 minutes) Event HistO • Remote test:loaded/unloaded ry • Automatic override on generator failure(►oaded test and • View up to 99 time and date-stamped events on the display or exercise) on a personal computer equipped with optional Monitor III . Peak shave delay enable/disable software. • Current monitoring t • Downioad up to 2000 events with Monitor III software or . Pre/post-transfer,9 individual time delays for selected loads download complete event history file to a PC or a memory device . Current-based load control settings:high/iow current levels and connected to the USB port. load add/remove priority for 9 separate loads t • Prime power sequence alternates between two generator sets Main Logic Board Inputs and Outputs • Resettable historical data • Two(2)programmable inputs • Two(2)programmable outputs,isolated form C(SPDT)contacts `System parameters factory-set per order. rated 1 amp @ 30 VDC,500 mA @120 VAC t Requires optional current sensing kit. Modbus�is a registered trademark of Schneider Electric. Main Board I/O S ecifications Output contact e Isolated form C SPDT Output contact rating 1 amp @ 30 VDC,500 mA @ 120 VAC I/O terminals wire size ran e 12-24 AWG KSS-DCTA-0400S, continued Programmable Inputs Volta e and Fre uenc Sensin • External time delay input Parameter Default Ad'ustment Ran e • Extemal battery fault Undervolta e dro out 90%of picku 75%-98% • External common fault Undervoltage pickup 90%of nominal 85%-100% • Inhibit transfer • Load shed to force transfer to OFF(programmed-transition Overvolta e dro out* 115%of nominal• 106%-135% models only;requires optional load shed kit) Overvoltage pickup 95%of dropout 95°/a-100% • Peak shave/area p�oteCtion input Unbala�ce enable Disable Enable/Disable • External teSt Unbalance dropout 20% 5%-20% • Three-source system disable U�balance pickup 10% 3%-18% Volta e dropout time 0.5 sec. 0.1-9.9 sec. Programmable Outputs Underfrequenc dropout 99%of ickup 95%-99% • ChiCago al8rm COnt�ol Underfrequency pickup 90%of nominai 80%-95% • COmmon alarm events Overfrequency dropout 101%of icku 101%-115% • Contactor position Overfrequency pickup 110%of nominal 105%-120% • Exercise active Frequency dropout time 3 sec. 0.1-15 sec. • Failure to aCquire Standby SourCe '690 volts,maximum.Default=110%for 600 volt a �ications. • Failure to transfer • Generator engine start,source N and E Ad'ustable Time Dela s • I/O module faults Time Dela s Default d"ustment Ran • Load bank control En ine start,Source S2 3 sec. -60 sec. t • Load control active(pre/post transfer delay, up to 9 outputs) En ine start,Source S1 en/ en 3 sec. • Loss of phase fault,source N and E En ine cooldown,Source S2 5 sec. • Externai battery fault En ine cooldown,S1 en/ en sec. • Non-emergency transfer • Not in automatic mode Fail to ac uire standb source 1 min. -60 min. • Over/underfrequency faults,source N and E(generator) Fail to acquire preferred source 1 min. • Over/undervoltage faults,source N and E ransfer, referred to standb 3 sec. • Peak shave/area protection active ransfer,standb to referred 15 min. • Phase rotation error,source N and E ransfer,off to standb 1 sec. • Preferred source supplying load ransfer,off to referred 1 sec. • Software-controlled relay outputs(four maximum) Fail to s nchronize 30 sec. • Source available, preferred and standby uto load test duration 30 min. 1-60 min. • Standby source supplying load 1 min.increments • Synchronizing output Prime power run duration 0 min. min.-100 days. • Test active 6 min.increments • Transfer switch auxiliary contact fault Load control Time Dela s: • Transfer switch auxiliary contact open Pretransfer to referred sec. • Voltage unbalance Post-transfer to referred sec. Pretransfer to standb sec. -60 min. Post-transfer to standb sec. Load add Sourcel/Source2 0 sec. Load remove Sourcel/Source2 0 sec. Note:Time delays are adjustabie in 1 second increments,excep as noted. Engine start can be extended to 60 minutes with an External Batte Su I Module Kit. KSS-DCTA-0400S, continued Application Data Environmental S cifications UL-Listed Solderless Screw-Type Terminals for Operating Temperature -20°C to�o°c(-a°F to 158°F� External Power Connections Stora e Tem erature -40°C to 85°C -40°F to 185°F Humidi 5%to 95%noncondensin Normal, Emergency,and Load Terminals Switch Cables per Max Number Range of Wire In ut and Out ut Connection S cifications Rating, Pole of Cables per Sizes Copper Component Wire Size Range Amps Pole or Aluminum Main board I/O terminals #12-24 AWG 0400 1 1 #4 AWG to 600 I!O module terminals #14-24 AWG MCM 0400 2 2 #1/0 AWG to 250 MCM Use 60°C minimum wire for#14 to#1 AWG.Use 75°C minimum wire for 1/0 AWG and lar er. Codes and Standards • The ATS meets or exceeds the requirements of the following • EN61000-4-4 Fast Transient Immunity Severity Level 4 specifications: • IEC 60947-6-1,Low Voltage Switchgear and Control Gear; • Underwriters Laboratories UL 508,Standard for Industrial Multifunction Equipment;Automatic Transfer Switching Control Equipment Equipment • Underwriters Laboratories UL 1008,Standard for Automatic • EN61Q00-4-5 Surge Immunity Class 4 Transfer Switches for Use in Emergency Standby Systems file (voltage sensing and programmable inputs only) #E58962(automatic),#E86894(nonautomatic) • IEC Specifications for EMI/EMC tmmunity: • CSA C22.2 No. 178 certification at 600 VAC available,file# o CISPR 11, Radiated Emissions LR58301 o IEC 1000-4-2, Electrostatic Discharge • NFPA 70, National Electrical Code o IEC 1000-4-3,Radiated Electromagnetic Fields • NFPA 99,Essential Electrical Systems for Health Care Facilities o IEC 1000-4-4,Electrical Fast Transients(Bursts) • NFPA 110, Emergency and Standby Power Systems o IEC 