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2251 RUTHERFORD RD; ; CB012175; Permit
City ,of Carlsbad 1635 Faraday Av Carlsbad, CA 92008 07-31-2001 Commercial/Industrial Permit Permit No: CB012175 Building Inspection Request Line (760) 602-2725 6096 07/31/01 0002 01 02 CGP 235-26 Job Address: Permit Type: Parcel No: Valuation: Occupancy Group: Project Title: 07/31/2001 2251 RUTHERFORD RD CBAD Tl Sub Type: 2120612000 Lot#: $4,0QO.OO Construct.ion Type: Reference #: Q-BIOGENE -BACK UP GENERATOR INDUST 0 NEW Applicant: Owner: R J OGDEN ELECTRICAL ,.,.,_GAUTSCH JAMES W &~LIZABETH S REVOCABLE TRUST 11-2 Status: Applied: Entered By: Issued: ln~pect Area: f\\308 BASSWOOD AVE CARLSBAD CA 92008 ?60-434-1834 451 S GRANADOS-AVE SOLANA BEACH CA 92075 ISSUED 06/25/2001 JM Plan Approved: 07/31/2001 Total Fees: $235.26 Total Payments To Date: . $0.00 Balance Due: $235.26 Building Permit · Add'I Building Permit Fee Plan Check Add'I Plan Check Fee Plan Check Discount Strong Motion Fee Park Fee LFM Fee Bridge Fee BTD#2 Fee BTD#3 Fee Renewal Fee Add'I Renewal Fee Other Building Fee Pot. Water Con. Fee. Meter Size Add'I Pot. Water Con. Fee Reel. Water Con. Fee ~{! f;,.L:. Inspector: ' $53.49 $0.00 $34.77 $146.00 $0.00 · ${00 $0.00" $0.0b· $0.00 •' $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Meter Size Ad<il Reel. Water Con. Fee · Meter Fee . SDGWAFee . , CFO Payoff Fee PFF, . , PFF (CFD Fund)· 1,.icense Tax LicenseTax(CFD Fund) Traffic Impact Fee , : na:mc Impact (CFD FL,Jnd) PIZUMBING TOTAL ELECTRICAL TOTAL MECHANICAL TOTAL Master Drainage Fee: Sewer Fee: Redev Parking Fee: Additional Feesi TOTAL PERMIT FEES FINAL APPROVAL $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $235.26 Date: Ci /t 1,,Jo-i., I Clearance: _____ _ NOTICE: Please take NOTICE that approval of your project includes the "Imposition" of fees, dedications, reservations, or other exactions hereafter collectively referred to as "fees/exactions.· You have 90 days from the date this permit was issued to protest imposition of these fees/exactions. If you protest them, you must follow the protest procedures set forth in Government Code Section 66020(a), and file the protest and any other required information with the City Manager for processing in accordance with Carlsbad Municipal Code Section 3.32.030. Failure to timely follow that procedure will bar any subsequent legal action to attack, review, set aside, void, or annul their imposition. You are hereby FURTHER NOTIFIED that your right to protest the specttied fees/exactions DOES NOT APPLY to water and sewer connection fees and capactiy clianges, nor planning, zoning, grading or other similar application processing or service fees in connection with this project. NOR DOES IT APPLY to any fees/exactions of which vou have oreviouslv been aiven a NOTICE similar to this or as to which the statute of limitations has oreviouslv otherwise exnired. . M /4,_,5 /J_;; PERMIT APPLICATION CITY OF CARLSBAD BUILDING DEPARTMENT 1635 Faraday Ave., Carlsbad, CA 92008 FOR OFFICE USE ONLY PLAN CHECK No.®/ ~/75 EST. VAL. __________ _ Validated By__,,-1-1--=--=--""'.::'"*"-==-.-+.,...,.- Date ________ ~q_..1t::..~~~- Address (include Bldg/Suite #) Business Name (at this address) Legal Description Lot No. Subdivision Name/Number Unit No. Phase No. Total # of units Assessor's Parcel f /. OX WM 12l>~ZJl'cJJ/ ~ Description of Work SQ. FT. #of Stories # of Bedrooms # of Bathrooms Name Address City State/Zip Telephone # Fax # i~t1~;,;;~~~-:~;;~1~°b1QMi~~c~sf~~~~f-~;~i~~~i~~YJtts,-:.;,7?;:t/IiJ~~Jfir Name Address City State/Zip Telepho"ne # i4'Z..~~~fsq_W1_a~~:ij'7:~~VZA/:.·~-~=:::~~:;~ =-~~,::~:~:_::"".:.:.s·:Lil::~~-::z~~::;£:2:~:-::i~i>::1::.,:;:~£,~i:i:--~~ E -;;,,· ;_1:t,/i:'.-.:{1r:0z~1 Name Address City S,tate/Zip Telephone# Es:Z_::::,c;:Qw:_~@:'9'!hs.CQ.MP.~Ji!Y\N"~~- <sec. 7031.5. Business and Professions Code: Any City or County which requires a permit to construct, alter, improve, demolish or repair any structure, prior to its issuance, also requires the applicant for such permit to file a signed statement that he is licensed pursuant to the provisions of the Contractor's License Law [Chapter 9, commending with Section 7000 of Division 3 of the Business and Professions Code) or that h_e is exempt therefrom, and the basis for the alleged exe~ption. Any violation of Section 7031.5 by any applic ntjo_r a permit subjects the applicant to a civil penalty of not more than five undred dollars ($500]). K . :J: 66i ~ L 130 ~S.Si M, t:::-4-US 1-~6 r_;-r//7 Name Address City State/Zip ~elep ~e # State License# 'ft/() 0?,-0 License Class . <!':.-/C, J.I IC-City Business License# ':J e~ ~ ~ Designer Name Address City State/Zip · Telephone State License # _________ _ ~~'~WQ1iKl;a$.~J~QMf!~J~1$AlJ,Q,N·, --,~: ""'\" ~ ,,,,-'" ,,r" .. ~~,;;2\,,«~,<v~,-~1~-~:H,·;:. '" ;,_·' -~ ~-~-..:~,:~ ~= ~--w l,, -~, ::::72:~"-~ ~~~'t-~C?~-=:;;-\1=7 ll:.~?,::~~:~;-¼:~l~~·£] Workers' Compensation Declaration: I hereby affirm under penalty of perjury one of the following declarations: D I have and will maintain a certificate of consent to self-insure for workers' compensation as provided by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued. D I have and will maintain workers' compensation, as required by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued. My worker's compensation insurance carrier and·policy number are: Insurance Company __ ~-----------------Policy No. Expiration Date _______ _ (THIS SECTION NEED NOT BE COMPLETED IF THE PERMIT IS FOR ONE HUNDRED DOLLARS ($100] OR LESS) ~ CERTIFICATE OF EXEMPTION: I certify that in the performance of the work for which this permit is issued, I shall not employ any person in any manner so as to become subject to the Workers' Compensation Laws of California. WARNING: Failure to secure workers' compensation coverage is unlawful, and shall subject an employer to criminal penalties and civil fines up to one hundred thousand dollars , 00), in addition to the cost of compensation, damages as provided for in Section 3706 of the Labor code, interest and attorney's fees. . DATE 6-2-o -Z.Oo / I, as owner of the property or my employees with wages as their sole compensation, will do the work and the structure is not intended or offered for sale (Sec. 7044, Business and Professions Code: The Contractor's License Law does not apply to an owner of property who builds or improves thereon, and who does such work himself or through his own employees, provided that such improvements are not intended-or offered for sale. If, however, the building or improvement is sold within one year of completion, the owner-builder will have the burden of proving that he did not build or improve for the purpose of sale). D I, as owner of the property, am exclusively contracting with licensed contractors to construct the project (Sec. 7044, Business and Professions Code: The Contractor's License Law does not apply to an owner of property who builds or improves thereon, and contracts for such projects with ·contractor(sl licensed pursuant to the Contractor's License Law). D I am exempt under Section ______ Business and Professions Code for this reason: 1. I personally plan to provide the major labor and materials for construction of the proposed property improvement. D YES ONO 2. I (hav!l / have not) signed an application for a building permit for the proposed work. 3. I have contracted with the following person (firm) to provide the proposed construction (include name / address / phone number/ contractors license number): 4. I plan to provide portions of the work, but I have hired the following person to coordinate, supervise and provide the major work (include name / address / phone number/ contractors ficense number): _______________________ ~---------------------- 5. I will provide some of the work, but I have contracted (hired) the following persons to provide the work indicated (include name / address / phone number / type of work): ________________________ ~--~---------------------------- PROPERTY OWNER SIGNATURE______________________ DATE ________ _ ~iiQ'Mfi:~1S:tBfs:fij.¢:r19.Ki=fftri:0Jt~{t1~£Nffit1P1,Qirl~Pii~ir§;,9N.X!:r:;:7:S::~ :.-· ::-.:,:~::-cc7~p::;::;-::}~:f;:;;rc.:f::1::~iifC'?:~:t:·:tY!1~:t::::~ Is the applicant or future building occupant required to submit a business plan, acutely hazardous materials registration form or risk management and prevention program under Sections 25505, 25533 or 25534 of the Presley-Tanner Hazardous Substance Account Act? D YES ~ NO Is the applicant or future building occupant required to obtain a permit from the air pollution control district or aJr quality management district? X YES O NO Is the facility to be constructed within 1,000 feet of the outer boundary of a school site 7 D YES ){' NO IF ANY OF.THE ANSWERS ARE YES, A FINAL CERTIFICATE OF OCCUPANCY MAY NOT BE ISSUED UNLESS THE APPLICANT HAS MET OR IS MEETING THE REQUIREMENTS OF THE OFFICE OF EMERGENCY SERVICES AND THE AIR POLLUTION CONTROL DISTRICT. ~L~:~coN'sravci:1®EM5iNCiAGeNCV:7:·,~;:·:-::?-:;· · --.•. __ .. ;,., ,>.; , _. :;:;~:r:;"';;'_·77[3,w; q -,_,;;,7;:r~J".:~:::- 1 hereby affirm that there is a construction lending agency for the performance of the work for which this permit is issued (Sec. 3097(i) Civil Code). LENDER'S NAME LENDER'S ADDRESS. f9tc. i"·APPl:.ICANT.CERTU11C-A'FJOfl?',7:" ~:;'.: . , ' -"·:::,,;,,, 2 ', .. ', ' . . , ~, , , ' ',,;:· ~ )f,~:.J::t.:.:s::r:: ,.;.,;l.~~::,,,;¢~:'!.::..: .. :~;.::~:;~,.~.J;;·,;, },.:,:~--' ::,,.ffi; ;,;,,,;:, ,· ... ;.i::.~;;;:::;;,~_,,,,.-;,;;_, ::_".2:,··,;; I certify that I have read the application and state that the above information is correct and that the information on the plans is accurate .. I agree to comply with all City ordinances and State laws relating to building construction. I hereby authorize representatives of the Citt of Carlsbad to enter upon the above mentioned pron""ty for inspection purposes. I ALSO AGREE TO SAVE, INDEMNIFY AND KEEP HARMLESS THE CITY OF CARLSBAD AGAINST ALL LIABILITIES, .Jilifl~ENTS, COSTS AND EXPENSES WHICH MA,Y IN ANY WAY ACCRUE AGAINST SAID CITY IN CONSEQUENCE OF THE GRANTING OF THIS PERMIT. ~: An OSHA permit is-required for excavations over 5'0~ deep and demolition or construction of structures over 3 stories in height. EXPIRATION: Every permit issued by the building Official under the provisions of this Code shall expire by limitation and become null and void if the building or work authorized by such permit is not comme ed within 180 days from the date of such permit or if the building or work authorized by such permit is suspended or abandoned at any time after the work is com d f r a period of 180 days (Section 106.4.4 Uniform Building Code). / / APPLICANT'S SIGNATURE --'--i"+>-&'l'f""::·~::::::::::.:::-_ ... ________________ DATE ~ / L/ { ,!!-£)0 I WHITE: File YELLOW: Applicant PINK: Finance //a 7 LI City of Carlsbad Bldg Inspection Request For: 06/11/2002 Permit# CB012175 Title: Q-BIOGENE -BACK UP GENERATOR Description: Type: Tl Sub Type: IN DUST Job Address: 2251 RUTHERFORD RD Suite: Lot O Location: APPLICANT R J OGDEN ELECTRICAL Inspector Assignment: RCB Phone: 7609291700EX 105 Inspector: /( C/!> Owner: GAUTSCH JAMES W&ELIZABETH S REVOCABLE TRUST 11-2 Remarks: FINAL ON BACK UP GENERATOR Total Time: CD Description 19 Final Structural 39 Final Electrical Associated PCRs Inspection History Date Description 08/09/2001 34 Rough Electric Act Comments Requested By: WILLIAM JONES Entered By: CHRISTINE ~ fjN#-~,.....,,.,, ~ ,,,._ ~ Act lnsp Comments AP RC STILL NEED TO BUILD THE BLOCK WALL -PER PLAN 'PLANNINC/ENCINEERINC APPROVALS . . -~ PERMIT NUMBER CB (9~ {]5_ DATE :P/4'2 ADDRESS _ ~f)..~z ~ f?.J.: ·: ': : -_ ;,_. .: RESIDENTIAL · . : . -· -. . .:: i~ .\: :: . < • . . ·, . -~. ,\. "" TENANT IMPROVEMENT ' -- ·.'::'.-},.:;, t:.'RESIDENTIAL,ADDITIONc:MINOR .. ;::-.Ji::/:-..:·. -.. -.PLAZA·-1.CAMIN.O:REAE. -. "-.::··_: (<$10,000.00) ·: ·:;:_; :··:-; -' • ... ·-·; . •: ,•. :.· .. CARLSBAD COMPANY STORES --VILLACE FAIRE - COMPLETE :OFFICE BUILDINC' OTHER ___ (_1~~-~-_...--=-'. "------------------------_,_ . PLANNER ------------DATE' ------- DATE 2{3/oz DOCS/Mlsforms/Plannlng e~ineering Approvals ~: . . .. ~: PLANNING DEPARTMENT , BUILDING PLAN CHE5 REVIEW CHECKLIST () fl L ;J Plan Chee~ ~-, CB O / ;J-/ / Address } ) ) f fe:',v, V v/_ fJ__ Planner ~m; ~'.'J~t/v Phone (760) 602-_C(-t,-,/:Jtf,))1r--Cf.___ ___ _ APN: . 'lf1tT--[JfJ/r ;J!) .!l OI' 0 Type of Project & Use: ~-e·.veiP(WL.-. Net Project Density: · DU/AC Zoning: 0 ~ M Gene~al Plan: . P:£::. Facilities Management Zone: -=5 __ _ CFD lin/n11tl #_~Date of participation: ____ Remaining net dev acres: Circle One --- (For non-'residential development': Type of land used created by this permit: ________________ -_______ ) ·Legend: [8J Item Complete D Item l~cQmplete -Needs your action D D Environmental Review. Required: YES· NO TYPE ------- DATE OF COMPLETION: -------,------ Compliance with conditions of approval? If not, state conditions which require action. Conditions of Approval: D D Discretionary Action Required: YES NO. TYPE ---- APPROVAL/RESO. NO. _____ DATE--,--__ _ PROJECT NO. ------------ 0 THE R RELATED CASES:'-----..-.---,----------------- I Compliance with conditions or approval? -If not, state conditions which reqLJire action. Conditions of Approval: 11 D D Coastal Zone Assessment/Compliance Project site l~cated in Coastal Zone? YES NO CA Coastal Commission Authority? YES NO If Caiifornia Coastai' Commission Authority: Contact them at -3111 Camino Del Rio North, Suite 200, San Diego CA 92108-1725; (619) 521-8036 Determine status (Coastal Permit Required or Exempt): Coastal Permit Determinatio·n ··Form already completed? YES NO If NO, complete Coastal Permit Determination Form now. Coastal Permit Determinatio~ Log· #:- Follow-Up Actions: 1) Stamp Building Plans as "Exempt" or "Coastal Permit Required" (at minimum Floor Plans). 2) Complete Coastal Permit Determination Log as needed. H:\ADMIN\COUNTER\BldgPlnchkRevChklst Ir" r,, D D D lnclusionary Housing Fee required: YES NO (Effective date of lnclusionary Housing Orpinance -May 21, 1993.) Data Entry Completed? YES NO · (A/f!/Ds, Activity Maintenance, enter CB#, tcioibar, Screens, Housing .Fees, Construct Housing Y/N, Enter Fee, UPDATE!) Site Plan: D D D 1 . Provide a fully dimensional s.ite plan drawn to scale. Show: North arrow, property lines, easements, existing arid proposed structures, streets, existing street improvements, right-of-way width, dimensional setbacks and existing topographical lines. D D D 2. Provide legal description of property and assessor's parcel number. Zoning: D D D 1. Setbacks: Front: Required Shown _______ _ Interior Side: Required Shown ------Street Side: . Required Shown _____ _ Rear: Required · Shown ------------ D D D 2. Accessory structure setbacks: Front: Required _· ______ -._ Shown _____ _ Interior Side: .Required '. Shown _____ _ Street Side: Required · Shown -------Rear: Required Shown ------Structure separation: Required Shown _____ _ D D D· 3. Lot Coverage: Required __ _.;...