1000-4-5,Surge Voltage • IEEE Standard 446, IEEE Recommended Practice for o IEC 1000-4-6,Conducted RF Disturbances Emergency and Standby Power Systems for Commercial and o IEC 1000-4-8, Magnetic Fields Industrial Applications o IEC 1000-4-11,Voltage Dips and interruptions • NEMA Standard IC10-2005, Electromechanical AC Transfer Switch Equipment • IEEE 472(ANSI C37.90A)Ring Wave Test Contacts Resistive Load Inductive Load Motor Load, NC Motor Load, NO Engine Start Contacts 2 A@ 30 VDC N/A N/A N/A Auxiliary Contacts 15 A@ 250 VAC N/A N/A N/A Weights & Dimensions See ADV drawings for weights and dimensions. Allow 15% additional weight for packing materials. KSS-DCTA-0400S, continued Withstand /Close-On Ratings (WCR) Standard Transition Model The transfer switch is rated for use on a circuit capable of delivering not more than the RMS symmetrical amperes listed at 480 volts maximum, but no greater than the interrupting capacity of the selected circuit breaker. Circuit breakers are supplied by the customer.All WCR values are available symmetrical RMS amperes and tested in accordance with the withstand/closing requirements of UL 1008. Certified Withstand/Closin Current Ratin s in RMS S mmetric Am eres Current Limitin Fuse S eci�c Coordinated Breaker Rattin s Switch Rating, Maximum Fuse Fuse Class Maximum *Maximum 'Maximum *Maximum amps Size,amps Amps Voltage Circuit Breaker Amps Size, amps 0400 600 J 200000 480 V/60 Hz 800 50000 0400 600 RKS, RK1 100000 480 V/60 Hz 800 50000 Suitable for emer enc and standb a lications on all classes of load,30%tun sten rated on all am era es Suitable for emergency and standby applications on all classes of load,30%tungsten rated on all amperages Ratings with Specific Manufacturer's Circuit Breaker Withstand/closing ratings(WCR)in RMS symmetrical amperes for specific manufacturers'circuit breakers. ithstand Current Ratings, Maximum Current in RMS Symmetrical Amperes When Coordinated with: Switch Rating, WCR, Voltage, Max. Manufacturer Type Max.Size, amps amps RMS amps 400 50000 480 Cutler-Hammer HJD,JDC 250 400 50000 480 Cutler-Hammer HKD, CHKD, KDC, LCL, 400 LA TRIPAC 400 50000 480 Cutler-Hammer HLD, CHLD, LDC, CLDC 600 400 50000 480 Cutler-Hammer NB TRI-PAC 800 400 50000 480 Square D KI, KC 250 400 50000 480 Square D LI, LXI, LX, LE, LC 600 400 50000 480 Square D MX, ME, MH 800 400 50000 480 Siemens CFD6, HFD6 250 400 50000 480 Siemens CJD6, SCJD6, HHJD6, 400 HHJXD6, SHJD6, HJD6 400 50000 480 Siemens CLD6, SCLD6, HHLD6, 600 HHLXD6, SHLD6, HLD6 400 50000 480 Siemens CMD6, SCMD6, HMD6, 800 SHMD6, HMXD6, MD6, MXD6, SMD6 400 50000 480 GE SFL, SFP, TFL,THLC2 250 400 50000 480 GE SGL4, SGP4,TB4, 400 THLC4,TL64 400 50000 480 GE SGL6, SGP6,T66, 600 TJL4V,TKL4V, TJL1 S-6S 400 50000 480 GE SKL8, SKP8, TB8, SKH8 800 400 50000 480 Merlin Gerin CF250L, CF250H 250 400 50000 480 Merlin Gerin CJ400L, CK400H, 400 CJ400H, CK400N 400 50000 480 Merlin Gerin CJ600H 600 KSS-DCTA-0400S, continued 400 50000 480 Merlin Gerin CK800H, CK800N 800 KSS-DCTA-0400S, continued Accessories Accessories are available either factory-installed or as loose kits, unless otherwise noted. Warranty • Warranty-1-year KSS-DCTA-0400S, continued �r��lel ��e��gn�tian h+��1 tatec�iertism Tr�s��ar� Cksntrrrl� �'a�tage Pol�� Eru�c�sure Gurr�rrt Ratir�g �atisc�➢�rre�su� ��.........._. .��,.,,,,r,.. ��,,...�,. ..._x...�,�► ._ , ,..Y. ..._, � i C-�1 �l �l Im � � 1 I �K,. _ � I�`-I ❑ %❑ ❑ - ❑ ❑ ❑ ❑ � ❑ R�€�rci tt�e tr�nsf�r swit�h rt�d�:l t��sit�n�ticm in the bc�x�s. 'Th�trans�r s�ritch m+�F cf�signat�n cf+etir��s �h�ra+�t�risti+cs ar�ratir�s�s explai�cl b�nw. Sampi� Mod�l �esi�n�tic�n: �45P=[7CT�t-0�Qfl� l�vc�+el hlurttber c�f Pc�1�,`�ir�;s K: f€r�hker T�ansfier Switc� �� C�. �-pc�le,�-wir�r st�[id�eutral , / T: .�-pate,4wire,sotid neutratL� IS��cla�nism V: 4-pal�;4-wire,scvitc�tl n+�utr�l S: 5p�cifi�-E3�eaker Rated .l�� Er€�losure Tr�n�ition A: t�lEFu1A i-��'/ a: �JE�4 S: 5tar�ci�rd �� B: N'EMA �� F: EVE�A 47C P: P'rr�t�r�€rtme� C: NE�rtA 3R G: C7pen unit CC►t�trt)fs � i NEMAi ��sure i� s�t�d�rd. C�ther types ar� D: MF'AG"' 15(3f} �val�Ie tc�c�r�er. M�ropr�;�or Conttals,Aut�maf� F: MPAG"� 15(�t� Curr�r�t Ratir�: C�umbers rndirate th�current Micr�rprrs�sst�r �ntrv[s, E'+�t�-Ac��r+atic ra�ing t�f the switch in arnperes: �falt�g��Freq��n�y Ot7� * fl�flt� i��i� G. �+DB Vtslts,�&4 Hz � ��` �2��`_. �Bt�C� 01 C1t� t12�fl*" 1 t7i�{� G: �2f3�lt�t5j�{1 Nz 415t) � i��{�{} �.� F: 2��c�tsi�U Hz G. �$�1 Vt�tts��t}Mz - �tar�dar�i-�r�sita�m r�l��r�i�. �i_ 4t�t}llolt�f�t�Mz ,3: 41 Ei Vott�r��U Nz E�: 4�{34'�ItsJ'6Cl H� Mliscell�ne�us M: 4�fl Vr�ftsJ�s{l Mr �q ,�nd�r'd�nc�ctit�r�s � P: 3�t}Volts�6�}Nz F�: ��(�V+r�ktsi�f�F-tz _...__._.............................................. _......_..........__..................._............................_ _.._.. Kt��LER POVIWER SYSTEIVIS � � � � � � � ��_ TIB-102 P��WER SYSTE�ViS TECHNICAL INFORMATION BULLETIN Alternator Data Sheet Alternator Modei: 4R9X Frequency: 60 Hz Speed: 1800 RPM Leads: 12(6 Lead, 600 Volt) kW" kVA Class B Class F Class H Voltage Power 80°C 90°C 95°C 105°C 130°C 125°C 750°C L�I/L-� Phase Factor Connection Continuous Llo ds ABS Continuous Standb Continuous Standb 139/240 3 0.8 y�ye $4.0 88.5 90.5 95.0 103.0 101.5 109.5 277/480 105.0 110.5 113.0 118.5 128.5 126.5 136.5 127/220 3 0.8 y�/ye 83.0 87.5 89.5 93.5 101.5 100.0 108.0 254/440 103.5 109.0 111.5 116.5 126.5 125.0 135.0 ��1'�' � �� ':1� �� ; ��U6.5 _. .,, �` . :� ` ��° ��- F�, g'' � �3�:n 110/190 3 0.8 Wye 74.5 78.0 80.0 &4.5 91.5 89.5 96.5 220/380 93.0 97.5 100.0 105.5 114.0 111.5 120.5 120/240 3 0.8 Delta 82•0 86.0 88.0 92.0 100.5 98.5 106.5 102.5 107.5 110.0 115.0 125.5 123.0 133.0 120/240 1 1.0 Dogleg 64.5 67.5 68.5 71.0 77.5 