-,--__ Shown ------ D ·o D 4. Height: Required _____ _ Shown ------ DD D ·s. Shown ------ ~DD ,Shown -----e-q:>11-f-. -~ OK TO ISSUE AND ENTERED APPROVAL INTO COMPUTER DATE ----- H:\ADMIN\COUNTER\BldgPlnchkRevChklst EsGil Corporation In Partnership with Government for Building Safety DATE: 7 /30/01 JURISDICTION: City of Carlsbad PLAN CHECK NO.: 01-2175 PROJECT ADDRESS: 2251 Rutherford ~d SET: II PROJECT NAME: Q-Biogene -Optional Stand-by Generator ~~ D PLAN REVIEWER D FILE [8J The plans transmitted herewith have been corrected where necessary and substantially comply with the jurisdiction's building codes. D The plans transmitted herewith will substantially comply with the jurisdiction's building codes when minor deficiencies identified below are resolved and checked by building department staff. D The plans transmitted herewith have significant deficiencies identified on the enclosed check list and should be corrected and resubmitted for a complete recheck. D The check list transmitted herewith is for your information. The plans are being held at Esgil Corporation until corrected plan$ are $Ubmitted for recheck. D The applicant's.copy of the check list is enclosed for the jurisdiction to forward to the applicant contact person. D The applicant's copy of the check list has been sent to: [8J Esgil Corporation staff did not advise the applicant that the plan check has been completed. D Esgil Corporation staff did advise the applicant that the plan check has been completed. Person contacted: Telephone#: Date contacted: (by: ) Fax#: Mail Telephone Fax In Person D REMARKS: By: Doug Moody Enclosures: Esgil Corporation D GA D MB D EJ D PC 7/20/01 trnsmtl.dot 9320 Chesapeake Drive, Suite 208 + San Diego, California 92123 + (858) 560-1468 + Fax (858) 560-1576 EsGil Corporation In Partnership with Government for Building Safety DATE: 7/10/01 JURISDICTION: City of Carlsbad PLAN CH~CK NO.: 0l-~175 SET:I PROJECT ADDRESS: 2251 Rutherford Rd PROJECT NAME: Q-Biogene -Optional Stand-by Generator ~T ~ D PLAN REVIEWER D FILE D The plans transmitted herewith have .been corrected where necessary and substantially comply with the jurisdiction's building codes. 0 The plans transmitted herewith will substantially comply with the jurisdiction's building codes when minor deficiencies identified below are resolved and checked by building department staff. D The plans transmitted herewith have significant deficiencies identified on the enclosed check list · and should be corrected and resubmitted for a complete recheck. ~ The check list transmitted herewith is for your information. The plans are being held at Esgil Corporation until corrected plans are submitted for recheck. D The applicant's copy of the check list is enclosed for the jurisdiction to forward to the applicant . . contact person. rgj The applicant's copy of the check list has been sent to: R. J. Ogden Electric 1308 Basswood Ave, Carlsbad, CA 92008 D Esgil Corporation staff did not advise the applicant that the plan check has been completed. ~ Esgil Corporation staff did advise the applicant that the plan check has been completed. Person contacted: R. J. Ogden Electric~~ ~J«)Telephone #: 760-434-1834 Date contacted: t ( lD (by: t5) Fax #: 7(.Q o · l.(?::>L,l · {SO 7 Mail Telephone .,,---Fax__,, In Person D. REMARKS: By: Doug Moody Enclosures: · Esgil Corporation D GA O'MB D EJ o·pc 6/28/01 trnsmtl.dot 9320 Chesapeake Drive, Suite 208 + San Diego, California 92123 + (858) 560-1468 + Fax (858) 560-1576 . City of Carlsbad 01-2175 7/10/01 PLAN REVIEW CO~RECTION LIST TENANT IMPROVEMENTS PLAN CHECK NO.: 01-2175 OCCUPANCY: N/A TYPE OF CONSTRUCTION: N / A ALLOWABLE FLOOR AREA: SPRINKLERS?: N/ A REMARKS: DATE PLANS RECEIVED BY JURISDICTION: 6/29/01 DATE INITIAL PLAN REVIEW COMPLETED: 7/10/01 FOREWORD (PL.EASE READ): JURISDICTION: City of Carlsbad USE: Stand-by Generator ACTUAL AREA: N / A STORIES: HEIGHT: OCCUPANTLOAD:N/A DATE PLANS RECEIVED BY ESGIL CORPORATION: 6/28/01 PLAN REVIEWER: Doug Moody This plan review is limited to the technical requirements contained in the Uniform Building Code, Uniform Plumbing Code, Uniform Mechanical Code, National Electrical Code and state laws regulating energy conservation, noise attenuation and access for the disabled. This plan review is based on regulations enforced by the Building Department. You may have other corrections based on laws and ordinances enforced by the Planning Department, Engineering Department, Fire Department or other departments. Clearance from those departments may be required prior to the issuance of a building permit. Code sections cited are based on the 1997 UBC. The following items listed need clarification, modification or change. All items must be satisfied before the plans will be in conformance with the cited codes and regulations. Per Sec. 106.4.3, 1997 Uniform Building Code, the approval of the plans does not permit the violation of any state, county or city law. To speed up the recheck process, please note on this list (or a copy) where each correction item has been addressed, Le., plan. sheet number, specification section, etc. Be sure to enclose the marked up IJ~~ when you submit the revised plans. TENANT IMPROVEMENTS WITHOUT SPEClFIC ENERGY DATA OR POLICY SUPPLEMENTS (1997UBC) tiforw.dot ,, City of Carlsbad 01-2175 7/10/01 Piease make all corrections on the original tracings, as requested in the correction list. Submit three sets of plans for commercial/industrial projects (two sets of plans for residential projects). For expeditious processing, corrected sets can be submitted.in one of two ways: 1. Deliver all corrected sets of plans and -calculations/reports directly to the City of Carlsbad-Building Department, 1635 Faraday Ave., Carlsbad, CA 92008, (760) 602-2700. The City will route the plans to EsGil Corporation and the Carlsbad Planning, Engineering. and Fire Departments. 2. Bring_ on~ corrected set of plans and calculations/reports to EsGil Corporation, 9320 Chesapeake Drive, Suite 208, San Diego, CA 92123, (858) 560-1468. Deliver all remaining sets of plans and calculations/reports directly to the City of Carlsbad Building Department for routing to their Planning, Engineering and Fire Departments. NOTE: Plans that are submitted directly to EsGil Corporation only will not be reviewed by the City Planning, Engineering and Fire Departments until review by EsGil Corporation is complete. 1. Each sheet of the plans must be signed by the person responsible for their preparation, even though there are no structural changes. Business and Professions Code. · 2. Provide a statement on the Title Sheet of the plans stating that this project sball comply with the 1998 edition· of the California Building Code (Title 24 ), which adopts the 1997 UBC, UMC and ·UPC and the 1996 NEC. 3. Please indicate on the plans the-over-current protection device in the 400A panel used to protect panel EM. 4. Please provide a panel schedule for panel EM. 5. Please note on the plans that the emergency exit lighting and egress illumination is not dependent upon the performance of the optional stand- by generator. 6. Please show on the pl~ns the requited signage for the optional stand-by generator and indicate the locations of the signs. Per section 702.8 of the NEC 7. Please indicate on the plans the available fault current at the generator and the rating of the transfer switch. To speed up the review process, note on this list (or a copy) where each correction item has beeri addressed, i.e., plan sheet, note or detail number, calculation-page, etc. ., City of Carlsbad 01-2175 7/10/01 Please indicate here if any changes have been made to the plans that are not a result of corrections from this list. If there are other changes, please priefly describe them and where they are located in the plans. Have changes been made to the plans not resulting from this correction list? Please indicate: Yes D No D The jurisdiction has contracted with Esgil Corporation located at 9320 Chesapeake Drive, Suite 208, San Diego, California 92123; telephone number of 858/560-1468, to perform the plan review for your project. If you have any questions regarding these plan review items, please contact Doug Moody at Esgil Corporation. Thank you. ,t City of Carlsbad 01-2175 7/10/01 VALUATiON AND PLAN CHECK FEE JURISDICTION: City of Carlsbad PREPARED BY: Doug Moody PLAN CHECK NO.: 01-2175 DATE: 7 / 10/01 BUILDING ADDRESS: 2251 Rutherford Rd BUILDING OCCUPANCY: TYPE OF CONSTRUCTION: BUILDING AREA Valuation Reg. VALUE PORTION ( Sq. Ft.) Multiplier Mod. Generator .. Air Conditioning Fire Sprinklers TOTAL VALUE -.. Jurisdiction Code cb By Ordinance ! 1994 UBC Building Pernit Fee t£} ~ ' -.. ---'" . -~-., , ... _,,, ~ . ~ Type of Review: D ~omplete Review D Structural Only D R~petitive Fee ., r-8 Repeats * Based on hourly rate Comments: 0 Other @ Hourly ...._ _______ 1._..sJ Hours * Espil Plan Review Fee ($) J $180.00) $144.oo) Sheet 1 of 1 macvalue.doc Carlsbad Fire Department 012175 1635 Faraday Ave. Carlsbad, CA 92008 Plan Review Requirements Category: Fire Prevention (760) 602-4660 bate of Report: _06_1_28_12_0_0_1 __________ _ Bl!ildingJ>lan Reviewed by: Name: R. J. Ogden Electric Address: 1308 Basswood Avenue City, State: Carlsbad CA 92008 , Plan Checker: Job#: 012175 Job Name: Q-Biogene Bldg#: CB012175 -----------------.----- Job Address: 2251 Ruther:tord Rd Ste. or Bldg. No. ~ Approved D Approved Subject to D Incomplete Review The item you have submitted for review has been approved. The approval is based on plans, information and / or specifications provided in your submittal; therefore any changes to these items after this date, including field modifications, must be reviewed by this office to insure continued conformance with applicable codes and standards. Please review carefully all comments attached as failure to comply with instructions in this report can result in · suspension of permit to construct or install improvements. The item you have submitted for review has been approved subject to the attached conditions. The approval is based on plans, information and/or specifications provided in your submittal. Please review carefully all comments attached, as failure to comply with instructions in this report can result in suspension of permit to construct or install improvements. Please resubmit to this office the necessary plans and / or specifications required to indicate compliance with applicable codes and standards. The item you have submitted for review is incomplete. At this time, this office cannot adequately conduct a review to determine compliance with the applicable codes and / or standards. Please review carefully all comments attached. Please resubmit the necessary plans and / or specifications to this office for review and approval. 1st 2nd 3rd Other Agency ID FDJob# · 012175 -------FD File# '. ·, ""-:-,"-' . \~ -, . -'/. -: I . ' . ; -' '. ·- I . rl 1000 100 1() . 1 O.J . Short Circuit .Decrement Curve ': l _,' '. .· . I . I j . I : I i. I _. ·1 ,· l: I I , I . • ' II I ... ' -. ~ . f I' I : ~ l . '\. ' II ,. 1 --... '1 \ ,, .. l 0.01 ....., ____ --'---'-~i---...i.._.... ................. '-"-t,-_,_, .. """, ____ ...._.~ . 10 100 . 1000 10000 ~TORE CURUNT (amps) --3 phue 1yrmnetrloal • • Liu ta Lh111: 1ph -'" ·Lw lO Neutral lph f. , ~-' ~-' ' . : . ', ,{ •) I .. AIR POLLUTION CONTROL DISTHICT COUNTY OF SAN DIEGO October 2, 2001 QBIOGENE INC 2251 RUTHERFORD RP CARLSBAD CA 92008 Air Pollution Control Board Greg Cox District 1 Dianne Jacob District 2 Pam Slater District 3 Ron Roberts District 4 Bill Horn District 5 Air Pollution Control District R. J. Sommerville Director After examination of your Application No. 977038 for an Air Pollution Control District (District). Authority to Construct and Permit to Operate for an emergency engine/generator located at 2251 Rutherford Rd., Carlsbad, CA 92008, the District has decided on the following action: Authority to Construct is granted pursuant to Rule 10, 20, 21 and 1200 of the Air Pollution Control District Rules and Regulations for: Emergency standby engine, John Deere diesel engine, Model 4045TF150, 100 bhp, EPA Tier 1 certified of engine family number YJ!)XLO6.8014, equipped with turbocharger, driving a 60 KW generator. The engine listed above shall be referred to herein as the "engine". This Authority to Construct is granted with the following conditions: 1. Permittee shall provide access, facilities, utilities and any necessary safety equipment, with the exception of personal protective equipment requiring individual fitting and specialized training, for source testing and inspection upon request of the District. 2. The emissions of oxides of nitrogen (NOx) in parts per million by volume (ppmv), calculated as nitrogen dioxide at 15% oxygen on a dry basis shall not exceed 6.9 g/bhp-hr or 535 ppmv. (Rule 69.4.l(d){l)) 3. The emissions of carbon monoxide (CO) calculated at 15% oxygen on a dry basis, shall not exceed 4,500 ppmv. (Rule 69.4.l(d)(2)) l 4. The engine shall use only California Diesel Fuel. (Rule 69.4.l(d)(4)) 5. Air contaminant emissions from engine exhaust and engine crankcase vent shall not be more dense than 20% ( or Number 1 on Ringlemann Chart) for more than three (3) minutes in any consecutive 60 minute period. (Rule 50) 6. The equipment described above shall not cause or contribute to public nuisance. (Rule 51) 7. The engine operation shall not exceed 52 hours per calendar year for non-emergency purposes (testing and maintenance), and 200 hours per year for total use. (Rule 69 .4.1 (b )(3)(i) and Rule 1200) 9150 Chesapeake Drive• San Diego• California 92123-1096 • (858) 650-4700 FAX (858) 650-4659 • Smoking Vehicle Hotline 1-800-28-SMOKE $ Printed on Recycled Paper QBiogene Inc. Application No. 977038 October 2, 200l -2- 8. The engine shall be equipped with either a non-resettable totalizing fuel meter or a non-resettable elapsed operating hour meter. (Rule 69.4.l(e)(3)) 9. The engine shall be constructed to accommodate installation of catalyzed diesel particulate filters in the future. -. 10. The owner or operator shall conduct periodic maintenance of this engine and add-on control equipment as recommended by the engine and control equipment manufacturers or as specified by any other maintenance procedure approved in advance, in writing, by the District. The periodic maintenance shall be conducted at least once each calendar year. (Rule 69 .4.1 (f)(2)) 11. The owner or operator of the engine shall keep the following records: California Diesel Fuel certification, manual ofrecommended maintenance provided by the manufacturer, or other maintenance procedures as approved in writing, in advance, by the District. These records shall be kept on site for at least the same period of time, as the engine to which the records apply is located at the site. (Rule 69.4.l(g)(l)) 12. The owner or operator of this engine shall maintain an operating log containing, at a minimum, the following: dates and times of engine operation, indicating whether the operation was for non- emergency purposes or during an emergency situation and the nature of the emergency, if available (these records are not required if the total engine operations for any purpose, including emergency situation, do not exceed 52 hours in a calendar year); total cumulative hours of operation per calendar year, based on actual readings of engine hour or fuel meter; records of periodic maintenance including dates maintenance was performed, (Rule 69 .4.1 (g)(2)) 13. All records shall be kept on site for at least three (3) years, unless otherwise indicated by the conditions of this permit, and made available to the District upon request. (Rule 69.4.l(g)(6)) 14. Initial or periodic source test is not required until an appropriate test method is approved by the District and ARB, provided that the engine and control system are maintained in accordance with the condition~ of this permit, and there is no evidence of engine tampering. (Rule 69 .4.1 (i)( 4)) 15. This Authority to Construct authorizes temporary operation of the above-specified engine. This -temporary Permit-to Operate shall take effect·upon written notification to the District that construction has been completed in accordance with this Authority to Construct. This temporary Permit to Operate will remain in effect, unless withdrawn or modified by the District, until a revised temporary permit (Startup Authorization) is issued or a Permit to Operate is granted or denied. 16. Upon completion of construction in accordance with this Authority to Construct and prior to commencing operation, the pennittee must complete and mail, deliver or fax the enclosed Construction Completion Notice to the District. After mailing, delivering or faxing the notice, the permittee may commence operation of the engine. Operation must be in compliance with all of the conditions of the Authority to Construct and Applicable District rules. 17. This Authority to Construct shall be posted on or within 25 feet of the engines or maintained readily available at all times on the operating premises. This Air Pollution Control District Authority to Construct does not relieve the holder from obtaining permits or authorizations, which may be required by other governmental agencies. QBiogene Inc. Application No. 977038 -3- October 2, 2001 Within 30 days after receipt of this Authority to Construct, the permittee may petition the Hearing Board for a hearing on any conditions imposed herein in ~ccordance with Rule 25. This Authority-to Construct is not transferable and will expire on October 2, 2002, unless an extension is requested-in writing. If you have any questions regarding this action, please contact the undersigned at (858) 650-4542. &~o/1~ CAMQt'.h NCiUYEN Assistant Air Pollution Control Engineer CN:el enclosure 1.D.#15 8157A CONSTRUCTION COMPLETION NOTICE San Diego County Air Pollution Control District 9150 Chesapeake Drive San Diego, CA 92123-1096 (858) 650-4700 FAX: (858) 650-4659 Please complete the "APPLICANT USE ONLY" portion of this notice and fax or mail it to the APCD. The following information has been included based on your application information. Please note any corrections to this information. COMPANY NAME (OBA): OBIOGENE INC. APPLICATION#: __ 9.._77"""'0=38=---- EQUIPMENT ADDRESS: 2251 RUTHERFORD RD. CARLSBAD CA TYPE OF EQUIPMENT: EMERGENCY ENGINE/GENERATOR APCD PROJECT ENGINEER: ______ C=AM~O'""'UI=N~G~UYE~=N~----'---TELEPHONE: (858) 650-4542 APPLiCANT USE ONLY DATE CONSTRUCTION WAS COMPLETED: -------------------------- PERSON PROVIDING.NOTIFICATION (Please Print): ----------------------------- SIGNATURE:---------------------------------- DATE OF NOTIFICATION: ____________ TELEPHONE: ___________ _ APCDUSE I.D.#:15 8157A VAX. ENTRY DATE: DATE RECEIVED: SUBMITTAL DATA Q-BIOGENE EMERGENCY GENERATOR SYSTEM BCEW#5673 MAY22,2001 PREPARED FOR R. J. OGDEN ELECTRIC 1308 BASSWOOD A VENUE CARLSBAD, CALIFORNIA 92008 PREPARED BY LYN EDDS BAY CITY ELECTRIC WORKS, INC. 3375 HANCOCK STREET SAN DIEGO, CA 92110 (619) 298-6193 ---·--r· I 2 Every KOHLER power system is computer designed and engineered before it goes to the factory floor to ensure compatibility, reliability and proper output. Since the 1920s, Kohler Co. has provided an extensive range of quality on-site electrical power systems and products for standby, prime power, peak shaving and interruptible rate applications. From the generator sets that powered Admiral Byrd's history-making journey to the Antarctic to today's sophisticated computer- controlled systems, Kohler Co. is a leading manufacturer of integrated power systems. Kohler offers power systems for any size application-from residential units to multi-genset industrial installations. For dependable on-site electrical power, Kohler is your single source for Power on Demand. ---- I ( I ( C ( I [ d I / --- r J Designed with global on-site power needs in mind, KOHLER® power systems offf;)r several unique features to ensure complete customer satisfaction. A worldwide network of factory- trained KOHLER Power Professionals is at your service for power system planning, information, application assistance, sales, installation and maintenance. KOHLER on-site power systems are also setting a standard for performance in the industry. • KOHLER gensets pass endurance runs and meet generator temperature rise guidelines established by NEMA (MG1-22.40). • Torsional tests ensure that engines and g-enerators are free of harmful vibration. • All KOHLER gensets meet or exceed the transient performance requirements of ISO 8528-5. • All models pass a three-phase short circuit test for a duration of 10 seconds, repeated 10 times at intervals long enough to prevent cumulative heating. • All models ·are laboratory tested to determine motor starting capabilities. • KOHLER gensets meet or exceed the standards of NEMA, IEEE, ANSI, and CSA. Your KOHLER power system can be fully assembled and tested prior to shipping to ensure proper on-site performance. 3 '' ---r 4 Emergency standby power and peak shaving for this manufacturing facility are provided by two 2000 kW KOHLER generator sets housed within sound-attenuated enclosures. KOHLER@ DIESEL GENERATORS FROM 20 KW TO 2000 KW FEATURE A VARIETY OF VOLTAGE, FREQUENCY AND APPLICATION OPTIONS AS WELL AS A COMPLETE LINE OF ACCESSORIES. • Versatile enough to meet the demanding requirements of prime power applications at heavy construction sites, mining and timbering operations, and industrial plants. • Connected in parallel, will meet any output requirements. • Ideal for interruptible rate applications at facilities wishing to curtail electrical energy costs while enhancing operating security. • KOHLER diesel generators are well known for their exceptional motor starting ability and voltage recovery (10 times faster than many competitive generators of an equivalent rating). • NEMA class H insulation materials, multiple varnish dips and a fungus- resistant epoxy coating protect against harsh environments. • Advanced design completely eliminates exciter lag during "load on" transients. • Standard components include a pre- lubricated ball bearing and disc coupling between the engine and generator. ~ \ \ \ ( i I ! I r \ l I I ( i \ f ) ) \..____: \ L I I ~ ' -·-- I Engine • A heavy-duty, four-cycle industrial engine supplies power and offers self-diagnostic featu"res to help prevent shutdowns . • Low fuel consumption • Environmentally-friendly • Reduced noise levels Alter'f'!ator • The brushless permanent magnet generator (PMG) design ensures short circuit current capability, allowing coordination and tripping of down stream breakers. Optional Equipment • Enclosures (sound or weather) • Transfer switches • Exhaust system components • Fuel tanks ··, diesel generator 30ROZJ 35/44 27/34 32/40 25/31 30REOZJ* 35/44 27/34 32/40 25/31 40ROZJ 41/51 34/42 37/46 30/38 40REOZJ* 42/53 34/43 38/48 31/39 50ROZJ 55/69 42/53 50/63 38/48 50REOZJ* 55/69 42/53 50/63 38/48 60ROZJ 62/78 50/62 56/70 45/56 60REOZJ* 61/76 50/62 55/69 45/56 80ROZJ 94/118 78/98 85/106 71/89 80REOZJ* 94/118 78/98 85/106 71/89 100ROZJ 105/131 92/115 95/119 84/105 100REOZJ* 105/131 92/115 95/119 84/105 135ROZJ* 135/169 112/140 120/150 100/125 150ROZJ* 160/200 132/165 145/181 120/150 180ROZJ* 190/238 160/200 175/219 136/170 200ROZJ 205/256 None 185/231 None 20ROZK* 20/25 18/22 18/23 16/20 30ROZK* 29/36 25/31 26/33 22/28 40ROZK* 42/53 36/45 38/48 33/41 50ROZK* 50/63 48/60 45/56 43/54 60ROZK* 60/75 57/71 55/69 521,65 70ROZK* 74/93 73/91 67/84 66/83 80ROZK* 81/101 None 75/94 None 90ROZK* 92/115 88/110 84/105 80/100 100ROZK* 100/125 None 91/114 None 115ROZK* 115/144 112/140 105/131 104/130 135ROZK* 135/169 None 120/150 None 150ROZK* 150/188 136/170 135/169 124/155 170ROZK* 170/213 148/185 155/194 136/170 200REOZP* 205/256 192/240 185/231 172/215 230REOZD* 240/300 196/245 215/269 176/220 250REOZD* 265/331 232/290 236/295 212/265 275REOZD* 275/344 224/280 250/313 204/255 300REOZD* 300/375 252/315 270/338 228/285 350REOZD* 355/444 320/400 305/381 276/345 400REOZD* 410/513 360/450 370/463 320/400 450REOZD4* 460/575 408/510 420/525 368/460 500ROZD4 515/644 492/615 None 440/550 600ROZD4 610/763 540/675 555/694 492/615 600ROZM 610/763 None 555/694 None 750ROZD4 760/950 672/840 None 612/765 800ROZD4 815/1019 728/910 740/925 660/825 900ROZD4 920/1150 812/1015 835/1044 736/920 900ROZM 900/1125 708/885 825/1031 652/815 1000ROZD4 1020/1273 None None None 1000ROZM 1020/1275 844/1055 925/1156 808/1010 1250ROZD-4 1250/1563 1100/1375 1140/1425 1000/1250 1500ROZD4 1500/1875 1320/1650 1360/1700 1200/1500 1750ROZD4 1750/2188 1540/1925 1590/1988 1400/1750 2000ROZD4 2000/2500 1760/2200 1820/2275 1600/2000 Prime Ratings are continuous for the duration of the power outage with no limitation to hours. 10% overload capacity is permitted for 1 hour in 12 hours. Standby Ratings are continuous for the duration of any power outage. No overload is permitted. All ratings: 50 Hz, 220/380V; 60 Hz, 227 /480V; .8 power factor applies to all kW ratings. 5 * EPA Certified Engine. ~--------------------------------------'---------------------- 6 KOHLER 230 kW gas generator Two on-site training labs house 10 KOHLER generators for hands-on instruction at the Federal Aviation Administration's Oklahoma City headquarters. Kohler currently supplies all of the gas and diesel units for FAA sites throughout the United States. KOHLER@ GAS GENERATORS ARE SPECIFICALLY ENGINEERED WITH THE LATEST TECHNOLOGY TO GIVE YOU THE BEST PERFORMANCE.CHOOSE FROM 20 KW TO 275 KW. • Gas generators operate from a constant, low-cost fuel source. • No on-site liquid fuel storage required. • Natural gas, LP and auto changeover options meet applicable codes. • Engineered with low pressure gas systems to avoid the need for expensive compressors. • KOHLER gas generators can operate with fuel supply pressures as low as 5" of water column without sacrificing performance. \ t I I ! ( ', I ! ! I I ( '1 I I r r --- 't· :r:, 't .... ;~ ! Engine • All KOHLER generators are equipped with the latest engine/fuel management technology for precise frequency control and transient performance. Alternator • Permanent magnet excitation provides the industry's fastest response times, plus superior motor starting capabilities. Optional Equipment • LP or natural gas fuel systems • LP/natural gas automatic changeover systems • LP liquid withdrawal systems • Multiple control options to meet any application need Ratings Chart _,. 60013 Ollllil IiiJ "\ --1111110 B (., onoil -- G0Hz 50Hz G0Hz 50Hz STANDBY RATINGS I PRIME RATINGS Model Nat Gas LP Nat Gas LP Nat Gas LP Nat Gas LP kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA kW/kVA 20RZ 19/24 20/25 15/19 16/20 17/21 18/23 14/18 15/19 30RZG 35/44 35/44 27/34 27/34 33/41 33/41 26/32 26/32 35RZG 39/49 40/50 31/39 32/40 36/45 37/46 29/36 29/36 45RZG 42/53 46/58 33/41 37/46 38/48 42/53 30/37 34/42 50RZG 55/69 55/69 42/53 42/53 50/63 50/63 39/49 39/49 60RZG 60/75 63/79 48/60 53/66 55/69 59/74 45/56 49/61 80RZG 80/100 80/100 70/87 70/87 73/91 73/91 63/79 63/79 100RZG 95/119 100/125 79/99 83/104 85/106 90/113 71/89 75/94 135RZO 145/181 128/160 130/163 116/145 150RZO 150/188 124/155 135/169 108/135 180RZD 180/225 160/200 160/200 144/180 200RZD 205/256 180/225 185/231 164/205 230RZD 240/300 204/255 215/269 184/230 250RZD 255/319 224/280 230/288 204/255 275RZD 280/350 244/305 255/319 220/275 Ratings are three phase and based on high-wye voltage connections. j 7 r .... -}, KOHLER 8.5 kW gas generator 8 KOHLER@ RESIDENTIAL/ COMMERCIAL GENERATORS- DIESEL 6 TO 15 KW OR GAS 8.5 TO 22 KW-OFFER PEACE OF MIND WHEN UTILITY POWER IS NOT AVAILABLE. Emergency power for smaller applications is just as important as it is for larger industrial applications. Kohler believes residential and commercial power requirements deserve the same uncompromising performance levels, worldwide distributor support and broad range of optional equipment as the larger systems. • All generator sets and components are prototype engineered, factory-built and production-tested. Gas Engines • With more horsepower per kW than other products on the market, powerful Kohler V-twin air-cooled engines provide full generator-rated output. • Liquid-cooled gas generators are powered by reliable Ford 4-cylinder, OH\J engines. • All comply with stringent emissions standards established by the Environmental Protection Agency and California Air Resources Board. • Electronic governor provides clean, precise frequency regulation. Diesel Engines • Heavy-duty Yanmar engines. • Available prime-or standby-rated. .