76.5 82.5 64.5 67.5 68.5 71.0 77.5 76.5 82.5 347/600 3 0.8 �/ye 83.5 88.0 90.0 94.5 102.5 101.0 109.0 104.0 110.0 112.5 118.0 128.0 126.0 136.0 * All data tested in accordance with IEEE Standard 115. Kohler Co.reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Submittal Data:139/240 Volts,0.8 PF,7800 RPM,60 Hz,3 Phase,130°C Rise Symbol PerUnit Ohms Symbol Value Typical Cold Resistances Typical Time Constants Phase Resistance 0.054 0.024 Armature Short Circuit Ta 0.007 sec. Rotor Resistance 16.96 7.585 Transient Short Circuit T'a 0.065 sec. Typical Reactances Transient Open Circuit T'da 0.748 sec. Synchronous Typical Field Current Dired X, 2.969 1.328 Full Load ITFL 21.6 amps Quadrature Xq 1.523 0.681 No Load ifNI 5.6 amps Transient Typical Short Circuit Ratio 0.337 Unsaturated X'c� 0.292 0.131 Harmonic Distortion Saturated X', 0.257 0.115 RMS Total Harmonic Distortion 3.20% Subtransient Max.Single Harmonic 5th Direct X"a 0.123 0.055 Deviation Factor(No Load,L�) <5% Quadrature X"q 0.114 0.051 Telephone Influence Factor <50 Negative Sequence XZ 0.118 0.053 Insulation Class Zero Sequence Xo 0.011 0.005 per NEMA MG1 1.66 H Phase Rotation ABC TIB-102 4R9X 60 Hz 5/11n � 4R9X, 60 Hz, 139/240,277/480 Volts,Wye TYPICAL ALTERNATOR EFFICIENCY* 100 98 96 94 � 92 c m � 90 °�,' 88 0.8 PF 86 84 82 80 0 10 20 30 40 50 60 70 80 90 100 110 Output(KVV) 4R9X,60 Hz, 139/240, 277/480 Volts,Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 40 35 30 o, 25 'o d � 20 0 > ° 15 10 5 0 0 50 100 150 200 250 300 350 400 450 500 Locked Rotor KVA * All data tested in accordance with IEEE Standard 115. Kohler Co.reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. 2 4R9X 60 Hz 5l11n TIB-102 4R9X, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 1000 I 100 __ i � 10 w d � � � 1 � '� 0.1 I � 0.01 1 1000 10000 0 100 Armature Current(A)" �Alternator damage curve 3 phase symmetrical ��Line to Line 1 ph � • Line to Neutral 1 ph *Instantaneous current(t=0) is asymmetric. Divide by 1.73 for symmetric. TIB-102 4R9X 60 Hz 5/11n 3 4R9X,60 Hz, High Wye Connection SHORT CIRCUIT DECREMENT CURVE 1000 i 100 _ _ __ _ _ _ _ - — � - - - � 10 ' w d E � � � � - — I � � � 0.1 �I . , � 0.01 10 100 1000 10000 Armature Current(A)" �Altemator damage curve 3 phase symmetrical ��Line to Line 1 ph � • Line to Neutral 1 ph *Instantaneous current(t=0) is asymmetric. Divide by 1.73 for symmetric. 4 4R9X 60 Hz 5/11n TIB-102 _... _... Kt3H�.�R_PC�WER SYSTElvlS_ • • � . • �(�, TIB-114 f��/VER ��STEMS TECHNICAL INFORMATION BULLETIN Generator Set Sound Data Sheet Sound Pressure Data in d6(A) Generator Open Unit, Weather Sound Set Model Hz �oad Raw Exhaust Isolated Exhaust Enclosure Enclosure 80REOZJF 60 100%Load 112.4 84.9 83.0 69.3 No Load 100.1 80.9 79.0 68.3 Note: Sound pressure data is the logarithmic average of eight perimeter measurement points at a distance of 7 m(23 ft.), except Raw Exhaust data which is a single measurement point at 1 m(3.3 ft.)from the mouth of a straight pipe exhaust. 80REOZJF 60 Hz Sound Pressure Leveis d6(A) Distance, Measurement Odave Band Center Frequency{Hz) Overall Load m�ft� EnGosure Position Level 63 125 250 500 1000 2000 4000 8000 Ri ht 40.7 60.9 61.7 63.1 59.5 58.2 55.3 50.7 68.3 Front�ti ht 46.0 58.5 62.6 66.1 63.2 59.8 59.6 52.6 70.3 Front 48.2 58.6 61.4 66.3 622 62.1 61.5 55.6 70.6 Fron6Left 49.7 59.9 62.9 66.1 62.4 60.6 59.7 54.4 70.5 100% ��23) Sound Left 45.4 59.1 62.8 63.6 59.1 59.4 58.4 54.3 68.9 Load Back Left 42.3 58.7 63.4 62.3 59.7 58.9 57.4 52.8 68.6 Back 48.2 56.6 59.6 63.9 59.4 58.6 56.8 51.5 67.8 Back Ri ht 48.0 56.4 61.7 62.5 61.2 58.8 56.9 51.1 68.0 8{�os.log avg. 46.9 58.8 62.1 64.5 61.1 59.7 58.6 53.2 69.3 Sound Pressure Leveis dB(A) Distance, Measurement Fronf Fronf Back- Back- 8�os. Load m�ft� EnGosure position Right Right Front Le� Left Left Ba� Right log avg. 100% ��23) Weather Overall Levels 81.2 84.3 78.9 82.6 83.0 83.1 85.3 82.8 83.0 Load Sound Pressure Levels dB�A) Load Distance, Measurement Octave Band Center Frequency(Hz) Overall m(ft.) Position 63 125 250 500 1000 2000 4000 8000 Level Ri ht 56.9 62.2 73.4 74.5 74.8 78.4 73.9 68.6 83.1 FronERi ht 58.0 65.0 72.9 73.0 76.1 79.7 77.4 72.2 86.2 Front 64.7 61.3 72.5 73.9 73.7 75.3 70.4 64.5 80.8 , Open Unit, FronfLeft 64.4 61.1 72.6 75.9 77.4 79.4 75.8 70.2 84.5 100/o ��23) isolated Left 67.8 64.7 74.0 78.7 78.2 79.0 75.0 71.5 84.9 Load �haust Bacl�Left 66.9 62.4 74.0 76.9 75.6 76.8 77.0 72.3 85.0 Back 63.4 62.3 73.3 75.2 74.0 77.1 78.4 75.6 87.2 Back�ti ht 57.7 61.9 72.6 76.2 75.9 80.2 75.8 70.7 84.7 8�os.log avg. 64.1 62.8 732 75.9 76.0 78.5 76.0 71.6 84.9 Sound Pressure Levels d6(A) Distance, Octave Band Center Frequency(Hz) Overall Load Exhaust m(ft.) 63 125 250 500 1000 2000 4000 8000 Level 100°/a � (3.3) Raw Exhaust No Silencer 75.2 94.8 98.6 101.4 104.0 103.7 107.8 105.9 112.4 Load � � TIB-114 80REOZJF 60 Hz 8/12 1 80REOZJF 60H� Sound Pressure Levels d6(A) Distance, Measurement Octave Band Center Frequency(Hz) Overall Load m�ft� Enclosure position Level 63 125 250 500 1000 2000 4000 8000 Right 47.9 60.0 62.0 62.3 57.8 55.4 50.1 41.6 67.3 Front�2ight 51.0 58.7 63.3 65.7 622 57.0 55.9 43.5 69.7 Front 52.5 58.2 61.1 65.7 61.4 59.9 59.0 47.0 69.6 Front�eft 51.9 60.0 63.9 65.4 61.5 56.2 55.0 44.4 69.7 N0 7(23) Sound Left 49.7 58.3 63.1 62.2 57.2 54.9 51.0 42.7 67.4 Load Back-�eft 42.6 60.4 65.1 61.0 58.4 55.8 50.1 42.5 68.3 Back 46.8 54.3 58.4 62.8 57.5 53.8 50.2 38.5 65.9 Back�ti ht 44.6 55.8 61.1 61.3 59.8 56.1 50.4 40.2 66.6 8�os.log avg. 49.5 58.6 62.6 63.7 59.9 56.5 54.1 43.2 68.3 Sound Pressure Levels d6(A) Distance, Measurement Front- Front- Back- Back- 8�os. Load m�ft� EnGosure position Right Right Front �eff Le� Left Ba� Right log avg. No ��23) Weather Overall Levels 78.5 79.3 78.9 80.0 80.4 78.3 76.7 78.8 79.0 Load Sound Pressure Levels d6(A) Distance, Measurement Odave Band Center Frequency(Hz) Overall Load m(ft.) Position Level 63 125 250 500 1000 2000 4000 8000 Ri ht 49.9 63.1 73.2 72.7 73.6 74.9 70.7 61.7 80.4 Front�i ht 50.3 63.2 71.9 71.6 76.0 76.1 72.4 64.9 81.2 Front 53.3 63.0 72.4 74.0 74.4 75.4 70.3 62.8 80.8 Open Unit, Front�.eft 48.7 62.7 72.2 74.5 76.9 75.5 73.0 65.0 81.9 No ��23) Isolated Left 46.0 65.4 73.6 76.6 76.6 75.4 71.9 64.2 82.3 Load Exhaust Back�eft 49.5 61.1 72.6 74.5 73.5 72.5 71.2 64.1 80.2 Back 45.9 64.3 72.3 72.0 71.6 68.4 71.0 64.8 78.6 Back�ti ht 50.4 63.7 72.1 74.2 75.4 73.8 71.1 62.6 80.7 8�os.log avg. 49.8 63.5 72.6 74.0 75.1 74.5 71.5 63.9 80.9 Sound Pressure Levels dB(A) Distance, Odave Band Center Frequency(Hz} Overall Load � � Exhaust m �• 63 125 250 500 1000 2000 4000 8000 Level No � �3.3) Raw Exhaust(No Silencer) 70.4 82.5 85.8 90.9 93.0 93.4 92.9 93.6 100.1 Load 2 80REOZJF 60 Hz 8/12 TIB-114 _.._........................__...._................ ......................... ..............................................._.__.............................................._.. KC�HLER_PC�WER SYSTElVIS_. • � . . Kt�HLER� PC�WER SYSTEIVIS 80REOZJF 60 HZ. DIESEL INDUSTRIAL GENERATOR SET EMISSION DATA SHEET ENGINE INFORMATION Model: John Deere,4045HF285H Bore: 106mm(4.19 in.) Nameplate BPH @ 1800 RPM: 133 Stroke: 127mm(5.00 in.) Type: 4-CyGe,4 Cylinder,Inline Displacement: 4.5 L(276 cu.in.) Aspiration: Turbocharged,Charge Air-Cooled Compression Ratio 19:1 EPA Family: CJDXL04.5119 EPA Certificate: CJOXL04.5119-015 1/4 1/2 3/4 Full PERFORMANCE DATA: Standbv Standb Standb Standb Engine bkW @ Stated Load 41.77 55.69 7425 99.00 Fuel Consupumtion(g/kWh) 285.50 264.80 241.90 224.60 Exhaust Gas Fiow(m3/s) 1152.00 Exhaust Temperature(°C) 579.00 EPA CERTIFICATE EXHAUST EMISSION DATA: DATA HC(Total Unbumed Hydrocarbons) 0.2 0.340 0.120 0.050 0.040 NOx(Oxides of Nitrogen as NO2) 3.4 3.240 2.940 3.840 5.320 CO(Carbon Monoxide) 1.3 2.770 2.600 1.760 1.190 PM(Particular Matter) 0.17 0.281 0.246 0.148 0.132 Values are in glkWh TEST METHODS AND CONDITIONS ISO 8528 D2 Data and specifications subject to change without notice For further information, please contact Todd Loes at John Deere Power Systems, 319-292-6050 w q o • C7 N V •L� c0 .d m '" �y � t« � .� a� � p w o A �a �� c � AN cd � °' .v � � � � oz �„ N � � o a. f-� � p o •� ti � v, y E.�y �� rfAr � •a�i � � � •� a�i O �� a � o � � � � C7 0 �� .� a O�.i a ~ z "> >; N o� > �y�.y�U � a ' v°' `' ` �!a� � Nw ; y � J�/ � � O � C >, «w,�,,, v� ..c � •on y � cr f.r��Q o � z b � � � T � w �Z� > N c .n .D � C �w ,�, U d,Q! 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Transfer Switch and Bypass Isolation Transfer Switch One-Year Limited Warranty Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original consumer, Kohler Co.warrants,for the period indicated below,each product to be free from defects in materials and workmanship. Repair, replacement,or appropriate adjustment at Kohler Co.'s option will be furnished if the product,upon Kohler Co.'s inspection,is found to be properly installed,maintained,and operated in accordance with Kohler Co.'s instruction manuals. A Kohler distributor,dealer,or authorized representative must pertorm startup. This warranty does not apply to malfunctions caused by damage,unreasonable use, misuse,repair or service by unauthorized persons,or normal wear and tear. Kohler Product Warranty Coverage* Transfer Switch and Bypass Isolation Switch One(1)year from date of startup *Some restrictions may apply. Contact your Kohler distributor/dealer for full details. The following will not be covered by the warranty: 1. Normal wear,periodic service,and routine adjustments. 6. Rental of equipment during performance of warranty 2. Damage caused by accidents, improper installation or repairs. handling,faulty repairs not performed by an authorized 7. Non-Kohler-authorized repair shop labor without prior senrice representative,or improper storage. approval from the Kohler Co.Warranty Department. 3. Damage caused by operation above or below rated 8. Expenses incurred investigating performance complaints capacity, voltage, or frequency; modifications; or unless the problem is caused by defective Kohler installation contrary to published specifications,codes, materials or workmanship. recommendations,and accepted industry practices. g, Maintenance items such as fuses, lamps, and 4. Original installation charges and startup costs, adjustments. 5. Damage caused by negligent maintenance such as: a. Failure to provide a clean,dry environment. b. Failure to perform recommended exercising. c. Failure to pertorm scheduled maintenance as prescribed in supplied manuals. d. Useofotherthanfactory-suppliedor-approvedrepair parts and/or procedures. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co.within 60 days afterthe date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co.using the Kohler Co.ship date as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative, or write Kohler Co., Generator Service Department, Kohler,WI 53044 USA. KOHLER CO.SHALLNOT BE LIABLE FOR SPECIAL,INCIDENTAL,ORCONSEQUENTIALDAMAGES OFANY KIND including,but not limited to,incidental consequential labor costs,installation charges,telephone charges,ortransportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty nor is anyone authorized to make any on our behalf. ANY IMPLIED OR STATUTORY WARRANTY,INCIUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts,or the exclusion or limitation of incidental or consequential damages,so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights,and you may also have other rights that vary from state to state. KOHLER� KOHLER CO.Kohler,Wisconsin 53044 Phone 920-565-3381,Fax 920-459-1646 POWER SYSTEMS Forthe nearest sales/service outlet in the US and Canada,phone 1-800-544-2444 KohlerPowerSyste ms.com TP-5373 72/99d Stationary Standby and Prime Power One-Year or Two Thousand (2000)-Hour Limited Warranty Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original consumer, Kohler Co. warrants,for the period indicated below, each product to be free from defects in materials and workmanship. Repair, replacement,or appropriate adjustment at Kohier Co.'s option will befurnished if the product,upon Kohler Co.'s inspection,is found to be properly installed, maintained, and operated in accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty does not apply to malfunctions caused by damage,unreasonable use, misuse,repair or service by unauthorized persons,or normal wear and tear. Kohler Product Warranty Coverage* Generator Set&Accessories One(1)yeaz or 2000 hours(whichever occurs first)from date of initial startupt Prime Power Generator Set 20 kW or Larger One(1)year or 2000 hours(whichever occurs first)from date of initial startupi' *Somerestrictionsmayapply. CoMactyourKohlerdistributor/dealerforfulldetails. #Startup must occur within 24 months of original shipment by Kohler Co. The following will not be covered by the warranty: 1. Normal engine wear, routine tuneups, tuneup parts, 7. Engine coolant heaters, heater controls, and circulating adjustments,and periodic service. pumps after the first year. 2. Damage caused by accidents, improper instailation or g. Rental of equipment during performance of warranty handling, faulty repairs not performed by an authorized repairs. service representative,or improper storage. 3. Damage caused by operation with improper fuel or at 9. Parts purchased from sources other than Kohler Co. speeds, loads, conditions, modifications, or installation Replacement of afailed Kohler part with a non-Kohier part contrary to published specifications or recommendations. voids warranty on that part. 4. Damage caused by negligent maintenance such as: 10. Radiators replaced rather than repaired. a. Failure to provide the specified type and sufficient 11. Fuel injection pumps not repaired locally by an authorized quantity of lubricating oil. servicing dealer. b. Failure to keep the air intake and cooling fin areas clean. 12. Non-Kohler-authorized repair shop labor without prior c. Faiture to service the air cleaner. approval from Kohler Co.Warranty Department. d. Failure to provide sufficient coolant and/or cooling air. 13. Engine fluids such as fuel,oil,or coolant/antifreeze. e. Failure to pertorm scheduled maintenance as prescribed in supplied manuals. 14. Shop supplies such as adhesives,cleaning solvents,and f. Failure to regularly exercise the generator set under rags. load(stationary applications only). 15. Expenses incurred investigating performance complaints 5. Original installation charges and startup costs. unless the problem is caused by defective Kohler 6. Starting batteries and the following related expenses: materials or workmanship. a. Labor charges related to battery service. 16. Maintenance items such as fuses, lamps, filters, spark b. Travel expense related to battery service. piugs,loose or leaking clamps,and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co.within 60 days afterthe date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co.using the Kohler Co.ship cJate as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., Generator Service Department,Kohler,WI 53044 USA. KOHLER CO.SHALLNOT BE LIABLE FOR SPECIAL,INCIDENTAL,ORCONSEQUENTIALDAMAGESOFANY KIND including,but not limited to,incidental consequential labor costs,installation charges,telephone charges,or transportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty nor is anyone authorized to make any on our behalf. ANY IMPLIED OR STATUTORY WARRANTY,INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts,or the exclusion or limitation of incidental or consequential damages,so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights,and you may also have other rights that vary from state to state. KOHLER� KOHLER CO.Kohler,Wisconsin 53044 Phone 920-565-3381,Fax 920-459-1646 PO�NE R SYST EMS For the nearest sales/service outlet in the US and Canada,phone 1-800-544-2444 KohlerPowerSystems.com TP-5374 12/99c _ ..... _ _.. _.._.. _ _._.._ KaHLER POWER SYSTEI�/1S ' . • �� :, ;, �� s ° s �� `' � _ "� : fi � �� Certi�cate US95I0189 � �� : ' �'� T�YB t118DflQBfR6Bl S�0� _ _ __...s ___.A..,.,...,,. M,_ ,. � � f s �� y� �� Kohler Power Systems Americas �� F � d�� ` �� N7650 County Road LS �# g �� Sheboygan,WI 53083 ' • � � � �� u ` United States �� ,��a��"� � � has been assessed and certibed as meatr�g d�e requirements a � �� O , �� iso 9001 :2oos �°�j2a �,� � s{�,��` �� Og �� .� ,F. � .� �� ' For 1he to0owk�p act�ie,s �_€ ¢��° ��;f; �� Desi9n,mmufacture,and distributor suppat for electrical gen�ators, �� alternabrs,automauc transfe�switches,and switchgear. ,�� `�°�£�� Fwm�ca�aa«a re�a��me�cope a�ns ce�e.,d u��ca�ry or �� ISO 80012008 requiretnenis may be ab�ined by oa�g Qie oiganiza6an � �� This ce�ificate is valid from 17 iJovember 2009 u�il 16 November 2012 and b-x �� remains valid subjed to satisfactory sun►eiElance audits. k Recertification auc�t due a minimum of 30 days before the expiration date. � Issue 8.Certified since February 1995 � � � � �� 3 This is a multi-site ce�tification. � � ��' �� , °; Addihonal site details are listed on su uent �� 4 Pages. �� ¢�� . � , r � � ��y �� WN//J��ir��s;� ��:�� S/ d v �� c-,v �s P✓�� ; f r d " ZaChelly pfn,emik � °� a'��`��'� Ikasdkd6on Ale�myer�No11h AmeriCa �,� � �� # � � � �& :� SGS US Teskg Compay,lnc,Syslems and Sen�Ces CerificaUon � 201 flw�le 17 Pbro1��fad,New Jersey�07W0 USA • � i �� t+1 201 508 3000 f+t 2018254556 wvmus.sqs.can "��:°��'`� Tfpc cerll�e rernak�s fie propehy�SGS and sheN be telumed upon roquest . ��ti � .'