__ I I I I i 1 i ( I ! ' ! ·1 ) l ' I J l ( ·1 I. ' r C-··1 l ' ! ,. l I I I I -I I I I 1· I I I I I I 1: I I I I I I I t I .., Jobsite. installation inspection, initial startup, and initiation of warranty, by a Bay City Electric Works field technician. Testing will utilize BGEW furnished load banks. Fuel for testing is exclwded. Jobsite orientation and training of operating personnel Kohler limited warranty, effective from date of startup, for: 1 year or 2000 hours (whichever occurs first) as published in Kohler Brochure. · KOHLER POWER SYSTEMS I I I I I I I I I I I I I I I I I I· I Isochronous governor Low battery voltage High battery voltage Loss of input/output Generator line circuit breaker, installed in generator terminal box, 225 amps, 3 pole. Pre-alarm contacts, for: Anticipated low oil pressure Anticipated high water temperature Low water temperature Overvoltage protection shutdown Local emergency stop button Lube oil and antifreeze, initial fill One (1) Kohler Remote Annunciator Panel One (1) Kohler Model GLS-168341-0225 Automatic Transfer Switch, rated at 225 amps, 120/208 volt, 3 phase, 4 wire, 3 pole, plus solid neutral, in Nema I cabinet for indoor wall mounting. · Standard features for this model include: UL 1008 listing Single coil-solenoid operating mechanism High speed, 1/6 second transfer time Test switch, simulates power failure Disconnect plug for intelligence circuit Gold flashed engine start contacts Adjustable normal source voltage sensing Close differential voltage sensing LED diagnostic lamps Time delay normal to emergency, 0.6 -60 seconds Time delay on engine starting, fixed at 3 .seconds Time delay emergency to normal, 1-30 minutes Frequency/voltage relay for emergency source Main shaft auxiliary contacts, (1) NO/NC on normal, (1) NO/NC on emergency The following optional features are also included: Pilot lite, normal position Pilot lite, emergency position Pilot lite, normal available Pilot lite, emergency available Exerciser clock, with (2) position switch, for Loaded/unloaded testing One (1) Service and operation manual Kohler factory prototype testing Kohler factory production testing, with: Certified test report KOHLER POWER SYSTEMS I I I I I I I I I I I I I I I I I ·I I (* requires optional device for lar:np to function) Running time meter Cycle cranking, 15 second on/off, and 75 second lockout Alarm horn, with silencing switch Generator ·output voltage adjusting rheostat, +/-5% Overvoltage shutdown Remote start/stop arrangement, 2-wire Lamp test switch Meter range selector switch "Run/Off-Reset/Autd' selector switch Engine cooldown timer, 5 minute Kohler broadrange generator, with solid state volts/hertz regulator, material and temperature rise per Nema MG1-1.66. 100 percent block load acceptance per NFPA-110. Vacuum impregnated epoxy varnish, fungus resistant per MIL-1-24092. Capable of sustaining 300% of rated current up to 10 seconds. Structural steel base assembly Vibration isolators Low coolant level shutdown Radio suppression to commercial standards Fan and belt guards Junction box Operating instructions Radiator sized to 122°F (50°C) ambient The following optional accessories are also included: Weather housing, with sound attenuation for 70 dba at 23 feet, in free field environment. Jacket water heater, 1500 watts, 120 volt input. Flexible fuel lines Sub-base fuel tank, 75 gallon (15 hours at fullload),with: Fuel level gauge Low fuel level alarm switch Double wall construction for secondary containment UL 142 Label Inner tank leak alarm Battery rack and cables Starting battery set, 12 volt, 900 CCA Battery charger, automatic float/equalize type, 240 vac input, 1 O amp DC output, with: UL listing "Power on" lamp DC ammeter and voltmeter Input and output fusing Reverse Polarity protection Automatic float/equalize operation · Alarm contacts, for: KOHLER POWER SYSTEMS I I I I I I I I I I I I I: I I I I I I 5 TESTING AND WARRANTY KOHLER GENERATOR TEST :PROGRAM 018-56 CERTIFIED TEST REPORT INSTALLTION CHECKLIST START-UP PROCEDURE START-UP NOTIFICATION LOAD TEST REPORT ONE-YEAR WARRANTY TP-5374 I I INDEX I I DIVISION SUBMITTAL DATA REFERENCE# BILL OF MATERIAL I 1 KOHLER GENERATORS I 60REOZJ GENERATOR SET G5-148 ALTERNATOR DATA SHEET TIB-102-27,28 DIMENSION PRINT (GENERATOR) ADV-6305 1 of 5 I DIMENSION PRINT ADV-6305 3 of5 DIMENSION PRINT (HOUSING) ADV-6305 5 of5 DIMENSION PRINT (FUEL TANJ() ADV-6270 2 of 4 I DIMENSION PRINT (FUEL TANK) ADV-6270 3 of 4 I 2 GENERATOR CONTROLLER DECISION MAKER 3+ CONTROLLER SPEC SHEET G6-30 I DIMENSION PRINT ADV-5849 1 of 6 WIRING DIAGRAM 327153 SCHEMATIC DIAGRAM ADV-6002 I 3 ACCESSORIES I CIRCUIT BREAKER 225 AMP .X-6304 1 of 3 CIRCUIT BREAKER DIMENSION ADV-5912 BATTERY CHARGER SPEC SHEET G6-15 I WIRING DIAGRAM 233967 REMOTE ANNUNCIATOR G6-1 1· DIMENSION PRINT ADV-5957 INTERCONNECTION DIAGRAM 328912 1 of3 INTERCONNECTION DIAGRAM 328912 2 of3 I 4 AUTOMATIC TRANSFER SWITCH GLS TRANSFER SWITCH SPEC SHEET Gll-73 I S340+ CONTROLS Gll-74 SCHEMA TIC DIAGRAM (225 AMP) 362172 I DIMENSION PRINT (225 AMP) ADV-6472 DIAGRAM, INTERCONNECTION 362164 2 of2 I I • l ) Alternator • Unique PowerBoost'" excitation system provides exceptional response to load char:iges. • Designed for use in residential/commercial applications such as nursing homes, schools, telecommunications sites, police and fire departments, agricultural operations, small office buildings and homes. Controller • Decision-Maker™ controllers provide fully- automatic operation of the generator set. • Safety shutdown protection is provided for low oil pressure, high-temperature, over- crank, over voltage and overspeed. Optional Equipment • Weather housings • Automatic transfer switches to meet any ) power system need ) • Other accessories available to meet application requirements Ratings Chart STANDBY kW RATING 60/50 HZ 60/50 HZ AIR-COOLED GAS Natural Gas LP Gas 10RY & 10RZ 9.0/8.0 10.0/8.0 12RY & 12RZ 9.0/8.0 12.0/10.0 17RY 17.0/13.0 17.0/13.0 18RY & 18RZ 16.0/13.0 18.0/15.0 22RY 20.0/16.7 22.0/18.3 DIESEL Standby Prime 6ROY &6ROZ 6/5.0 5.5/4.5 10ROY & 10ROZ 10/8.0 9.0/7.5 15RZ & 15ROZ 15/12.5 13.5/11.0 commercial power systems are renowned for their innovative design and reliable performance. 9 10 KOHLER M340 Transfer Switch ONE OF THE MOST COMPREHENSIVE AUTOMATIC TRANSFER SWITCH LINES IN THE INDUSTRY, KOHLER@ ATS COMPLEMENT THE FULL LINE OF KOHLER POWER SYSTEMS. A VARIETY OF TRANSFER SWITCHES OFFER ENOUGH FLEXIBILITY TO MATCH ANY POWER REQUIREMENT. • Safe, dependc;ible protection for communications systems, farms, airports, hospitals, and any other facility that requires a constant source of electricity. • Kohler supplies UL 1008-listed power switching mechanisms that transfer to the emergency source in under 1/6 second. • Transfer switches from 30 amps thru 4000 amps are available. Switches are available in manual, non-automatic, automatic and bypass configurations. • Kohler also manufactures a complete line of transfer switches which meet IEC and CSA standards for applications out- side the United States. Circuit breaker- style mechanisms, both with overload protection and without, are available in ratings from 40 to 4000 amps. ATS Controls • Both domestic and international automatic transfer switches utilize either solid-state electronic logic or microprocessor-based controls. Both systems provide source monitoring, control, and diagnostics, while the M340 has additional functionality including communications. I I I I ~ ( ] ~ I_J ] I ' l ? ] KOHLER DESIGNS AND MANUFACTURES SWITCHGEAR FOR EMERGENCY /STANDBY, POWER MANAGEMENT AND PRIME POWER APPLICATIONS. USING PROVEN COMPONENTS COMBINED WITH A SOLID UNDERSTANDING OF THE POWER INDUSTRY, KOHLER@ SWITCHGEAR IS DESIGNED TO SERVE AS A MONI- TORING AND SWITCHING STATION FOR VIRTUALLY ANY APPLICATION. • Kohler offers a full line of automatic paralleling switchgear to meet any need - emergency standby, prime power and energy management. • During emergency situations, when utility power fails or fluctuates outside acceptable voltage or frequency levels, KOHLER switchgear starts· the standby system and connects it to the load. • In prime power applications, KOHLER switchgear will synchronize, parallel and automatically match the number of prime power generator sets to the size of the load being drawn from the bus. • Interruptible rate and peak shaving switchgear systems are possible with Kohler utility paralleling capability. T :.@{;~~ 0:~g'@ : t]Jgr,,q'' g::: [] ·'i ••. : ·; ._;_u~. • ·II•:•• --~:-·,---. • ' ., ' KOHLER DLGK Switchgear '_··1 .. . 11 -· ' r-----------------------------------------------...... ·----------~ 12 ~-·:·, ... A: ·:1 -; , • • I ~ gas-generator set The keypad of the KOHLER Decision-Maker 340 incorporates a comfortable tactile feel. It can annunciate over 40 faults on its integral lighted alphanumeric display. ! . FROM THE VERY BASIC TO SOPHISTICATED MICROPROCESSOR-BASED CONTROLS, KOHLER CAN MEET MOST ANY APPLICATION NEED. • Monitors and displays numerous electrical and mechanical parameters along with diagnostics to help protect both the generator set and electrical system. • The KOHLER@ Decision-Maker'" 1 has shutdowns for low oil pressure and high engine temperature and can be equipped with engine gauges and voltage/ampere meters. • The KOHLER Decision-Maker 3+, in addition to the same features of the Decision-Maker 1, is supplied with a complement of diagnostic indicator lights, and conforms to NFPA standards. • The KOHLER Decision-Maker 340 can be applied to any generator set 20kW to 2000kW. Using micro- processor technology, this controller allows the user to both monitor parameters and control the generator set through a remote PC with optional Windows'"-based software. L ' C l L.. j r L. ~ [ c:· L, l r l C l ( ( l. ) l ) ' ,. I ii r C ' I j r -... .------------------------------------------------------------~·-'· J \ KOHLER SWITCHGEAR COMMUNICATION SYSTEM Jii.l CJ CJ CJ -· • -• mmm • [ffl] 0000 0000 J ,r II ,r II Remote 0 Personal •11211, 11aao Computer IIIUi 61ili • cda lfij • ~ !! !! 111mm111 111mm11 •••aaaaa [g) • Modem • "" "" = KOHLER DLGKIDLUK Switchgear with PLC Personal Computer 0 KOHLER Generator Set with the Decision-Maker 340 Serial Communications Wire ~~:I' f,s;.:,. ~ LL· ·<J.-! KOHLER Transfer Switch with M340 Logic ~~~i 'f-,'=:_. tr: KOHLER Transfer Switch with M340 Logic KOHLER generator sets with the Decision-Maker 340 controller and transfer switches with M340 or M340+ logic can communicate through a single common cable to the switchgear. 15 I •i I .·I I ·1 I ] I -:1 I I ·1 I -~ Rental Power. KOHLER® Rental Power offers a complete line of generators. The units have been engineered to ensure maximum output under difficult and varied conditions and are one of the quietest in the industry. Marine Generators. KOHLER Power Systems offers gasoline and diesel marine generators from 3.5 to 65 kW, 50 Hz and 60 Hz, all designed for high-level performance, safe operation, and easy maintenance. Mobile Generators. KOHLER Power Systems offers a quality line of mobile generator sets, with exceptional motor starting, heat recovery capabilities, and performance as needed for the mobile market. Other services available from Kohler distributors include: • Ouicksize Power System sizing and installation software • KOHLER Engineer's Guidebook • Electronic KOHLER engineering drawings To learn more about KOHLER Power Systems contact your distributor. 09001 fJlKOHLER -GENERATORS INTERN<\TIONALLY REGISfERED Ptinted in U.S.A 012-18 © 2000 by Kohler Co. 10/00 www.kohlergenerators.com Use of this matetial for reproduction on the Internet and World Wide Web 1s strictly prohibited without wtitten permission by Kohler Co. Kohler Co. resetves the fight to change product spec1ficabons. designs and standard equipment without notice and without incurring obligations. KOHLER CO. GENERATOR DIVISION KOHLER. WISCONSIN 53044 PHONE 920-565-3381 FAX 920-459-1646 CALL TOLL-FREE IN THE U.S AND CANADA 1-800-544-2444 r ~ C I l I \ c I I [ C ( I I I I ~ I I f -I I i 0 0 0 0 . ,,_ -·/"r _,' KOHLER OFFERS A FULL LINE OF ACCESSORIES DESIGNED TO MEET THE HIGHEST STANDARDS FOR QUALITY AND SAFETY. From hospitals and construction sites to telecommunications and remote sites around the world, Ko~ler can customize a genset to fit your application with a wide selection of accessories and components including: • Sound enclosures • Weather housings • Sub-base diesel fuel tanks • Day tank systems • Generator set control options • System monitoring and control • Float/equalize battery charger • Remote annunciator • Silencers • Circuit breakers • In-skid fuel tank KOHLER sub-base fuel tank KOHLER steel weather housing 13 ,, 14 ---1 n: 7\ ( )/ --i l! -----------------------------------------L1. ·uoo~@o@@lliJCf®@ Cf@@~~®OTI~ __________ n_ Kohler invites customers to witness for themselves pre-site testing of their assembled power system. Complete system testing reduces start-up time and ensures quality performance on the job site. COMPLETE SYSTEM COMMUNICATION CAPABILITIES AND PRE-SITE PERFORMANCE EVALUATIONS MAKE KOHLER@ POWER SYSTEMS THE BEST IN THE INDUSTRY. To ensure on-site job performance and compatability, every KOHLER power system - including the transfer switch, switchgear and controller, can be tested as a complete unit before being shipped. This optional service confirms the performance and compatibility of each component throughout the system, and reduces customer job site start-up time. This single-source responsibility means added peace of mind for the end user. Remote monitoring and control is also a service your KOHLER Power Professional can provide. This service is particularly useful for maintenance and genset communication in remote locations. A worldwide network of factory-trained Power Professionals is standing by to assist you-24 hours a day, 7 days a week. That's Power on Demand. U; r L ' i [ I r I '-I· I r r I ,--· I ~ I I I I I I I It I I I I I I I ,' Model: 60REOZJ • KOHLER.POWER SYSTEMS 4 Cycle 190-600 V Diesel - • • ~9001 -~ INTERNATIONAllY RfGISTERED Ratings Range Standby: kW Prime: kVA kW kVA 60Hz 54-62 54-78 49-56 49-70 SO Hz 45-51 45-64 38-46 40-57 Generator Ratings 130°C Rise Standby Rating Generator Voltage PH Hz kW/kVA Amps 120/208 3 60 61/76 212 120/240 3 60 61/76 183 120/240 60 54/54 225 127/220 3 60 60/75 200 139/240 3 60 60/75 180 220/380 3 60 60/75 114 277/480 3 60 60/75 90 4P10 . 347/600 3 60 60/75 72 110/190 3 50 50/62 188 110/220 3 50 50/63 165 110/220 1 50 45/45 205 115/200 3 50 46/58 167 120/208 3 50 45/56 155 220/380 3 50 50/62 94 230/400 3 50 46/58 84 240/416 3 50 45/56 78 120/208 3 60 61/76 212 120/240 3 60 61/76 183 120/240 1 60 58/58 242 127/220 3 60 61/76 200 139/240 3 60 62/78 186 220/380 3 60 61/76 116 277/480 3 60 62/78 93 4S7 347/600 3· 60 62/78 75 110/190 3 50 51/64 194 110/220 3 50 51/~ 168 110/220 1 50 48/48 218 115/200 3 50 51/64 185 120/208 3 50 51/64 HS · 220/380 · :·.3~.!50,_, 51/64 97 230/400 :i~: · 50 ... · 51/64 92 240/416 3 .50 ., 51/64 89 105°C Rise Prime Rating ·kW/kVA Amps 55/69 191 55/69 166 49/49 204 55/69 181 53/66 160 55/69 105 53/66 80 53/66 64 45/56 171 46/57 151 40/40 182 42/52 152 38/48 132 45/56 86 42/52 76 38/48 66 55/69 191 55/69 166 53/53 221 55/69 181 55/70 166 55/69 105 56/70 84 56/70 67 46/58 175 46/58 151 44/44 200 46/58 166 46/58 160 46/58 87 46/58 83 46/58 80 Standard Features • Kohler Co. provides one-source responsibility for the generating system and accessories. • The generator set and components are prototype tested, factory built, and production tested. • The generator set provides one-step load acceptance. • The generator set meets European and Environmental Protection Agency (EPA) emissions standards. • A one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Generator features: o Kohler's unique Fast-Response™ excitation system delivers the fastest voltage response in the industry. o Brushless, rotating-field generator has . broadrange reconnectability . o Kohler's permanent magnet-excited generator (PMG) provides superior short-circuit capability. • Other features: o Controllers are available to meet all applications. See controller features inside. o Low coolant level shutdown protects the generator set from overheating. o Integral vibration isolation eliminates the need for installation of vibration spring isolators under the unit. D 0 D RATINGS: AU three-phase units are rated at O.j! power factor. All single-phase units are rated at 1.0 power factor. Standby Ratings: Standby ratings apply to installations served by a reliable utility source. The ·standby rating is applicable to varying loads fort he duration of a: power outage. There is no overload capability for this rating. Ratings are in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. Prime Power Ratings: Prime power ratings apply to installations where utility power is unavailable or unreliable. M. varying load, the number of generator set operating hours is unlimlted. A 10% overload capacity is . available for one hour in twelve. Ratings are In accordance with ISO-8528/1, overload power In accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. For limited running time and base load ratings, consult t~e factory. Obtain the technical information bulletin (TIB-101) on ralings guidelines for the complete ratings definitions. The generator set manufacturer reserves the right to change the design or specifi_cations withO!Jl notice and without any obligation or liability whatsoever. NOTE: Order separate generator set specs for so or 60 Hz as this model cannot change frequency. GENERAL GUIDELINES .FOR l;>ERATION: ALTITUDE: Den~te 1.5% per aos·rn (1000 ft.) elevation above 2288 m (7500 ft.). TEMPERATURE: Derate 0.5% per 5.5°C (10°F) temperature above 40°C (104°F) GS-148 (60REOZJ) 8/99a Alternator Specifications Specifications Generator • Compliance with NEMA, IEEE, and ANSI standards _M_a_n-uf-a-ct-u-re-r __________ K_o_h_le_r_______ for temperature rise. Type 4-Pole, Rotating Field • Sustained short-circuit current of up to 300% of rated Exciter type Brushless Permanent current for up to 10 seconds. Leads: quantity, type Voltage regulator Insulation: Material ......................... . Temperature rise) ................ . Bearing: quantity, type Coupling Amortisseur windings Voltage regulation, no load to full load Unbalanced load capability One-step load acceptance Magnet 12, Reconnectable Solid State, Volts/Hz NEMA MG1 -1.66 Class H 130°C, Standby 1, Sealed Flexible Disc Full :1:2% 100% of Rated Standby Current 100% of Rating • Sustained short-circuit capability enables downstream circuit breakers to trip without collapsing the generator field. • Self-ventilation and dripproof construction. • Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life. • Superior voltage waveform from a two-thirds pitch stator and skewed rotor. • Solid-state, volts-per-hertz voltage regulator with ±2% no-load to full-load regulation. Peak motor starting kVA: 480 V, 380 V 4P10 (12 lead) • Fast-Response™ brushless alternator with brushless (35% dip for voltages below) exciter for excellent load response. 250 (60 Hz), 180 (50 Hz) 480 V, 380 V 4S7 (12 lead) ........ Engine Engine Specifications Manufacturer Engine: model, type Cylinder arrangement Displacement, L (cu. in.) · Bore and stroke, mm (in.) Compression ratio 270 (60 Hz), 190 (50 Hz) Application Data 60Hz 50Hz John Deere 4045TF150, 4-Cycle, Turbocharged 4 In-line 4.52 (276) 106.5x 127 (4.19x5.00) 17.6:1 7.6 (1500) 6.4 (1250) Engine Electrical Engine Electrical System (12/24 V*) Battery charging alternator: Ground (negative/positive) ...... . Volts (DC) .................... . Ampere rating ................ . Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Qty., CCA rating ............. .. Battery voltage (DC) 60Hz 50Hz 12 Volt/24 Volt Negative 12/24 65/45 12/24 1 , 640/2, 575 12 Piston speed, m/sec. (ft./min.) Main bearings: quantity, type .Rated rpm 5, Replaceable Insert *12-volt or 24-volt engine electrical systems are available . Max. power at rated rpm, kWm (BHP) Cylinder head material Crankshaft material Valve material: Intake ....................... . Exhaust .................... .. Governor: type, make/model Frequency regulation, no load to full load 1800 1500 75 (100) 62 (83) Cast Iron Forged Steel Chromium-Silicon Steel Stainless Steel Mechanical, Stanadyne/DM4 3-5% Frequency regulation, steady state :1:0.33% Air cl~aner type, all models Dry Exhaust Exhaust System 60 Hz 50 Hz Exhaust flow at rated kW, m3/min. (cfm) 13.6 (480) 10.4 (367) Exhaust temperature at rated kW, dry exhaust, °C (°F) 505 (946) 526 (979) Maxim4m allowable back pressure, kPa (in. Hg) 7.5 (2.2) Exhaust outlet size at engine hookup, mm (in.) 101.6 (4) Fuel Fuel System Fuel supply line, min. ID, mm (in.) Fuel return line, min. ID, mm (in.) Max. lift, engine-driven fuel pump, m (ft.) Max. fuel flow, Lph (gph) Fuel prime pump Fuel filter Recommended fuel Lubrication Lubricating System Type Oil pan capacity, L (qts.) Oil pan capacity with filter, L (qts.) Oil filter: quantity, type Oil cooler G5·14B (60REOZJ) B/99a 60Hz 8 (0.31) 6 (0.25) 0.9 (3.0) 50Hz 117 (30.8) 113 (29.7) Manual 1, Final #2 Diesel 60Hz 50Hz Full Pressure 12.2 (13) 13.2 (14) · 1, Cartridge Water-Cooled • • • - • - • Application Data Cooling {Standard Radiator) Cooling System Ambient temperature, 0 c (°F) Engine jacket water capacity, L (gal.) Radiator system capacity, including engine, L (gal.) Engine jacket water flow, Lpm (gpm) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) Water pump type Fan diameter, including blades, mm (in.) Fan, kWm (HP) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H20) 60 Hz 50 Hz 50 (122) 8.5 (2.25) 18.4 (4.9) 144 (38) 121 (32) 43 (2445) 37 (2104) Centrifugal 483 (19) 3.0 (4.0) 1.5 (2.0) 0.125 (0.5) Cooling (Optional Systems) Remote Radiator System* _Exhaust manifold type Connection sizes: Water inlet, mm (in.) ........... . Water outlet, mm (in.) .......... . Static head allowable above engine, kPa (ft. H20) City Water Cooling (CWC) System Exhaust.manifold type Water inlet, in. . ............... . Water outlet, in. . .............. . 60Hz 50Hz Dry 51 (2.0) ID Hose 44 (1.75) ID Hose 63 (21) 60Hz 50Hz Dry 0.5NPT ., 0.5 NPT * Contact your local distributor for cooling system options and specifications based on your specific application. Operation Requirements Air Requirements Radiator-cooled.cooling air, m3/min. (scfm)t Cooling air required for gen. set when equipped with ewe or remote radiator;. based on 14°C (25°F) rise and ambient · temp. of 29°C (85°F), m3/min. (cfm) Combustion air, m3/min. (cfm) Heat rejected to ambient air: Engine, kW (BTU/min.) ........ . Generator, kW (BTU/min.) ...... . t Air density = 1.20 kg/m3 or 0.075·1bm/ft3 Fuel Consumption . Diesel, Lph (gph) at % load 100% 75% 50% 25% ·.• . • ; ' J 60Hz 50Hz 102 (3600) 82 (2900) 82 (2900) 71 (2500) 5.2 (185) 4.0 (140) 15.5 (880) 12.3 (700) 7.7 (440) 6.9 (390) 60Hz -50Hz Standby Prime 18.5 (4.9) 14.4 (3.8) 15.1 (4.0) 1:1 .4 (3.0) 10.6 (2.8) 7.6 (2.0) . 6.8 (1.8) 4.9 (1.3) Controllers Available Controllers Decision-Maker"' 340 Controller Audio/visual annunciation with NFPA 110, Level 1 capability Programmable microprocessor logic with digital display Compatible with 12-volt or 24-volt engine electrical systems Remote start, prime power, remote annunciation, and remote communication capability Decision-Maker"' 3+, 16-Light Controller Audio/visual annunciation with NFPA 11 O, Level 1 capability Microprocessor logic with AC meters and engine gauges Compatible with 12-volt or 24-volt engine electrical systems Remote start, prime power, and remote annunciation capability Decision-Maker"' 3+, 7-Light Controller Audio/visual annunciation with NFPA 11 o, Level 2 capability Microprocessor logic with AC meters and engine gauges Compatible with 12-volt or 24-volt engine electrical systems Remote start, prime power, and remote annunciation capability Decision-Maker"' 1 Controller Provides remote or automatic start with NFPA compliance Uses single-light annunciation with basic control functions Relay logic with three models-standard, standard with engine gauges, and expanded with AC meters and engine gauges Compatible with 12-volt engine electrical systems only Manual Controller Designed for prime power and mobile applications Uses single-light annunciation with basic control functions Relay logic with AC meters and engine gauges Compatible with 12-volt engine electrical systems only Engine Gauge Box Controller for Paralleling Switchgear Interfaces between generator set and switchgear for paralleling switchgear applications Engine gauges with emergency stop switch Compatible with 12-volt or 24-volt engine electrical systems NOTE: See the respective controller spec sheet for additional controller features and accessories. GS-148 (60REOZJ) 8/99a KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455 Standard Features and Accessories Additional Standard Features • Battery Rack and Cables • Emission Compliant Engine • Integral Vibration Isolation • Oil Drain Extension • Operation and Installation Literature • Permanent Magnet-Excited Generator (PMG) Accessories Enclosed Unit D Exhaust Silencer, Critical or Industrial D Silencer Mounting Kit for Housing ,Jj Sound Shield Enclosure CJ Tail Pipe and Rain Cap Kit :6 Weather Housing ', Open Unit ·o Exhaust Silencer, Critical or Industrial D Flexible Exhaust Connector, Stainless Steel Cooling System , D Block Heater 0 City Water Cooling D Radiator Duct Flange D Remote Radiator Cooling Fuel System 0 Auxiliary Fuel Pump D Day Tanks l] Flexible Fuel Lines D Fuel Pressure Gauge ;d Subbase Fuel Tanks '' Electrical System 0 Battery Q Battery Charger, Equalize/Float Type D Battery Charger, Trickle Type D Battery Heater Engine and Generator D Air Cleaner, Heavy Duty D Air Cleaner Restriction Indicator O Bus Bar Kits 0 CSA Certification D Current Transformer Kit :o. Electronic Isochronous Governor O Generator Strip Heater [] Line Circuit Breaker (NEMA type 1 enclosure) O Line Circuit Breaker with Shunt Trip (NEMA type 1 enclosure) D NFPA 11 O Literature D Optional Generators O Ra~ed Power Factor Testing D Rodent Guards D Safeguard Breaker 0 Skid End Caps O Voltage Regulation, 1 % D Voltage Regulator Sensing, Three-Phase Paralleling System D Load-Sharing Module D Reactive Droop Compensator O Remote Speed Adjust Potentiometer/Electronic Governor D Voltage Adjust Potentiometer D Voltage Regulator Relocation Kit Maintenance O General Maintenance Literature Kit D Maintenance Kit (includes standard air, oil, and fuel filters) O Overhaul Literature Kit O Production Literature Kit Controller (Declslon-Maker1M 340 and Declslon-Maker1M 3+) O Common Failure Relay Kit O Communication Products and PC Software (Decision-Maker™ 340 controller only) O Controller Cable, 12 m (40 ft.) D Customer Connection Kit D Dry Contact Kit (isolated alarm) O Engine Prealarm Sender Kit O Prime Power Switch ·q Remote Annunciator Panel D Remote Audio/Visual Alarm Panel D Remote Emergency Stop Kit D Run Relay Kit Miscellaneous Accessories D ----------------- 0 ----------------- WEIGHTS AND DIMENSIONS Overall Size, L x W x H, mm (in.): 4P10: 2083 X 787 X 1181 (82.00 X 31.00 X 46.51) 4S7: 2083 X 787 X 1156 (82.00 X 31.00 X 45,51) Weight (Radiator Model), wet kg (lbs.): 1006 (2218) C C L-----•ail NOTE: This drawing Is provided for reference only and should not be used for planning Installation. Contact your local distributor for more detailed Information. DISTRIBUTED BY: BAY CITY ELECTRIC WORKS, INC. 3375 Hancock St. San Diego, CA 92110 (619) 298-6193 @ Kohler Co., 1997, 1999. All rights reserved. GS-148 (60REOZJ) B/99a - - I 1·· 1 I I I I I I I I I I I I I I I I KOHLER. POWER SYSTEMS TECHNICAL INFORMATION BULLETIN TIB-102 1./96 -------------------------------------- Alternator Data Sheet I Alternator Model: 4P10 Frequency: 60 Hz Speed: 1800 RPM Leads: 12 (6 Lead, 600 Volt) - -Voltage Power L-N/L•L Phase Factor Connection 80°c · 139/240 3 0.8 Wye 44.0 277/480 (55.0) 127/220 3 0.8 Wye 46.0 254/440 (57.5) . 120/208 3 0.8 Wye 50.0 24_0/416 (62.5) 110/190 3 Q.8 Wye 50.0 220/380 (62,5) 120/240 3 0.8 Delta 51.0 (63.8) 120/240 1 1.0 Dogleg 45.0 (45.0) 120/240 1 0.8 Dogleg 30.0 .. (37.5) 347/600 3 0.8 Wye 45.0 (56.3) kW* (kVA) 90°c 9s0c Lloyds ABS 47.5 49.0 (59.4) (61.3) 49.5 51.0 (61.9) (e3.8) 52.5 54.0 (65.6) (67:5) 52.0 53.5 (65.0) (66.9) 54.0 55.5 (67.5) (69.4) 47.0 48.0 (47.0) (48.0) 32.0 33.0 (40.0) (41.3) 48.0 49.5 (60.0) (61.9) 1os0c 130°c Prime 12s•c Standby 53.0 58.5 60.0 (66.3) (73.1) (75.0) 55.0 59.5 61.0 (68.8) (74.4) (76.3) -57.0 61.0 62.0 (71.3) · (76.3) (77.5) 56.0 · 59.0 60.0 (70.0) (73.8) (75.0) 59.0 62.0 63.0 (73.8) (77.5) (78.8) 50.0 53.0 54.0 (50.0) (53.0j (54.0) 35.0 39.0 40.0 (43.8) (48.8) (50.0) 53 .. 0 58.5 60.0 (66.3) (73.1) (75.0) * All data tested in accordance with IEEE Standard 115. Kohler Co. teseryes the right to change the design or specifications without notice and without any obligation or liability whatsoever. · Submittal Pata: 139/240 Volts, 0.8 PF, 1800 RPM, 60 Hz, 3-Phase Symbol Per Unit Ohms Symbol Value Typical Resistances Typical Time Constants Phase Resistance 0.027 0:021 Armature Short Circuit Ta 0.009 sec .. Rotor Resistance 4.397 3.378 Transient Short Circuit Td 0.089 sec. Typical Reactances Transient Open Circuit Tdo 0.971 sec. Synchronous Typical Field Current Direct Xct 2.295 · 1.763 Full Load lfFL 20.11 amps Quadrature Xq 1.111 0.853 No Load lfNL 6.53 amps Transient Typical Short Circuit Ratio 0.533 Unsaturated X'du 0.238 0.183 Harmonic Distortion Saturated X'd 0.210 0.161 RMS Total Harmonic Distortion 2.7% Subtransient Max. Single Harmonic 5th Direc_t X"d 0.093 0.071 Deviation Factor (No Load, L-L} 4.9% Quadrature x· 0.087 ·0.061 q Telephone Influence Factor <50 Negative Sequence X2 0.090 0.069 Insulation Material Class Zero ·sequence Xo 0.006 0.005 per NEMA MG1-1.66 H Phase Rotation ABC TIB-102 1/96 27 ~ C c» 'G m .,. TYPICAL GENERATOR EFFICIENCY* 139/240, 277 /480 Volts, Wye 100-.--------------,---..-,--....... ------,--------,-- 95~---+----+-~~-+---+----+---+--t--+---4---+-----I 90 ,.,,. ---- 85 80 75+---+---+---+----+---s~-+---+---t---+---+----+---I 70----------------------------------10 15 20 25 30 35 40 45 50 55 60 65 70 35 30 25 Q. iS CD 20 c:n as ·= ~ 15 .,. .10 5 0 0 Output (kW) TYPICAL MOTOR STARTING CHARACTERISTICS:* 139/240, 2n/480-Volts, Wye /~ _,,, / /. / , ,.,, V / ~ 50 100 150 200 250 Locked Rotor kVA 300 * All data tested In accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notlce and without any obligation or liability whatsoever. 28 TIB-102 1/98 I I I I I I I I ·1 I I I I I 1, I I I I 8 'in' r-: a. .:::.~ 70 [2.75] R 7 438 [17.25] 24 VOLT BATTERY LOCATION 6 5 1 · 421 [16.57) • l1 413 [16.25] .-, 0 co w lO ~ 4 3 2 llE.V Ml£ REV!S10N Br -6-2-97 NEW DRAWING (50282] KCS A 1-7-96 (1.-5) OIL DRNN REIJ)CAT£D [=J KCS B 1-7-99 RfDAA'liN IN ME1RIC AND GEHfRIC TITlBlLOCK ADDED (57438] KGS C +-7-99 SEE SHEET +-5. (58225) LRtl D ;, I I \ ~ /4?7' ~ ;.