�)r � t �af�1 � .AL�ig �Ft �{ ,�� v P��N? f : �� : k �'�:� /�d ay. '�� s i, � �`��r�-= g �.Mk�n��.wuNr nn•/.r rn.iw 4x.n uui�uc.:n rr,•w��,:wr.a �� { �� . ��M'a� ' ; �� _ E � �� _ � ' CertificaEe US95/0189,continued j � i �,�� ' _..__�_.. .__.__ _� _< ��° ��,� � --t-- �� rk-v,. �a�'��v��,�*�, : �d�y ��.�� Kohler Power Systems Americas � � ��:� �� = iso gool :2oos �� ; �� o ��a � � � �� OO, --s'�-na"� ��., . ' �SSU@$ ?OQ8 s�a��, ..,- ��4 � �Bd 800pB ��.,�''�� . �� 3= � �� Fwd�er Cla�ificali�regard'irg the scape of tfiis c�5licate and ihe appicab�ly of s � �� ISO 9001:2008 tequkemerKS may be obfainad by ooreuNkq the agarrsa6on f��`�y�i ��y� .��,��/ �Ii11r11111W B�€`` a q�u ^_L ��p� �.3 si�,��,�k{ � �7W 16 VO��a W�B'��5��Pry � �7�7YW�VA��7ti11.�. f � ` 4 �:3 s� i'�� e "i ��4 s��%c`��' i 4 �. � v � $; `��R` 2 � ..°�`� �r: y��: T"3 �U'* /-.`�s ��'� L. a� � '�i � �.� •:�' �� H� 1 1 �^`�.o �u?; �� r� �. �� % � � �� f< �� `�� °�_ �� s� � r �.,� x��a,� �, ��; ; �� z ��p�� . ��..,v.r.��...,, _._ �,,.._ S. � : � � � p.Mle Mdn�wlw�.M�1w�MM•a 4 MII Nu1f we.tlq M�wM N aw10rYM Kohler Standby/Prime Generator Set Test Program Testing is an integral partof quality assurance. In keeping with our uncompromising commitmentto quality,safety, and reliability,every Kohler Standby/Prime power generator set undergoes an extensive series of prototype and production testing. Prototype Testing � Generator set cooling and air flow tests to verify maximum operating ambient temperature. Prototype testing includes the potentially destructive tests necessary to verify design, proper function of � Reliability tests to demonstrate product durability, protective devices and safety features,and reliability followed by root cause analysis of discovered expectations. Kohler's prototype testing includes the failures and defects. Corrective action is taken to following: improvethe design,workmanship,orcomponents. � Aiternator temperature rise test per NEMA • Acoustical noise intensity and sound attenuation MG1-32.6. Standby and prime ratings of the effects tests. alternator are established during this test. � Maximum power test to assure that the prime Production Testing mover and alternator have sufficient capacity to operate within specifications. In production, Kohler Standby/Prime generator sets • Alternator overload test per NEMA MGi-32.8. are built to the stringent standards established by the prototype program. Every Kohler Generator set is • Steady-stateloadtesttoensurevoltageregulation fully tested prior to leaving the factory. Production meets or exceeds ANSI C84.1,NEMA MG1-32.17 testing includes the following: requirementsandtoverifycompliancewithsteady- � Statorandexciterwindinghigh-potentialtestonall state speed control specifications. generators. Surge transient tests on stators for • Transient test to verify speed controls meets or generators 180 kW or larger. Continuity and exceeds specifications. balance tests on all rotors. • Transient load tests per NEMA MGi-32.18, and • One-step, full-load pickup tests to verify that the ISO 8528 to verify specifications of transient performance of each generator set,regulator,and voltage regulation,voltage dip,voltage overshoot, governor meets published specifications. recovery voltage,and recovery time. • Regulation and stability of voltage and frequency • Motor starting tests per NEMA MG1-32.18.5 to aretestedandverifiedatnoload,i/41oad,1/21oad, evaluate capabilities of generator, exciter, and 3/4 load,and full-rated►oad. regulator system. • Voltage, amperage, frequency and power output • Three-phase symmetrical short-circuit test per ratings verified by full-load test. NEMA MG1-32.13 to demonstrate short circuit performance, mechanical integrity, ability to • The proper operation of controller logic circuitry, sustain short-circuit current. prealarm warnings, and shutdown functions is tested and verified. • Harmonic analysis, voltage waveform deviation per NEMA MG1-32.10 to confirm that the • Any defect or variation from specification generator set is producing clean voltage within discovered during testing is corrected and retested acceptable limits. prior to approval for shipment to the customer. Torsional analysis data, to verify torsional effects are not detrimental and that the generator set will provide dependable service as specified,is available upon request. Kohler offers othertesting at the customer's request at an additional charge. These optional tests include power factor testing, customized load testing for specific application, witness testing, and a broad range of MIL-STD-705c testing, A certified test report is also available at an additional charge. KOHLER� KOHLER CO.Kohler,Wisconsin 53044 Phone 920-565-3381,Fax 920-459-1646 POW E R SYST E MS For the nearest sales/service outiet in the US and Canada,phone 1-800-544-2444 KohlerPowerSystemscom �ia-5s iz/usa _ ...... . _... _. ................