---,----+--__..J D r-, 0 "<I; a. ~~ (0 IX) CONDUIT ENTRY ARE FOR GENSETS WITH CIRCUIT BREAKER OPTION. FUEL RETURN (FLEXIBLE FUEL LINES: 1/4-18 NPT MALE) -SEE NOTE 0 N N i-------965 [38.00)-..>..1-----1----i OPTIONAL BLOCK HEATER CONDUIT LOCATION\ -SEE NOTE , 178 [7.00)-t--;---i------ 12 VOLT BATTERY LOCATION 'o lO I') '-' Ol 0'J --+----+-------+- ---510 [20.06)---i 't_ EXHAUST C CONDUIT ENTRY AREA FOR GENERATOR LOAD LEADS (BOTTOM ENTRY) AND REMOTE CONNECTION TO TRANSFER SWITCH AND REMOTE _ANNUNCIATOR. SUGGESTED LOCATION FOR 126 [4.96] I I C B A 0 ~ 0 I{) r-, N I{) t I{) 0 t-Ut.L ::>Ul"'l"'LT lt"Lt.Xll::!Lt. t-Ut.L LINt.::i:-' 588 [23.15) 1/4-18 NPT MALE) -SEE NOTE ENGINE EXHAUST OUTLET 98 [3.86] o.o. \ :1~ · ·r,tr-1.-~ , ' ,.._ I U lnG4 ;ft~ I I I 'o '---14~ I I 0'J . -72 ·-cix CONTROLLER .--~-·::i;;; l .11 I I . .,,,. ._....,__ l == . ,,=,~ ., FACE "V 111 p ,. ,o '"' ~ = = JJ. I I I I'-r-I I I ~~ L_ V '-''- '11'"' ~ a ~ 1:, ~ : I I I Ii~ ; C/__c:--d'711 ( ( )I ~ §§ ~ j\ . I I I · ~ 111 I{) -' f I~ ~ j: 111 j ~ . . I~ ~!! -. . , C ~ ~ ~ •• • ~ I ~ 1 0 ~~ ,;"j ...' -I I I ~ 10_ (0 I . I--. -ti ~ L/~. . 0 ' • J -or--, ·---------------1-- IO g O V> · ,-'~ h •• <0:::!: ' ' ,..., ~ · r: . a ~ n .· l'-(0,-. .:::_no '• C -o -· lo OI I El e., . . . , '-' IO g . 1;, . , o,= Ol "V .. -. . t---I m-r--1~ ~-3'4B. . . t0.o, ~ :2 . • r 1L · "VLC) OQ Oo VVOVtr ~~ • 0 D . . a~. tJ} > . . D I")~ O o O 0 0 t 0, V> OIL DRAIN LOCATION_/ E 822 [32.34] FUEL INLET <0::E 4X ¢13 [.531) ,-MTG. HOLES 966 [38.03) FUEL RETURN Oo IO CD so 994 [39.15) Oo 1000 [39.38) CENTER OF BAU\NCE «i,_;: ..... ._. 1 fi7fi ffifi ool -· ?n'I rR nnl FUEL IN LET FITTING I.D. HOSE FOR 8 [.312: - ocn (0 :::!: --------, Oo LO tO r-.,-Ul,;;; , g~IOu:i ocn,--t--,i-0 (f) tD ~ O' 0 ._.._ (0 :::!: ci' I{) (0, (0 ~ ·i>-lOg ~,-,~~ t0 fJ~,.....,.--. en~ --(0 (0 •• ' i;;,,-, CJ? O? ~ ~ o 8 (() en .__..__, • • N N to r-,.. .__...__, ~ r----~~co~ cog ,,., (0 , ,co ~ ..._ r-- co (O' '-- 255 [10.03) 244 [9.61) 53 [2.10] FUEl RETURN FITTING FOR 6 [.;250) O.D. TUBING j--356 [14.00]=:i . ------711 [28.00]---~- 394 [ 15.50)--I ---~~-787 [31.00)----- 'o 0 n N '-' "V (X) LO ', 0 (f) (0~ . , ' I Oo LO CO ·-;;;'';,' '10 10 : ~ Ill ~~ :L.....JL-J O> "V !~~ WEIGHT (WET) 50 KW .. 90!? Kg [1995 LBS] 60 KW . 948 Kg [2090 LBS] · 60 KW IMS 1(;>06 Kg [2218 lBS] NOTES: 1) IF SUB-BASE FUEL TANK IS USED, REFER TO SUB-BASE FUEL TANK DRAWING TO DETERMINE CONDUIT LOCATIONS. 2) DIMENSIONS IN O ARE ENGLISH STANDARD EQUIVALENTS . ' 3) WHEN A HOUSING ,IS USED THE FUEL LINE MUST BE STUBBED UP FROM DIRECTLY lJNDER THE UNIT OR BROUGHT IN FROM THE END OF THE SKID. !METRIC CAD FILE I lll.ESS'OMJIIISE SPU:FID -i;=~N-KOHLERCQ L'< ro I 1 ·-· -L-----, ,---L-·--J1 50/60 KW~± ~:' -=1:~~=-~~-1 10 r-,... I ~± V Ul'ID'l'IEVKaDCIPl'.CXIIIE'llll'lmlml!ICCl.llD& I . ~ -1 2083 _[82.00] 1 RECONNECTABLE, ==:.' @-El ~ .... DIMENSIONPRIITT i ' . . IMPROVED MOTOR STARTING (IMS) _ ~ l 1;-';~ . · .1 I • . . , . . . .. · . . RECONNECT ABLE AND 600 VOLT GENERATOR ,_;. er I s-11-s<: .. o.18X ,-.... ~ ,-. 1-s 1 ;....11 · '' · , . . . . · JOHN DEERE 4045 ,,.._. er I s-11-91 ADV-6305 I D·cl -~ s·-,·-~--~-----______ 8 ·1 7 · 1 6 I 5 't 4 I 3 · I . 2 l """"'-I . " .. , -·=--·-----------------~---~-. - B O> AO> O> T"" 0 ('t') w z ::> ..., • a· 325 [12.79] IND--t----,.._ 284 [11. 17] CRIT ,_ ~ ~ -sf-r-: ....... 0) 0() ,;,.-~~-·i);]l!f;g~ a ~ 'io' t\j r-: ._, -sf-0() .... 7 6 5 r 597 [23.50] IND I ,eos [35.62{ c••j"'" [19.65] +-1--1:}---- -· . ---7r---1---ii----r--ir--- 0 0 . ·: D . --. 0 S\LENCER AND MOUNTING CRITICAL AND INDUSTRIAL r-...... 0 0 m~~ \I a:j .... ...... " ~ a' .. ,,.. ----~--.._........,,,,... ___ ---.....--........... C) ~ 0, <t',I <t',I RADIATOR DUCT FLA..NGE 0 0 -i-,.__, N 0 ...., 0 q <O ·~ ...... 0 co <O I o{I) co::1: '2,-;; LO <O ,-,...., O>o, Oo l'l-,i ~ .... ....... ._. -· D .. . . . .. , 4 .-. I-I-Cl!:: ca-a:: 0 ~ ~ 5 u q z 0:: -<) (0 o(/)ocn ,.__, .-..-, '°v <O :a: <O :::E I') IO m ----------0 cio 0000 N .... ~ LO <O 10 CO ._.._. ,.:.....,r-,,-,..,_, 0() a:, I") f"") .,-._ IX> a:, N N <Or--r--: o:i o:i a; NN It) It) IO LO 1-,Jt.-.JL-J'--' O>.-.;t-OJ v '°mr--o v -,;r "<I" 10 ,j-,--,... -l-----·-- D . --. -----------·-· ,., CX) r<) IO t'} . .., ,. ,-i.. • .,.,,. -----~ --:-:-:_-=-,,. DIME:NSIONS IN d ARE ENGl.,.ISH STANDARD 1;:QUIVALENTS. . : ·--::---____ s · · 4 3 THERMOSTAT LOCATION 2 ... , 00£ --'$-22-97 I IEW -i002ll21 I\ 11-13-991 RE!lfWIK II IElRIC AHi> GENERIC TllUlllDCI( ~3) fUl08lE ElOWJSf I\If AllOED [57438} C I 4-7-99 I SEE SIIEEr 4-5. [58225] 1...D 81' l(G$ KCS I.RH D BLOCK HEATER 83 [3.25) 708 [2787]J C FLEX EXHAUST OUTLEf 3~ N.P .T. Li \ FLEXIBLE EXHAUST KIT "" l ---"' : BLOCK HEATER ' 120 AND 240. VOLT '/ I k~ ·, oo U') <O . .---.,-, <O <O ,,q ~ mo e:!:, • r<) (0 .... t') IO IO ir ....- . ' \ 50/60 KW RECONNECT ABLE, IMPROVED MOTOR STARTING (IMS) RECONNECTABLE AND 600 VOLT GENERATOR . JOHN : DEE;R~ 4045 3 ? !METRIC CAD FILE! . KOH ...,,.,.,._ 111$ ............ 'IIJ5r lD'f IE BD a::r,r M M.Lmnsar .... .._.EIIKD. I -=NS~ I""' DIMENSION PRINT ---ADV-6305 ....,._ -1 3-5 B 0) AO> 0) <c- o (I') w z ::, ' -, DG1 .• I I I I I I I I I I I I I I I I I I-~ I 8 D FRONT C ) B A 8 7 1 · 616 [24.25] 0 lO ~ lO C? L..., -.i-L..., 0) <O r<) N ~---+-+-----------1+ -----f--t-----------1·+ ,...., ...., 0 r<) lO C? lO L..., L..., <O -.i-N 0) r<) 0 0 6 ENCLOSURE/GENERATOR FLOOR MTG PLAN 5 0 r=::' en '° '-' N IO 4 3 2 RlV M.lE RE.\'ISl0t( Br -&-2-97 NEW DIWIING [50282] ICCS A 5-12-95 (9-11) DIii 70.50 [1791] 00 NS REll0VED [54<112] KGS B 1-1:,..gg R£IlftAWN IN IEIRIC HID GEN£R1C ll1lfBtOCK N>OED [57438] KGS C 4--7-99 SEE SHEEr 4--5. [511225] LRH D REAR 254 [10.00] I , I \ 991 [39.ooJ---- 51 [2.00]-j 1- ---991 [39.00]----1--t 254 [10.00] l I ax lll13 [.531] ENCLOSURE MTG HOLES ;~ . == --1::1 ,, 11 I I 11 IT I I '7 ' rl 11 11 I I -H 11 -0 11 lO rl oi ~ 11 11 lO I I <O 11 " 11 I· I 11 1 ·1 11 I I 11 I· l 11 w -I I•· 11 . . 11 _= c:::= i::=_-===ii 11 WATER DRAIN 7 I Ii C 2845 [112.00] AIR INTAKE • 1 -(§) i-1067 [42.00]-i I,_ . -..:_al ----1::1 . 1::1 . ]1111111111r11111111111rr . . p ------------j I I 7 I I ~ 654 [25.75] .I ....... 1 DOOR OPENING (ff P) 1 ._ CL .J'.: I I• 'o'-' l e IO(!) ·z ~ ;;; z c...,w . on.. I I 00 I I IX) ct: I I 0 I I 0 .I I Cl I I _l I I ~~-------------~ LEFT SIDE VIEW SOUND ENCLOSURE DIMENSIONS IN -0 ARE ENGLISH STANDARD EQUIVALENTS. 6 5 'r 4 -1 ~ GENERATOR END VIEW I -i, I METRIC CAD FILE I IN!SS CJIIEa5E Sl'£CfE) - . IMPROVED MOTOR 1) DIEl5ION5 M£ IC IIR1.IIElDIS It,~-. -KOHLERCQ x.x :j: 5lMF1CE fN5H COIEJIA1t1I: IWl5IDN,. ll:Dtlll,, '" 5JD44 11.S.l. X ± -r MU:. 1115 ....._ M IDCll ,a lEM.. IS IIH1I ca., l'D'llft' MD . 50/60 KW RECONNECTABLE ""'.:."'-" 1115f'"ll..E.::m.:::=:."'l:'.=i:--1 STARTING (IMS) RECONNECTABLE -=...:;,~ ... DIMENSION PRINT AND 600 VOLT GENERATOR -KGS I 6-Z 97 • . -CWF I 6-6-97. "!""' 0.1BX 1-m. AIMJ05EDWG ,_,. 5-5 7 JOHN DEERE. 4045 _ CWF J 6-6-97 -.... · ADV-6305 I Del 3 2 -- B 0) AO> 0) T""' 0 ('t) w z :::::> -, ------------~--~_~·--·-----------•• ----~----· ~~ ---.. ----~ --+ ---" -~----------------------·----~------ D C B A 8 :r REMOVEABLE END CHANNEL 1 /2" HARDWARE 86 [3.38] 8 7 6 5 4 3 2 RtY MlE ReASk>N BY' -2-7-97 NEW DRAWING [45e94) KGS A 5-16-97 (D-8) 20-60 KW KITS AOOED [50282] KGS B 0-14-97 SHEEr 2 OF 4 WAS 2 OF 3; (D-8H0-2) ~-IIOIIED lO SllEEr J. [52161] llRII C 11-22-99 I REDRAWN II METRIC • GENERIC mu: BLOCK AOOED. [57438) llRII NOTES: THE SMALLEST CAPACITY TANK IN EACH MODEL D MAY BE ORDERED STANDARD OR AS A DAY TANK. © (D.06 05 TANKS MAY BE ORDERED AS SECONDARY CONTAINMENT OR CLOSED TOP DIKED. 90 Cils:10 1ct,d ©~ 1 YJtY/.....A:A FITTINGS: ~ -----------------------------------------~ --------------------------------~ --------------------------------------------------------------------------------------------------- I I h-----------------. --------------11--------n I I II I I I ! ii 11 . II I I I I I I 11 1·1 II I I I I I I II I I I I 1-------1 'I I I I 11 -II 11 I I ~ -I I I I W--------·~ -. ----------------_j_____ -.~ I ••• I • ! ...L___;.-~..: 0:: CJ I I F--~ --~~~-,---~ I ~~ I I I 1-~1-------Vi7 I I I_ .--------------i I I I :I " i, ii :1 .:j I 'I I--------------l- J__ -~--- I ,_ ,,/ .__..,. STUB UP WIDTl;i i----.J I 1. "K" NPT EMERGENCY VENT PER NFPA 30 2. 2" NPT FILL FOR OPTIONAL FUEL CAP AND RISER 3. 2" LEVEL GAUGE -STANDARD 4. 1-1 / 4" NPT FOR OPTIONAL NORMAL VENT AND RISER 5. "p" DIP TUBE-FUEL SUPPLY AND "L" REDUCER 6. "R" DIP TUBE-FUEL RETURN AND "$"REDUCER 7. 2" NPT FOR OPTIONAL LOW IC LEVEL ALARM SWITCH 8. 2" NPT FOR SENSOR/ PUMP CONTROL FLOAT (DAY TANK ONLY) 9. 1/2" NPT FOR OVERFLOW -2 GPM PUMP MAX. (DAY TANK ONLY) 10. 3/8" NPT FOR DAY TANK FILL (DAY TANK ONLY) 3/8" N.P.T. PUMP INLEr B ·:-·"•11--'t-'<-----c D B--i----K I 38 [1.50] 1fl • lli--~E .. , 7 3/8• NPT BASIN DRAIN 11/2" NPT FOR LEAK ALARM SECONDARY TANK EMERGENCY PRESSURE RELIEF VENT •L• N,P.T. (NOT APPLICABLE TO CLOSED TOP DIKED TANKS.) 6 5 110/120 VOLT ; PUMP & MOTOR LOCATION FOR DAY TANK OPTION ONLY (SEE CHART) lt-------F---~~-11 t-------G------i t-----~---"'---M-----'----t i----------N--0,-----1 IMETRl'C CAD FILE!. DIMENSIONS IN [ ] ARE ENGLISH STD. EQUIVALENTS 4 3 ,lll.eiS 01HEMl5[ ,e::HD -t) IJllfKSUCS Ill£ II liR1liE1DIS ~"!""'"""--KOHLER CQ A 0) 0) 0) T"" X.X ± st.WIICE fN!iH CIJDAtal-DMSION. IIHDt.. 55CM4 11.S.A. ~± 7-. :rr:-:-:.-:n~~-=::u.~.:: ~ ' M1 IINS flf lf.WII M ----Jl3lND,. ,:- 20-180 KW JOHN DEERE ~~ ... DIMENSION PRINT ....J DUAL WALLED SUB-BASE TANKS -Kcs 12.-7-91 0::: FOR SOUND HOUSING ·•-CWF 12-,;_97 -.. 0-12X 1-• ACN62708.DWG 1-2-4 (DIESEL ONLY) -CWF ·12-11-111 --ADV-6270 I DG <(Q.. 2 , ..... -1 ---.. 20-180 KW J.D. DUAL WALLED SUB-BASE TANK (DIESEL ONLY) CAPACITY SIDE -K-MODEL LITER [GAL] VIEW -A--8--c--D--E--F--G--H--J-(N.P.T.) -L--M- (SHT. 1) 151 40] 318 [12.5 660 [26.0] 473 18.62 584 23.0 · 2· 137 [5.4 284 75 610 [24] 2083 [82.0] (ROZJR) 473 r1B.62 584 23.0 0 3• -- 454 120 81 762 [301 787 (31.0] 584 23.0 3• --20-60 837 221 914 36 203 (8.0] 1676 ·(66.0] 2692 106.0 711 [28.0] 584 23.0 610 24.0l 3" 3/8-1/4 --KW 371 [14.62] 1045 276 914 361 3200 126.0 (REOZJR) 584 [23.0] 1067 [42.0] 4" -- 1211 332 82 813 321 2591 102.0 1118 r 44.ol 1194 f47.0l 1041 41.0 508 r20.01 4" -- 284 751 457 18] 2489 98.0l 660 [26.0] 524 20.62 584 23.0 0 2" 137 [5.4] , 473 125 610 24 2489 98.0I (ROZJR) 371 14.62 584 23.0 0 3" -- 757 200 81 762 30 2692 106.Q, 711 [28.0] 787 [31.0] 219 8.62 584 23.0 203 8.0] 3" --80-100' 1348 356 254 [10.0] 1930 [76.0] . (REOZJR) 371 [14.62] 584 [23.0] 1219 [48;0] 4" 3/8-1/4 KW 914 36 3683 146.0 -- 1681 444 813 32 2997 118.0 1118 r 44.01 1194 f47.0l 219 8.62 1041 41.0 508 20.0] 4" -- 2018 533 82 813 2997 118.0 1321 r52.01 1398 f55.0l 219 f8.62 1245 49.0 508 20.0l 4" 32 -- 379 100 457 18 2645 104.5 557 [21.92 711 28.0 0 2" 137 f5.4 681 180 610 24 2645. 104.5 303 11.92 711 28.0 0 3". -- 1041 275 81 762 30 2908 [ 114.5] 787 (31.0] 864 [34.0] 227 rB.92 711 28.0 254 10.0 4" 1/2 --135-150 305 [12.0] 2045 [80.5] KW 1946 514 914 f36l 4216 f166.0 711 28.0 1562 61.5 5• COUPLING -- 2430 642 813 f32l ; 3175 r125.o 1413 f58.ol 1549 r61 .Ol 219 [8.62] 1397 55.0 521 20.51 4" --B2 2919 [771 813 32 3115 ri25.01 1727 f68.0l 1803 r11.01 1651 65.0 521 20.51 5''. -- 379 I -100 318 12.5 627 24.62 991 39.0 0 3" 137 [5.41 757 I 200 457 18 2819 321 12.62 991 39.0 0 3" -- 1,136 300 81 610 24 [111.0] 1067 [42.0] 1143 [45.0] 0 4" 1/2 --150-180 2491 658 914 36 305 [12.0] 2210 [87.0] 3886 153.0 991 [39.0] 1067. 42.0 5" COUPLING --KW 219 [8.62] 3112 822 813 32 3327 131.0 1753 f69;0l · 1829 r12.01 1676 66.0 508 r20.01 . 5" --t: B2 142.0 · 787 T31.0l 5" · 3736 987 813 32 3607 1880 f74.0l 1956 f77.0l 1803 71.0 -- 3 . 20-180 KW J.D. DUAL WALLED sus...:BASE TANK FOR SOUND HOUSINGS (DIESEL ONLY) CAPACITY -L-DAY TANK MODEL -A--B-..,.c--D--E--F--G--H--J--K--M--N--P--R-LITER [GAL] (N.P.T.) MODEL AVAILABLE 151 401 318 [12.5] 2d3 2870 371 I 14.62· 2" 137 [5.4] 71 [2.8] YES (DIAG. SHEET 4) 20-60 284 75 318 [12.51 1676 660 711 787 346 I 13.62 .. 584 673 ·2· . 1014. 1092 ----NO KW 454 120 457 . 181 [8.00] , [66.0] . [113] [26.0] [28.0] [31.0] 219 8.621 [23.0] (26.5] 3• [39.94] (43.0] ----NO 284 175 318 r 12.51 3480 ·660 711 787 371 14.62 2· '137 [5.4] 71 [2.8] YES (DIAG. SHEET 4) 80-100 473 125 457 [181 254 1930 270 10.62 584 851 3• 1014 1092 --· NO [10.00} (76.0] [137] [26.0] (28.0] [31.0] [23.0] (33.5] · [39.94] [43.0] --KW 757 200 610 r241 371 14.62 3• ----NO 379 100 ' 318 I 12.51 397 15.62 3" 137 [5.4] 71 [2.8] YES (DIAG. SHEET 4) · 1,35-,-150 .681 180 457 r1B1 305 2045 3785 787 N/A 864 244 9.62 711 947 3• 1116 1194 ----NO KW 284 275 610 f24l [12.00] [80.5] . [149] [3i.O] [34.0] 397 15;52 [28.0] [37.3] 4• [43.94] [47] --NO (I, 15!)-180 379 100, 318 I 12,51 · 651 25.62 3• 137 [5.4] 71 [2.8] YES (DIAG. SHEET 4~ KW 757 200 457 rrni. 305 2045 3785 1067 N/A 1143 549 21.62 991 947 3• 1395 1448 .NO [12.00] [80.5] [149] [42.0] [45.0] [39.0] [37.3] [54.94]. [57] 1136 300 457 [18] . 244 9.62] 4• ----NO ' DIMENSIONS IN [ ] ARE ENGLISH STD. EQUIVALENTS. .. -.. , - -N--P- 71 f2.8 ---- --3/8" -- -- 211 [8.3] ------3/8" -- -- 211 f8.3 ------1/2" ---- 71 f2.8 ------1/2" -- -- STANDARD TANK WEIGHT APPROX. KG [LBS.] 293 645 349 768 432 951 387 853 478 1052 601 1323 440 967 555 I 1222 682 I 15.00. 448 [985 582 I 1280 676 I 1487 - -... DA1E """"""' er A 10-21--97 (A-1) SHf 3 --4 WAS 3--3; CHART AOOED FROM SHf 1 a: 2; (C,0--1) WISCONSIN Ol/lllOOR TANKS REMCMD FROM awm (D--2.3) -R-a: -s-AOOED; (C.D--8) 221, 276, 332. 356, #4, 533, 514, 1142. n1. 058, 822 It !11r7 GAL TANKS AOOell ro awrr. (531&1] LRH B 1-22-99 ~ IN METRIC a: GENERIC l11l.£ BlOCK AOOED. (57436] LRH C DAY TANK STANDARD -R--s-MODEL AVAILABLE TANK WEIGHT APPROX. KG [LBS.] YES (DIAG. SHEET 4) 199 438 NO 295 648 3/8 3/8-1/4 NO 388 853 NO 640 1430 NO 694 1530 - NO 740 1631 YES (DIAG. SHEET 4) 284 625 NO 365 804 NO 480 1057 3/8 3/8-1/4 'NO 807 17801 NO 857 1890] NO 943 2080 . YES (DIAG. SHEET4) 330 725 NO 428 941 ( NO 559 1230 1/2" 1/2-1/4 NO 975 2160 NO 998 2201 NO 1175 25901 . YES (DIAG. SHEET 4) 341 751 · NO 454 998 NO 555 1220 1/2" 1/2-1/4 NO . 1066 12350 NO 1231 f2715 <:l NO 1379 f3040l ', I .. r I . WISCONSIN OUTDOOR TANK WEIGHT . APPROX. KG [LB~.] . 340 ,747] 400 f880l 507 1115 444 [976 I 560 1232 · 721 1587 500 1101 ,. 616 1356 I METRIC CAD FILEI 749 1647 509 1119. 671 1476 .. 777 1709 lNDS OIIEME 5PEDRED - ~-DIDSIJMS 111/£. .. III.LIIEIDIS ICOHLERCQ lWIWaS-""""' --xx,. 7-. ----• -11.S.A. X ± 'llli---. • -.-1m1.. s-.a ca. tamY • _,.,. INST.,.. .. mm.mar• tlNEWII 9lnl ..am.--. .Ml.llllaSW .... Ol:IMMIQN-IISJM». = @-El--DIMENSION PRINT ' ........... '""1E -KGS 12797 ,-CWf' I 2-17-97 ..,.. NONE loo.,. NN627DC.DIIG I_, 3,-4 ,._ CWf' 12-17--97 _,. ADV 6270 D~ --. 0) 0) 0) T'"" -.::I" T"" ....I 0:: 0.. <( I ~ I I I I I I ti I I I I I I I , I GENERATOR ACCESSORIES • KOHLER.POWER SYSTEMS Generator Set Controllers • ~9001 -~RS INTERNATIONALLY REGISTERED $ $ $ o=:. o= Or.':!"' o=i.