_ KC�HLER P�WER_SYSTEIVIS � ' . • ' Generator Set�Transfer Switch Installation Checklist This document has generic content and some items may not apply to some applications. Check only the items that apply to the specific application. Read and understand all of the safety precautions found in the Operation and Installation Manuals. Make the following installation checks before performing the Startup Checklist. Note: Use this form as a general guide,along with any applicable codes or standards. Comply with all applicable codes and standards. Improper installation voids the warranty. Equipment Room or Weather Housing Does Not Dces Yes Apply Not ❑ ❑ 25. Is there an exhaust line condensate trap with a drain Yes Apply ❑ ❑ 1. Is the equipment installed in a fire-resistant room installed? (made of non-combustible material)or in an outdoor ❑ ❑ 26. Is the specified silencer installed and are the hanger weather housing? and mounting hardware tightened? ❑ ❑ 2. Is there adequate clearance between the engine and ❑ ❑ 27. Is a heat-isolating thimble(s)installed at points floor for service maintenance? where exhaust lines pass through combustible ❑ ❑ 3. Is there emergency lighting available at the wall(s)or partition(s)? equipment room or weather housing? ❑ ❑ 28. Is the exhaust line free of excessive bends and ❑ ❑ 4. Is there adequate heating for the equipment room or restrictions? 's the backpressure within outdoor weather housing? specifications. ❑ ❑ 5. Is the equipment room clean with all materials not � � 29• is the exhaust line installed with a downward pitch related to the emergency power supply system toward the outside of the building. removed? ❑ ❑ 30. Is the exhaust line protected from entry by rain, ❑ ❑ 6. Is the equipment room protected with a fire snow,and animals? protection system? ❑ ❑ 31. Does the exhaust system outlet location prevent Engine and Mounting entry of exhaust gases into buildings or structures? ❑ ❑ 32. Are individuals protected from exposure to high ❑ ❑ 7. Is the mounting surface(s)properly constructed and temperature exhaust parts and are hot parts safety leveled? decals present? ❑ ❑ 8. Is the mounting surface made from non-combustible qC Electrical System material? ❑ ❑ 9. Was the generator-to-engine alignment performed � ❑ 33. Does the nameplate voltage/frequency of the after attaching the skid to the mounting base? generator set and transfer switch match Generator sets with two-bearing generators require normal/utility source ratings. alignment. ❑ ❑ 34. Do the generator set load conductors have adequate Lubrication ampacity and are they correctly connected to the circuit breakers and/or the emergency side of the ❑ ❑ 10. Is the engine crankcase filled with the specified oil? transfer switch? Cooling and Ventilation ❑ ❑ 35. Are the load conductors,engine starting cables, battery charger cabies,and remote annunciator ❑ ❑ 11. Is the cooling system filled with the manufacturer's leads installed in separate conduits? specified coolantJantifreeze and purged of air? ❑ ❑ 36. Is the battery charger AC circuit connected to the �] [] 12. Is there adequate inlet and outlet air flow(electric corresponding voltage? louvers adjusted and ventilation fan motor(s) Transfer Switch,Remote Control S stem Accessories connected to the corresponding voltage)? y + ❑ ❑ 13. is the radiator duct properly sized and connected to ❑ ❑ 37. Is the transfer switch mechanism free of binding? the air vent or louver? Note: Disconnect all AC sources and operate the ❑ ❑ 14. Are flexible sections installed in the cooling water transfer switch manually. lines? ❑ ❑ 38. Are the transfer switch AC conductors correctly Fuel connected? Verify lead designations using the appropriate wiring diagrams. d ❑ 15. Is there an adequate/dedicated fuel supply? ❑ � 39. Is all other wiring connected,as required? ❑ ❑ 16. Are the fuel filters installed? Batteries and DC Electrical System ❑ ❑ 17. Are the fuel tanks and piping installed in accordance ❑ ❑ 40. Does the battery(ies)have the specified CCA rating with applicable codes and standards? and voltage? ❑ ❑ 18. Is there adequate fuel transfer tank pump lift ❑ a 41. Is the battery(ies)filled with electrolyte and capacity and is the pump motor connected to the connected to the battery charger? corresponding voltage? ❑ ❑ 19. Is the fuel transfer tank pump connected to the a ❑ 42. Are the eng�e starting cables connected to the emergency power source? battery(ies). ❑ ❑ 43, Do the engine starting cables have adequate length ❑ ❑ 20. Are flexible fuel lines installed between the engine and gauge? fuel inlet and fuel piping? ❑ ❑ 44. Is the battery(ies)installed with adequate air ❑ ❑ 21. Is the specified gas pressure available at the fuel ventilation? regulator inlet? ❑ ❑ 22. Does the gas solenoid valve function? ❑ ❑ 45. Are the ends of all spark plug wires proper�ly seated onto the coil/distributor and the spark plug. ❑ ❑ 23. Are the manually operated fuel and cooling water Special Requirements valves installed allowing manual operation or bypass of the solenoid vaives? ❑ ❑ 46. Is the earthquake protection adequate for the Exhaust equipment and support systems? ❑ ❑ 47. Is the equipment protected from lightning damage? ❑ ❑ 24. Is the exhaust line sized per guidelines and dces it have flexible connector(s)? Is the flexible connector(s)straight? Generator Set/Transfer Switch Startup Checklist This document has generic content and some items may not applyto some applications. Check only the items that apply tothe specific application. Read and understand all of the safety precautions found in the Operation and Installation Manuals. Complete the installation Checklist before performing the initial startup checks. Refer to Service Bulletin 616 for Warranty Startup Procedure Requirements regarding generator set models with ECM-controlled engines. Does Dces Yes qppy Yes�ply ❑ ❑ 1. Verify that the engine is filled with oil and the cooling ❑ ❑ 29. Close the normal source circuit breaker or replace fuses system is filled with coolant/antifreeze. to the transfer switch. ❑ ❑ 2. Prime the fuel system. ❑ ❑ 30. Check the normal source voltage,frequency,and ❑ ❑ 3. Open all water and fuel valves. Temporarily