=- o:=: ou.. or=-, o=-.. o==.. o:---o~:-o= O-'"-o-o-OEiili: ~ -~-IDHLER ~o., 16-Llght Controller $ o::=. oa.. O::::t"' o-o- o~-=-o=-.. 7-Llght Controller G6-30 8/99e Kohler® Decision-Maker™ 3+ Controllers Applicable to the following: 20-100RZ 135-275RZD 20-170ROZK 20-200ROZJ/REOZJ 200REOZP 230-400REOZD 450REOZD-4 500-2000ROZD-4 600/900/1 000ROZM • Controller is compatible with 12-or 24-volt engine electrical systems. • Controller with additional accessories meets the National Fire Protection Association requirements of NFPA-99 and NFPA-110. NFPA-110, Level 1 requirements typically apply to health care facilities; NFPA-110, Level 2 requirements apply to less-critical applications. • Contains microcomputer-based logic with a ROM (read-only memory)-based control algorithm. • Contains internal protection from electrical noise. • Vibration isolated from the engine/generator. • Can be mounted in several orientations on the generator set. • Conformal coating protects circuit boards from environmental damage. Decision-Maker™ 3+, 16-Light Controller for NFPA-110, Level 1 Requirements Oi=~fu: 0~.5.: O LO'NWATER TEMPERATURE OLOWOIL PRESSIJRE QOVERSPEEO D UPPER METER SCALES 1 OFF 3 I l3 u=, rr1["\ -~, LI-U \JU) LI-U u~ AMPS La'=t, ~ VOLTS 'V LOWER METER SCALES o~FAULT 0 LOWBATTERY VOLTAClE QoVESCRANK 0 HIGH BATTERY VOLTAGE 0=" O!f'.: RUN OFF/RESET AUTO 8ILENCa0NOR""-AIAAM L-6----J KOHLER =•Omrr Standard Features • Dimensions, W x H x D, mm (in.): 461 X 247 X 297 (18.15 X 9. 71 X 11.68) • Power source with circuit protection: 12 or 24 volt DC • 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) • AC interlock to prevent starter reengagement with engine running • DC circuit protection • Error-proof wiring harness for electrical connections • Panel lamps (2) • Analog gauges, 51 mm (2 in.): o Pressure gauge, oil o Temperature gauge, engine cooling system o Voltmeter, DC battery • Analog meters, 89 mm (3.5 in.): o AC ammeter, 2% of full-scale accuracy o AC voltmeter, 2% of full-scale accuracy o Frequency meter, 0.5% of full-scale accuracy • Prealarm indicators: o Auxiliary (multiple function) (red) o Battery charger (red)* o Fuel, low-level or pressure (red)* o Pressure, low oil (yellow)* o Temperature, low engine (red)* o Temperature, high engine (yellow)* o Voltage, high battery (yellow)* o Voltage, low battery (red)* • Shutdown indicators: o Auxiliary (multiple function)(red) o Emergency stop (red)* o Level, low coolant (utilizes auxiliary indicator) o Overcrank (red) o Overspeed (red) o Pressure, low oil (red) o Temperature, high engine (red) • Status indicators: o Air damper (red) (200-1600 kW 2-cycle, Detroit Diesel-powered models only, if equipped)* o Generator switch not-in-auto (red) o System ready (green) • Running time meter • Switches and standard features: o Continuous or cyclic cranking. The cyclic cranking provides up to 45 seconds of continuous cranking or 75 seconds of cyclic cranking (crank 15 seconds, rest 15 seconds, crank 15 seconds, etc.). The crank disconnect speed is 390 rpm (13 Hz). o Horn, alarm (with silencing switch) o Mode, prime power o Potentiometer, generator output voltage-adjusting (front panel mounted, ±5% of nominal voltage) (350-2000 kW models have adjustment on voltage regulator in junction box) o Shutdown, overvoltage protection o Start, remote 2-wire start o Switch, emergency stop (standard on 200-2000 kW DOC-and Mitsubishi-powered models only) o Switch, lamp-test o Switch, meter range selector o Switch, run/off-reset/auto (engine start) o Timer, engine cooldown, (5-minute fixed) * Requires optional kit or user-provided device to enable function and lamp Indication. G6-30 B/99e • • • - • Decision-Maker™ 3+, 7-Light Controller for NFPA-110, Level 2 Requirements · v91-TAGE EMERGENm oop 0 STOP ~ -ADJUST ONL y ©)~© 0 UPPER METER SCALES 1 OFF 3 I A..cMIPERES 0 0VEllSPEED O OVSACRANK o~p~~RE O ~PER RUN OfFJflESET AUTO ~ KOHLER Standard Features • Dimensions, W x H x D, mm (in.): 18.15 X 9.71 X 11.68 (461 X 247 X 297) • Power source with circuit protection: 12 or 24 volt DC • 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) • AC interlock to prevent starter reengagement with engine running • DC circuit protection • Error-proof wiring harness for electrical connections • Panel lamps (2) • Analog gauges, 51 mm (2 in.): o Pressure gauge, oil o Temperature gauge, engine water o Voltmeter, DC battery • Analog meters, 89 mm (3.5 in.): o AC ammeter, 2% of full-scale accuracy o AC voltmeter, 2% of full-scale accuracy o Frequency meter, 0.5% of full-scale accuracy • Prealarm indicators: o Auxiliary (multiple function) (red) o Temperature, low engine (red)* • Shutdown indicators: o Auxiliary (multiple function) (red) o Level, low coolant (utilizes auxiliary indicator) o Overcrank (redr . ~ · .w., ·-·. -"· i o Overspeed (red) o Pressure, low oil (red) o Temperature, high engine (red) • Status indicator: o Air damper (red) (200-1600 kW 2-cycle, Detroit Diesel-powered model only, if equipped)* • Running time meter • Switches and standard features: o Continuous or cyclic cranking. The cyclic cranking provides up to 45 seconds of continuous cranking or 75 seconds of cyclic cranking (crank 15 seconds, rest 15 seconds, crank 15 seconds, etc.). The crank disconnect speed is 390 rpm (13 Hz). o Horn, alarm (with silencing switch) o Mode, prime power o Potentiometer, generator output voltage-adjusting (front panel mounted, ±5% of nominal voltage) (350-2000 kW models have adjustment on voltage regulator in junction box) o Shutdown, overvoltage protection o Start, remote 2-wire o Switch, emergency stop (standard on 200-2000 kW DOC-and Mitsubishi-powered models only) o Switch, lamp-test o Switch, meter range selector o Switch, run/off-reset/auto (engine start) o Timer, engine cooldown (5-minute fixed) * Requires optional kit or user-provided devipe to enable function and lamp indication . '... 'f, GS-30 8/990 KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet In U.S.A. and Canada Phone 1-800-544-2444 Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264°6422, Fax (65)264-6455 Selected Decision-Maker™ 3+ Accessories O Common Failure Relay remotely signals auxiliary fault, emergency stop, high engine temperature, low oil pressure, overcrank, and overspeed via one single-pole, double-throw relay with 1 O amp at 120 VAC, 1 o amp at 28 VDC contacts. O Controller Cable in various lengths enables remote mounting of the controller. O Controller Connection Kit provides a cable connecting the controller to a terminal strip in the junction box. Specify the controller connection kit for junction box remote device connections. O Dry Contact Kits interface between the controller signals and customer-supplied accessories providing contact closure to activate warning devices such as lamps or horns. Kits are available in either one or ten single-pole, double-throw relays with 3 amp at 250 VAC contacts. A kit with twenty single-pole, double-throw relays with 3 amp at 250 VAC contacts is available on 350-2000 kW models. O FASTCHECK® hand-held diagnostic fault detector activates controller circuits without operating engine/ generator. Helps service or maintenance personnel quickly identify faults in controller and engine circuits. O Float/Equallze Battery Charger with Alarm Feature warns controller of battery charger fault, high battery voltage, and low battery voltage. Level 2 controller only offers remote indication using the remote annunciator kit. 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 Co. generator set distributor for availability. O Controller Mounted Emergency Stop Switch shuts down generator set immediately in emergency situations. Use the generator set master switch for normal shutdowns. Standard on 200-2000 kW DDC- and Mitsubishi-powered models only. O Prealarms warn of low water temperature, approaching low oil pressure, and approaching high water temperature. Kits for gas-fueled models include a low fuel pressure switch. Level 2 controller offers only remote indication. Order a remote annunciator for this feature with Level 2 controllers. O Remote Annunciator Panel enables the operator to monitor the status of the generator from a remote location. May be required for NFPA-99 and NFPA-110 installations. Kit includes separately mounted 14-relay dry contact kit. O Remote AudloNlsual Panel warns the operator of fault shutdowns and prealarm conditions. Common fault lamp and horn with silence switch. O Remote Emergency Stop Panel immediately shuts the generator set down from a remote station. O Run Relay provides a three-pole, double-throw relay with 1 O amp at 250 VAC contacts for indicating that the generator set is running or shut down. DISTRIBUTED BY: BAY CITY ELECTRIC WORKS, INC. 337 5 Hancock St. San Diego, CA 92110 (619) 298-6193 © Kohler Co., 1995, 1996, 1997, 1999, 2000. All rights reserved, GB-30 B/99e ' I . ··---~---,~ -- ----~... "'-,m,,, - L 7 6 5 .20 [5]-J. 17.75 [451] r·20 [5] EMERGENCY STOP SWITCH ' I (OPTIONAL JOHN DEERE/STANDARD DOC) I I ~ / §: ,...., II) c::i ...... II) '<I" ai N' !:2. tq 0 C'J .20 [5 ]- ,-, II) -IN ..... II) '<I" ai ..,., IN I') ,_, in ~ t II ~1\1\1\1\1\ll1\1hl1hl1ld1/,,,,,,,,,, HERTZ 19 ~1\1\1\1\1l1hhhl11Jhl,1,/,1,1,,,,,, A-{;\tOL,S $ 0 STOP 0 ~ WLTH.E EMERGENCY Q .lllJUST ONLY "' ii>.~ I • I In 111'1'£R METER SCH.ES II i ~1\1\1\1\1l1\llthhhldd1/,1,,,,,,,, A-{; MIP£RES • oE=: o=.= o=rr o~ oE o~ o=.flUl" o::.... ~Cl©· ~i~·~ ~i: ,_ --' i---4.8B [124] • I. 8.00 [203]---'-----i 5/16-18 UNC-2B (4 PLACES) DECISION-MAKER 3+ ENHANCED STD. BOX 20-2000 KW 17.75 [451] [5] EMERGENCY STOP SWITCH .,..... . r(OPTIONAL JOHN DEERE/STANDARD DOC) I l , 0 UPPER 11E1D1 SCH.£S . _!\1\1\1111tl1hhh11ld1/11,,,,,,,, ,,,,,\,11111tl1l1111i,,,,,,,,,,"'" ,,,11\1l11tlll1lihldd1/,1,1,1i,i1 -4 T {f-HERTZ A-c vm_n / . "-C -ERES ITD ... ~ ' 19 $ L • Lt~ 1111'$ u':\, IO LOWER ~ SC.US j - EMERGENCY 0 o=.= 0~ 0='!"' ~ YCIJ'HiE 0 STOP ONLY o-o-.lllJUST ~Q)© o_.-or=- • ------I;J,.-L-6---J .-o ...... IDHLER D J I 4.88 [124] i ~ nn f?n-,.1 1~5/16-18 UNC-2B (4 PLACES) r34l ] LIUnl STD. BOX 20-2000 KW --------------- ,_ ~--·-'-·-··. ·-·--' __ 5 --. ' --' .· 4 3 11.48 [292] J - 0 0 " 0 o. I I 1.32 [34] . I 8.00 [203] ,- 11.48 [292] . J Y' - 0 .. 0 ,, " 0 ·O I I 8.00 [203] I 4 3 J. :20 [5] I \ I -t-i I .. 70 [5] i 'i ., ·i j NFP.A-110 CONT,ROLLER ·: 2 I I ... E 2-1-117 {1,-1) SHEET 1 OF 7 WAS 1 OF a [411138) """'I --------------+--.... F 1 H&-911 (D--e.B-8) B.45 [215) WAS B.9e [228]: (C-8,A-8) 1.25 [32: WAS .75 [18); (C-4,lr-4) 1.32 [34) WIIS 2.30 [58); \£WS ,......,.-.1-rft Tft tu.TN.I ,..IDDCU'I ~""""'~ ~1-A L ._,., 1,-;_:::: ~~IV-~ ~1' CONIROllrD N'a£D rllnL"7"71 ·Ull: C ~ 1!-1~SEE Sl£ET 7-7 [02e58) H" 0-1 (/,-1) SHEET HI WAS 1-7 [93154) illfS NOTE: DIMENSIONS IN [ ] ARE MIWMETER EQUIVALENTS. D C ,8 0 0 0 C\I ~ 0::: w a:) ~ ~-===~-.---------------! w ,r-=..a=--·KOIII.EllCQ (.) ....,_ -vr ---·-II.SA. W •:1:... ............ :,n:.-=:-:.=-:.-=~--:n-= .a ~... ~--. ---------0 -::...S 1 ,_ DIMENSION PRINT • BSD j:5-2&-82 BSD 13-30-92 111111 3-30-tt "•. ¥._4 .... _ _.,.. AOV-5849 t 1-t D I I I D I I - I I) C I, I -c I ) I I 8 .1 ) I I - I I A I ) I I 8 I 7 I 6 I 5 & 4 I 3 I 2 I JUNCTION BOX REV I DATE REVISION BY IM ,-j--j-------------------------------------7N VOLTAGE REGULATOR BOARD ~-l---l--1---------------------------------70--------------+-----------~ F I 8-5-96 i(D-4) THIRD PANEL LAMP FOR OVERSIZED CONTROLLER ONLY ADDED_[4715B] IKAR G J12-16-961(C-1) BOCSH ALT. ADDED (C-2) NOT£ & GROUND FROM START£R 68 :~fil -------!: I ~ 38 58 18-- ~------C3-------, ~-----c2------, ~~~---,.1 I ti.•· 70 I I I' I j I j 1 ~~~70 1U 7N I I I I I. I I I I l"T""".- SAFE GUARD TERMINAL STRIP CO C1 C2 C3 70 7N QOOO 7N-+-- I c2 I 10 10 I I I I I I I 1 ~--~ C3 70 i "mJ I 6+-,a-I ~ Q ~ I OPTIONAL SAFE GUARD BREAKER 1-0 6 ll 'BLACK BLACK l I~ =• (6, CT1 CT2 CT3 USED FOR I~ REGULATOR iPTIONAL 3PH ~ I ,I ENSING ONLY -rJtTig~~ GENERATOR SPEED SENSOR ACTUATOR ,,,;:::PHOTO BOARD ~p V7, VB V9 VO 456 7 89 3 10. ,,n1~ '--, . . , · /31----r--1 , " I \ MAfN ~ I I I I 0 0•~ s:: /'~LO 2 11 1 12 ~ D ~ "--1 t:J At; '--HEAT SINK SPEED~~ ASSEMBLY SENSCR 12 LEAD STATOR • O -+ O O PMG EXCITER FIELD S2~ SHIELD 16---WHITE 24---RED 2----BLACK V7 o ,..VO ~VB 3 1 • ~-s ,, \ t:~li ------"'S~:::-<> 6 LEAD STATOR (600 V, ONLY) 8 NOTE: FOR 1 PH-3PH GENERATOR CONNECTIONS SEE ADV-6002. FOR 3PH & 600 VOLT GENERATOR CONNECTIONS SEE ADV-6004. l 7 l METER/CONTROLLER BOX ,--JP4 I l r • 7 24 38 39 12 INDICATOR• PANEL ASSEMBLY (IPA) ' ~ ~ E USE WITH OVERSIZE ~ ~~ 600 V, ONLY ~ I I - ~ A BATTERY VOLTS !27--H-----<J 1,r vs-----,'+--~+---V7 VB V9 LAM:z CONTROLLER ONLY ~ HERTZ A- V7F VO-!--t---, I VOLTAGE ADJUST l"g HOUR METER I + -H WATER TEMPERATURE )1111111~~-· 5 I V9 7C I 0 00 6 00~~ C T./METER SCALE VO LOW V7 UP CO C1 Cj ol iEilMINAL BLOCK rU 0 rttt -V0__...1, JUMPER co-c, C2-C3- 2 ----------, r;:==='.:============================::__, .I " 7 P3 .......... uaic:,,fl>U'l.p.t,,COa, t.1 "lo!NtA-N<n-UIOOtn NI I l I I 1-1-1-1-1-1- GROUND LUG ~ 40A ~ 14P 1170 9,\ 6 .._, Nt.o<.,,-N .. ..., g S •.OllD"->OlO,O 3~ vo-+--- P2 4P 4 3P 3 2P 2 1P 1 TB2 6 2 I 34 14N L I '-31A: 16- 1~1~1~,~,~,~1~,~1~,~,~,~1~,~1~1~1~1ID1~1~1~1N1-1 § W ~. ~ ~ ~ ~ ~ g g ~ ~ ~ ~ ~ ~ ~ ~ ~ g N ~ -~ ~ ~ ~ ~ CONTROLLER BOARD -1 5 'r 4 7 TO BATTERY ADDED [48792] I JVH I) H I 1-14-97 I (0-4) OVERSIZED lAMP REWIREO;(D-5) lfAD FROM A.C AMPS TO lAMP ENGINE REMOVED.(0-4) LEAD FROM lAMP TO OIL PRESSURC ADDEO [<8930) IKGSI)< J I 4-10-97 j(C-5) lfADS 67 & 68 CONNECTION ROOEO. [49539] ~ [ 10F I N 70 (10N) V .,/" INJECTOR PUMP ~ :,1 '\___J RED o,v ro---gJ INJECTOR PUMP I J ! Aw[.': ""1 T .cc. , __ ,., tl~ GROUNDED TO NEGATIVE SlUD ON STARTER BATTERY CHARGING ALTERNATOR A__ ~ ~ ' D 70 I- ~ D. + FOR 80-100 kw, FOLLOW DASHED LINES FOR BATTERY CONECllON. 10S (8S) NOTE: ~ 11 I I ll·c_ I ,i· 3 10N USED ON· GENSETS 125KW ' AND UP. BATTERY IJ 70 / N (10N) t-! I~'" , .. r-.. --~Ir-0 ,C'f"'I = ENGINE BLOCK GROUND LOW WATER LEVEL SENSOR ! ,.s~ ewe SOLENOID OPTIONAL I 5 7C J ~,J J ~ l PRE I WATER HIGH HIGH TE"1P. ENGINE ENGINE SENDING =rnL TEMP. TEMP. SWITCH UNIT PRESS. SWITCH SENDING UNIT DUAL H.E.T. AND P.H.E,l. SWITCH USED ON SOME ENGINES. I' N 7 I =l ft ' LOW WATER TEMP. SWITCH DEC 3+ CONTROLLER ( 1121-3¢ & 600 VOLT) W/ SP,LIT ACTIVATOR JOHN DEERE 20-180 KW DDC 20-100 KW DDC SERIES 40 125-180 KW 7 2 ! . PRE LOW OIL PRESSURE SWITCH LOW OIL PRESSURE SWITCH u1r~l¼!Ett~7.~ KOHLER CQ JOUC± .010 ANCLES± 1/r GENERA.TOR DMSION, KOHLER, WI 5304<t U.SA .XX ;t ,o:50 SURf"ACE f"INISH 116 DAAWING. IN OESICH '-HO DCTAIL. IS ICO!fl.£ft CO. PROPERTY N,f{) -r 'WUS'r l,jOT 8£ USED CXCCPT "" CONNZC110t4 ""1'H KOHLOI CO 'IIIORK. .X ;t .060 -../ J.IAX. AUftQfTSorOCSICI.IOAIINttmOt!ARCRCSCR\ICD "":.'::ALS o,;. mu: DIAGRAM, WIRING OFS JS tJ'f'flOl,'f;o SL 3-1-95 ~NONE: 3-21-95 f>1.0'11[D 7 """'-~. 327153,0WG I'"'° 327153 1-1 ID 8 I- A :"'. -~ .. ~- I£. ·-,f.- --:~ ,,. -· 00 ----------- )> a:J (") ~ . r--P----------------.