remove the phase sequence on three-phase models. The normal radiator cap to eliminate air in the cooling system. source must match the load. Replace radiator cap in step 21. ❑ ❑ 31. Open the normal source circuit breaker or remove fuses � � 4. Place the generator set master switch in the to the transfer switch. OFF/RESET position. Observe Not-in-Auto lamp and � � 32. Manually transfer the load to the normal source. alarm,if equipped,on the controller. � ❑ 33. Close the generator set main line circuit breakers,close ❑ ❑ 5. Press the lamp test,if equipped on controller. Do all the the safeguazd breaker,and/or replace the fuses alarm lamps on the panel illuminate? connected to the transfer switch. ❑ ❑ 6. Open the main line circuit breakers,open the safeguard ❑ ❑ 34. Place the generator set master switch in the RUN breaker,and/or remove fuses connected to the position. generator set output leads. a 0 35. Check the generator set voitage,frequency,and phase ❑ ❑ 7. Turn down the speed control(electronic governor)or sequence on three-phase models. The generator set speed screw(mechanical governor).* must match normal source and load. ❑ ❑ 8. Verify the presence of lube oil in the turbocharger,if ❑ ❑ 36. Place the generator set master switch in the equipped. See the engine and/or generator set OFF/RESET position. operation manual. � � 37. Open the generator set main line circuit breakers,open ❑ ❑ 9. Place the generator set master switch in the RUN the safeguard breaker,and/or remove the fuses position. Allow the engine to start and run for several connected to the transfer switch. seconds. � � 38. Reconnect the power switching device and logic ❑ ❑ 10. Verify that the day tank,if equipped,is energized. controller wire harness at the inline disconnect plug at ❑ ❑ 11. Place the generator set master switch in the the transfer switch. OFF/RESET position. Check for oil,coolant,and ❑ ❑ 39. Close the normal source circuit breaker or replace fuses exhaust leaks. to the transfer switch. Place the generator set master ❑ ❑ 12. Turn on the water/oil heaters and fuel lift pumps. switch to the AUTO position. ❑ ❑ 13. Check the battery charger ammeter for battery charging ❑ ❑ 40. Close the generator set main line circuit breakers,close indication. the safeguard breaker,and/or replace the fuses connected to the transfer switch. ❑ ❑ 14. Place the generator set master switch in the RUN 41. Place the transfer switch in the TEST osition load test position. Verify whether there is sufficient oil pressure. d � p � Check for oil,coolant,and exhaust leaks. or open normal source circuit breaker). NOTE: Obtain permission from the building authority before ❑ a 15. Close the safeguard circuit breaker. Adjust the engine proceeding. This procedure tests transfer switch speed to 50/60 Hz if equipped with an electronic operation and connects building load to generator set governor or to 52.8/63 Hz if equipped with a mechanical power. governor.* 16. If the s eed is unstable,ad ust accordin to the � ❑ 42. Readjust frequency to 50 or 60 Hz with total building ❑ ❑ P 1 9 loads.* appropriate engine and/or governor manual.* ❑ ❑ 43. Verify that the current phase is balanced for three ❑ ❑ 17. Adjust the AC output voltage to match the load voltage phase systems. using the voltage adjusting control. See the generator set/controller operation manual. ❑ ❑ 44. Release the transfer switch test switch or close the normal circuit breaker. The transfer switch shouid ❑ ❑ 18. Allow the engine to reach normal operating coolant retransfer to the normal source after appropriate time temperature. delay(s). ❑ ❑ 19. Check the operating temperature on city water-cooled ❑ � 45. Allow the generator set to run and shut down models and adjust the thermostatic valve as necessary. automatically after the appropriate cool down time ❑ ❑ 20. Manually overspeed the engine to cause an engine delay(s). shutdown(68-70 Hz on 60 Hz models and 58-60 Hz on � d 46. Set the piant exerciser to the customer's required 50 Hz models). Place the generator set master switch exercise period,if equipped. in the OFF/RESET position.* � � 47. Verify that all options on the transfer switch are adjusted ❑ ❑ 21. Check the coolant level,add coolant as necessary,and and functional for the customer's requirements. replace the radiator cap. Verify that all hose clamps are tight and secure. ❑ ❑ 48. If possible,run the building loads on the generator set for several hours or perform the load bank test if ❑ ❑ 22. Piace the generator set master switch in the RUN required. position. ❑ ❑ 49. Verify that all the wire connections from the generator ❑ ❑ 23. Verify the engine low oil pressure and high coolant set to the transfer switch and optional accessories are temperature shutdowns.* tight and secure. ❑ ❑ 24. Check the overcrank shutdown* ❑ � 50. Verify that the customer has the appropriate ❑ ❑ 25. Place the generator set master switch in the engine/generator set and transfer switch literature. OFF/RESET position. Instruct the customer in the operation and maintenance ❑ ❑ 26. Open the normal source circuit breaker or remove fuses of the power system. to the transfer switch. ❑ ❑ 51. Fill out the startup notification at this time and send the white copy to the Generator Warranty Dept. Include the ❑ ❑ 27. Disconnect the power switching device and logic warranty form if applicable. � controller wire harness at the inline disconnect plug at the transfer switch. ❑ ❑ 28. Manually transfer the load to the emergency source. * Some models with an Engine Electronic Control Module(ECM)may limit or prohibit adjusting the engine speed or testing shutdowns. Refer to appropriate documentation available from the manufacturer.