--1 ~OT USED ON FORD --FORD ONLY:_J ___ r1J:Ji= _____ f~~E:T~~N~C-7 I I 'T' I GOVERNOR I r~-70-7 BCA : I : 1----7 CONTROL I I BCA 10Pe I I 1 i::----~ I BCA -P-, I ®D+ r + I ,------i:r... L-,-i----_J r--11 I -WB+., -!<1-?0I : ACl"'Dl\f I I L.l~iJ. _____ _,,7, . 1 1 --, 1 1 .• 'i -, 1 I I 1 1 I -rr1' 10P I I . 1 I I 1 1 I I~~ 11 11 I DELCO I I BOSCH 10P I I PRESTOLITE 70 70 I t1,_l) IL.JI I : : : I I I I : H c_t-J~ I I I I I I I I .I lRlR r--, --~----------_._;--------~----1 ____ .J I I I plAi7 :ACTUATOR: L---~~--------i--------------+-..!-70 ,I I PICK I L ____ _, --- TERMINAL ID -- 0 TB 1 TB2 P3-P4 & J2Z DESCRIPTION 42A BATTERY VOLTAGE {FUSE 11 PROTECTED) 2 GROUND 3 REMOTE START GROUND 4 REMOTE START {ACTIVE LOW) - 9 CRANK MODE (OPEN•CYCUC;GROUNO=CONTINUOUS) 9A CRANK MODE GROUND 12 OVER CRANK INDICATOR 24 + 12VOC REGULATED 26 AUXILVIRY INDICATOR 32 COMMON FAULT/PRE-.IIARM UNE 1 (ACTIVATED BY - 00 ---1-2V_O_C_BA_TT_E_/!....jy 1 11 --12VOC BATTER~!:: ~(USED FOR : r-~~~~:..--®+P SELSW (CONTACTS SHOWN WITH SWITCH IN OFF POSITION) HET, PHET, LOP, PLOP, OS, LWT, OC, IF, AUX. FAULTS) STANDARD 32A COMMON FAULT LINE 2 (ACTIVATED B'I' E-STO?, OS, LOP, CONTROLLER SS 24V ONLY) ·: . I I I i--------l I I r-70----,-1 FSH I 17 I I I : IL __ __, It, I I I I L-J<I--J . L---1~------------------~ J I I t--70-----{Ih. I I I L s---7 7N ·r-?O---'-L_!:"_Jl 14P ·K20 10P--i' i=--14S CONTROLLER BOARD GROUND P1-5 ::5 ! I 14N--+-IOl--t ?O .----++-I--V7 --1---++-1--V7 '------.1 Pl-12-TO : FUSE 1 rn-34 AUXILIARY DELAY --31. SHUTDOWN AUXILIARY DELAY --31 SHUTDOWN rn-31A -3J Pl-22 P1-21 P1-15 Pl-13 ' P1-10 Pl-14 FUSE 2 FUSE 3 INHIBIT FOR 30 SEC, AFTER START, THEN 5 SECO.NDS. ·_ SHUTDOWN BATTERY I VOLTAGE P1-7 (FUSE 3) BATTERY . (VOLTAG~ P1-3 FUSE 3) :r85 ~~j- SFG • 2=_'?3'-1B1----, BATTERY I@]. VOLTAG~ P1-1 71 K2D (FUSE 3J BATTERY VOLTAG~ P2-1 {FUSE 3J GROUND P2-6 T81 ·1 1A-7 [oP,sl 7C~ .--+----J.-1-'i---VB r-1----1-++---vg ..++-i-J----j-J--1--VO -ST 1 ---, 12 42A I: 2 I I 70C !1. ?OR I: =<-='-'"""-"'co""T85 -P1-19 -56 -• P1-18 AUXILIARY IMMEDIATE -30 · SHUTDOWN Pl-17 56 11 8 48 : I 32A I I 26 I I 11 11 12 I I NOTE: CT WIRES GO DIRECTLY TO TB5 WHEN SAFEGUARD BREAKER IS NOT =-_.J-1--.:.:J-~USED. HET, AUX. FAULTS) 36 HIGH ENGINE TEMPERATURE INDICATOR 38 LOW OIL PRESSURE INDICATOR 39 OVER SPEED INDICATOR 43 Off /RESET COMMAND {ACTIVE LOW) 46 AUTO COMIMND (ACTM: LOW) 47 RUN COMMAND (ACTM: LOW) S6 ~R DAMPER INDICATOR 60 SYSTEM READY INDICATOR , 70C GENERATOR IN COOL DOWN 70R GENERATOR RUNNING BO NOT IN AUTO INDICATOR --------' 35 LOW WATER TEMPERATURE REQUIRES 40 PRE ALARM HIGH ENGINE TEMP. INDICATOR PRE A\ARM KIT TO 41 PRE ALARM LOW OIL PRESSURE INOICATO OPERATE '1 EMERGENCY-STOP RELAY (K4) GROUND ., ... EMERGENCY-STOP RELAY (K4) COIL, NEGATIVE 27 HIGH BATTERY VOLTAGE (ACTIVE LOW) USED FOR 48 EMERGENCY-STOP INDICATOR DEC 3+ 61 BATTERY CHARGER FAULT (ACTIVE LOW) ACCESSORIES 62 LOW BATTERY VOLTS {ACTIVE LOW) 63 LOW FUEL (ACTIVE LOW) • MUST HAVE JUMPER IF THERE IS NO EMERGENCY STOP KIT CONNECTED, 1P PRIME POWER OPERATION 2P PRIME POWER OPERATION Js~~8Wf JP PRIME POWER OPERATION KIT 4P PRIME POWER OPERATION 3¢ SELSW L1 L2 L3 39 I: L1 LO-L3 LO-L2 LO-L1 OFF L1 -L2 L2-L3 L1 -LJ 38 36 60, II PANEL LAMP I (OPT) • Lll ____ _ 0cT2 . L2 1 3 L3 5 CT3 7 B 1 2 3 4 5 6 C C C ,C M M C C C M C M C C C C C M M C C M C M 2 4 6 8 '-.I en P1-23}- Pl-l5 , PREALARM 80 41 62 32 35 40 63 61 I I I I I . 0 NOTE: 9 C C C C C C M M C 10 u, I I I I P1-24 AC CRANKS P2-3 DISCONNEcn_ p2_5 18 L71•15 1•1 312I 1h02 3 4 ·sA 9 4P3P2P1P 46 24383912264840 ___ . -. _ P3 ____ _ P4 IPA T56 HIGH v8t'Jl}ll T27 -----------_---::;-, AVR 6 9 3 1 7 4 10 2 11 V7 VB V9 I I I I VO V7 VB!V9 I I I -I\:_ USED FOR. OPTIONAL , . _J 3¢ REGUl:ATOR SENSING ,ONLY J L.: -I j ·58 38 SPEED SENSOR 16 24 _____ P_H_oT_o_so_ARD . . ~ SLB LJ P1-1-I_f Pl-2 1 - SPEED SENSOR ACTUATOR LEGEND A -A.C. AMMETER OPS -OIL PRESSURE SENDER P(#) -PLUG AVR -AUTOMATIC VOLTAGE REGULATOR BCA -BATTERY CHARGING ALTERNATOR BV .,.. BATTERY VOLTMETER CT -·CURRENT TRANSFORMER ESS -. EMERGENCY STOP SWITCH FS -FUEL SOLENOID ~tii = ~~~t:~\~1~~ ~6CW Ji~G~NR\sTJ~:rix~~~ SWITCH FSH -FUEL SOLENOID (HOLD) FSP ~ FUEL SOLENOID (PULL-IN) HET -HIGH ENGINE TEMPERATURE SWITCH HR -HOUR METER HZ -FREQUENCY METER IP -INJECTOR PUMP IS -IGNITION SYSTEM ~t ~· ~~f~~i~ t~\¼t~SlEt~f K20 -CRANK RELAY LOP -LOW OIL PRESSURE SWITCH LWT -LOW WATER TEMPERATURE SWITCH OPG ,... OIL PRESSURE GAUG~ )> SELSW -SELECTOR SWITCH SFG -SAFEGUARD BREAKER SLB -STATIONARY LED BOARD SM -STARTER MOTOR SS -STARTER SOLENOID TB1 ,2 -CONTROLLER BOARD TERMINAL BLOCK TB3 -CT/METER SCALE TERMINAL BLOCK TB4 -AC FUSE BLOCK TB5 -SAFEGUARD BREAKER TERMINAL BLOCK V -A.C. VOLTMETER VADJ -VOl:TAGE ADJUST WLS WATER LEVEL SENDER WTG WATER TEMPERATURE GAUGE WTS WATER TEMPERATURE SENDER 'a:, (") CURRENT 11 TRANSFORMER DOT OR "H1" 13 TOWARD 15 GENERATOR 17 19 21 23 TB4 M C M C C NOTE: C C C C C C C C BLANK DENOTES CONTACT OPEN "C" DENOTES CONTACT CLOSED C C 12 14 16 18 20 "M" DENOTES MAKE BEFORE BREAK CONTACT 1¢ -3¢ SELSW . G lHI l1 L2 L1-L2 L1-L2 LO-L1 B 1 2 M C C C M C M M C M C M C C C C C C C C C NOTE: L3 ll L2 OFF L3-L1 L1-L2 L2-L3 3 4 5 6 C C M M C M C M C C C M M C C M M C C M C M C C C C C C BLANK DENOTES CONTACT OPEN "C" DENOTES CONTACT CLOSED -02 -o4 -06 -o8 -010 -012 -014 -016 -018 -o2Q -022 -024 "M" DENOTES MAKE BEFORE BREAK CONTACT .,, ,,, " "' N I I ,!, .. I ~ ! 18 ., C ! ~ "' N FEBRUARY 15, 2000 I ' I ~ I I I I I I I It I I I I I I ~ I I N@~®§ __________ ~ I I I I I I I ------------ti ------------1 I· I I I I I I I I I. I I I I I I) I I I I I I I I I - SQUARE-D UL PART NUMBER REV. AMPS X-6304-50 DF 60 X-6304-51 DF X-6304-52 DF 80 X-6304-53 DF X-6304-54 DF X-6304-55 DF X-6304-56 DF 90 X-6304-134 DH X-6304-135 DH X-'-6304-57 DF . X-6304-58 DF 100 X-6304-59 DF' X-6304-60 DF X-6304-8 cw X-6304-9 cw X-6304-19 cw X-6304-20 cw X-6304-61 DF 125 . X-6304-62 DF X-6304-63 DF X-6304-64 DF X-6304-1 cw X-786-48 cw X-6304-10 cw X-6304-11 ,CW X-6304-65 DF 150 X-6304-66 DF x'-6304-67 DF X-6304-68 DF X-6304-'-2 cw X-6304-12 cw X-786-41 CW X-6304-24 cw X-6304-23 cw 175 X-6304-69 DF X-q304-70 . DF X-6304-71 DF X-6304-72 DF X-6304-73 DF X-6304-1.3 cw·. X-6304-14 cw X-6304-21 CW X-6304-22 cw X-6304-29 DB 200 X-6304-74 OF x~5304-75 OF X-6304-76 OF X .i=;"ln4-77 nF X-6304-3 cw X-6304-15 cw X-6304-16 cw X-6304-27 cw 225 X~6304-78 OF X-6304-79 DF X-6304-80 OF X-6304-81 OF X-6304-82 OF X-6304-83 OF X-6304-84 OF 250 X-6304-85 OF X-6304-86 OF X-6304-87 DF X-6304-138 DL X-6304-139 DL 300-400 X-6304-140 DL 8 MAX. VOLT POLES RATING 600 3 600 3 600 3 600 3 600 3 240 3 600 2 600 3 600 3 600 3 600 3 600 3 600 3 240 3 600 3 ,600 2 600 3 600 3 600 3 600 3 600 3 600 3 600 3 600 600 600 600 240 3 600 600 600 i=;nn 240 600 600 600 3 600 600 600 600 600 3 ' I ' 600 - I u I · SHUNT OTHER VENDOR FRAME TRIP FEATURES NUMBER FAL 12V DC AUX. SW. FAL-36060-1393 FAL NONE NONE FAL-36080 FAL 12V DC NONE FAL-36080-1039 FAL 24V DC NONE FAL-36080-11027 FAL NONE NONE FAL-36090 FAL 12V DC NONE FAL-36090-1039 FAL 24V DC NONE FAL-36090-1027 FAL 12V DC AUX. SW. FAL-36090-1393 FAL 24V DC AUX. SW. FAL-36090-1386 FAL NONE NONE FAL-36100 fAL ; 12V DC NONE FAL-36100-1039 FAL . 24V DC NONE FAL-36100-1027 FAL 12V DC AUX. SW. FAL-36100-1393 KAL NONE NONE KAL-36125 KAL · 12V DC NONE KAL-36125-1039 KAL ; 12V DC AUX. SW. KAL-36125-1393 KAL . 24V DC AUX. SW. KAL-36125-1386 KAP : NONE NONE KAP-36125 KAP 12V DC NONE KAP-36125-1039 KAP , 24V DC NONE KAP-36125-1027 KAL '. 24V DC NONE KAL-36125-1027 Q2L NONE NONE Q2L-3150 KAL NONE NONE KAL-26150 KAL ; 12V DC NONE KAL-36150-1039 KAL NONE NONE KAL-36150 KAP ' NONE NONE KAP-36150 KAP 12V DC NONE KAP-36150-1039 KAP ' 24V DC NONE KAP-36150-1027 KAL · 24V DC NONE KAL-36150-1027 . Q2L NONE NONE Q2L-3175 KAL 12V DC NONE -KAL-36175-1039 KAL NONE NONE KAL-261-75 KAL ' 12V DC AUX. SW. KAL-36175-1393 KAL 24V DC AUX. SW. KAL-"-36175-1386 KAP NONE NONE KAP-361-75 KAP I 12V DC NQNE · KAP-36175..:.1039 . KAP . 24V DC NONE KAP-36175-1027 KAL NONE NONE KAL-36175 KAL 24V DC NONE kAL-36175-1027 KAL NONE NONE KAL-36200 ! KAL 12V DC NONE KAL-36200-1039 KAL 12V DC AUX. SW. KAL-36200-1393 KAL , 24V DC AUX. SW. KAL-36200-1386 Q2M · NONE NONE Q2M2200MT KAP NONE NONE KAP-36200 KAP ' 12V DC NONE KAR-36200-1039 KAP 24V DC NONE KAP-36200-1'027 l<AI .. ?4V nr NONE KAI -,i:;?nn-1 n?7 Q2L NONE NONE Q2L-3225 KAL ' 12V DC NONE KAL-36225-1039 KAL ' NONE ·NONE KAL-36225 KAL 1 24V DC AUX. SW. KAL-36225-1386 KAP NONE N0NE •KAP-36225 KAP' 12V DC NONE KAP-36225-1039 KAP. 24V DC NONE KAP-36225-1027 KAL 24V DC NONE KAL-36225-1027 KAP NONE . NONE KAP-36250 KAP . 12V DC NONE KAP-36250-1039 KAP , 24V DC NONE KAP-36250-1027 KAL NONE NONE KAL~36250 KAL 12V DC NONE KAL-36250-1039 KAL : _24V D.C NONE KAL-36250-1027 ---LA1..:.1039 --. -LA1-1027 ---LA1-1212 7 I f:. I J ,& 4 I 3 I VENDOR PART NO. PART NO. OF SERV. ONLY OF SERV. ONLY REMARKS SHUNT TRIP SHUNT TRIP FACTORY INSTALLED ONLY ----- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -· ---- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY ----- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- ""' --- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY ----LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -------- FACTORY INSTALLED ONLY -------LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY. -. LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY ----- FACTORY INSTALLED ONLY ----- FACTORY INSTALLED ONLY, -- FACTORY INSTALLED ONLY -~ --LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS ONLY FACTORY INSTALL,ED ONLY -LOAD SIDE LUGS QNL Y --- FACTORY INSTALLED ONLY ----- FACTORY INSTALLED' ONLY --, FACTORY INSTALLED ONLY -- FACTORY -INSTALLED ONLY -------LOAD SIDE LUGS ONLY FACTORY INSTALL£[) ONLY -LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS ONLY FACTORY IN<:TAI IF[) ONI Y ---- FACTORY INSTALLED ONLY ----- FACTORY INSTALLED ONLY ----LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -. ·LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY -LOAD SIDE LUGS QNLY FACTORY INSTALLED ONLY -----LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY · -LOAD SIDE LUGS ONLY FACTORY INSTALLED ONLY' -LOAD SIDE LUGS ONLY --- FACTORY INSTALLED ONLY -- FACTORY INSTALLED ONLY -- 12VDC SHUNT TRIP ONLY, FOR LA FRAME -- 24VDC SHUNT TRIP ONL)', FOR LA FRAME ----AUXILIARY SWITCH ONLY; FOR LA FRAME C: D. - ' ', ' : I I I l'i : l l I I I i : i ! j '. ' i I ' .. " ! I I I : .. , ' 2 I 1 REV DATE Rf.VISlON BY W F DL 12-9-99 (A-8) X-6304-138 THRU -140 ADDED [60679] 1<AR DM 1-17-00 SEE SHffi 2 OF 3 [61104] MJK REVISION BlOCK INOICA1ES REVISION LEVEL OF DRAWING NOT PART REVISION. SEE PART REVISION LEVEL BEHIND PART NUMBER FOR CURRENT PART RE.VISION LEVEL . NOTE: UNLESS OTHERWI.SE Sl?ECIFIED, ALL BREAKERS TO BE SUPPLIED WITH LOAD AND LINE TER.MINALS SUITABLE FOR CURRENT RATING OF THE BREAKER. FOR BREAKER DIMS SEE ADV-5912 ALL 3 POLE BREAKERS MUST BE MARKED: "UL LISTED FOR USE ON SINGLE, AND TWO PHASE APPLICATIONS". UHi.£$$ CJTHUIIMS£SPCQJEJ -KOHLERCQ il'=s~KHE:5 J<D± ..,. ,N,1Q.CS±.1,r CDEAATOA DMSIOH. l<OHl£R. WI 53044 USA. JOC·:t,.oJO ....,..,.,_, TMS ~ N DDICN IMO DCT..._ IS 1«MDr cu ~ IMO • tlAJST NOi' E USCD £ICCOll1 IN CCNICC1'10N Mn1 llilH.OI'. CO WCRC. "± -7-. AU. taQff$ Of'" DC5ICN at trM)ffl0N NE. IIIE5E:IM'l), .-...cnoo,s± fflU' N'PR<NN.5 DATE BREAKER, CIRCUIT -JBM 3-28 91 _,.,, JS 4-30 91 NONE IOCIIQ. X6304A.OWG 1-n 1-J '"""" ,-.. EB 9-9-92 X 6304 I De . 0 0 0 N ~ ~ ~ I I I I I I I I .1 I I I I I I I I I 1· D - C ·1 ~ I B - A I 8 l 7 I 6 I 5 i 4 l 3 SUPPLIER FRAME SIZE I A I · B I C I D I E I F I G I r.g,,il I H I J I K L M N p R s T Q2L & Q2M (2 POLE} I 3.03 I 3.91 I 2.97 I 2.23 I 6.44 I 3.63 I .219 I 4 I -I .75 I 4.25 2.18 1.75 .88 2.50 1.25 Q2L (3 POLE) . _ J 3.03 I 3.91 I 2.97 I 2.23 I 6.44 I 3.63 I .219 I 2 I 1.50 I .75 I 4.25 2.18 1.75 .88 2.50 1.25 SQUARED Q4L -LAL I 4.06 I 5.84 I 5.98 I 2.99. I 11.00 I 6.14 I .250 I 2 I 2.00 I 1.00 I 9.25 3.99 3.06 1.53 3.98 1.99 FAL I 3.16 ( 4.16 ( 4.46 ( 2.23 ( 6.oo· ( 3.94 ( .219 ( 2 ( 1.50 I .75 ( 5.13 2.37 1.75 .88 2.53 1.27 KAL I 3.68 I 4.75 I 4.48 I 2.24 I 8.oo I 4.oo I .250 I 2 I 1.50 I .75 I 7.13 3.56 1.75 .88 2.53 1.27 MAL (2 & 3 POLE) I 4.53 I 6.55 1 8.96 I 4.48 I 14.oo I 7.90 I .250 I 2 I 3.oo I 1.50 I 10.69 4.45 3.75 1.88 4.00 2.00 PAF, PCF, PXF I 8.38 I 10.47 I 12.00 I 6.00 I 20.10 I 6.25 1.28 X .SOI 2 I 12.75 I 6.38 I 10.25 5.12 -TQD (3 POLE1 I 2.69 I ... I ,-I 6.56 1-----i I 2 I 1.38 I I 4.88 . TED -TEB I 3.38 I I I I 6.31 I I I 2 I 1.38 I I 4.88 GEN. ELECTRIC TFJ 4.06 10.12 2 1.38 7.75 -- TJJ-TJK-TJD 4.06 10.12 2 2.75 7.75 -- TQD (2 POLE) 2.69 6.56 4 1.38 4.88 EHB -EHD -EB -FDB 3.38 4.12 4.12 2.06 6.00 3.63 .250 2 1.38 .69 4.50 1.63 --1.19 .59 2.96 .59 CA (3 POLE} 2.69 4.12 6.50 .2 1.38 4.94 CA (2 POLE} I 2.69 I I 4.12 I I 6.50 I I I 4 I -I I 4.94 DA LDK I 4.06 I 4.95 I 5.49 I 2.75 I 10.12 I 5.25 I .250 I 2 I 1.12 I .86 I 8.44 I 3.52 I -I -I 2.63 I 1.31 I 3.75 I .83 WESTINGHOUSE LB -KD -KDB 4.06 4.95 5.49 2.75 10.12 5.25 .250 2 1.72 .86 8.44 3.52 --2.63 1.31 3.75 .83 JB -JD -JDB 4.06 4.95 4.13 2.06 10.00 4.72 .250 2 1.38 .69 7.25 3.17 --1.56 .78 3.94 2.92 LC 600 -LD I 4.06 I 5.50 I 8.25 I. 4.13 I 10.75 I 5.61 I .250 I 2 I 2.75 I 1.38 I 9.53 I 4.48 I -I -I 3.44 I 1.72 I 3.28 I 1.33 MC. I 4.06 I I 8.25 I I 16.00 I l I 2 I 2.75 I I 14.75 NC I 5.50 I I 8.25 I I 16.00 I I I 2 I 2.75 I I 14.75 Pc I 9.06 I I 12.06 I I 22.12 I I I 2 I 4.03 I I 19.84 CE106N I 3.94 l 5.04 I 4.13 I 2.06 l 5.04 I 2.52 l .219 I 1 I 1.38 I .69 I 3.54 I 1.77 I -I_ -I 1.83 I .92 I 3.35 I 1.68 CF250N I 4.53 I 5.71 I 5,51 I 2.78 ·1 10.11 I 4.31 I .219 I 2 I 1.77 I .89 I 7.09 I 4.29 I -I -I 2.00 I 1.00 I 3.35 I 1.28 CJ400N I 4.53 I 6.73 I 6.20 I 3.10 I 12.59 I 6.49 I .219 I 2 I 2.01 I 1.04 I 9.45 I 4.53 I -I -I 2.91 I 1.46 I 4.02 I 1.81 MERLIN GERIN I CJ600N 4.53 6.73 5;20 3. 10 12.59 6A9 .219 2 2.07 1.04 9.45 . 4.53 -· -· 2.91 1.4·5 4.02 1.81 · (U.L.) I _ C~800N 4.53 _ 6.77 8.26 4.13 15.74 8:70. .297 3 2-.75 1.38 9.44 4.09 7.87 2.56 2.91 1.45 4.09 1.45 I CK1200N 4.53 6.77 8.26 4.13 15.74 8.70 .297 3 2.75 1.38 9.44 4.09 7.87 2.56 2.91 1.45 4.09 1.45 CM1600HE 10.74 ·17.75 16.45 8.23 16.92 1.0.42 .406 2 15.35 7.68 9.44 2.75 --9.05 2.63 7.67 3.35 cM°2000HE l 10.74 I 11-:?s-l.16.45 I 8.23 l 16.92 I 10.421 .406 I · 2 I 15.35 I i.-68 I 9.44 l 2;75 I -I -I 9.os l 2.63 l 7.67 l 3.35 CM2500HE. -I 10,74 I 17.75 I 16.45 I 8.23 I 16.92 I 10.42 I .406 .. I 2 I 15.35 I 7.68 I 9.44 I 2.75 I -I -I 9.os I 2.63 I 7.67 I 3.35 c101N I 3.94 I 5.04 I 4.13 I 2.06 I ·5_04 I 2.52 I .219 I 1 I 1.38 I .69 I 3.54 I 1.77 I -I -I 1.83 ·I .92 I 3.35 I 1.68 c1.s1N [4.53 I s.48 I 4.13 I 2.01 I s.10 I 3.09 I .219 I 2 I ua I .69 I 4.72 I 2.40 I -I -I 1.97 I .98 I 3.4LJ_t-73 C250N I 4.53 I 5.71 I 5.51 I 2.78 1· 1,0.11 .I 3.92 I .219 I 2 I 1.77 I .89 I 7.09 I 4.6.9 I -I -I 2.00 I 1.00 I 3.35 I 1.68 C401N I 4.53 I 6.73 I 6.20 I 3.10 I 12.59 I ·6.49 I .219 I 2 I 2.07 I 1.04 I 9.45 ·1 4.53 I -I -I 2.91. I 1.46 I 4.02 I ·2.01 MERLIN GERIN I C630N 4.53 6.73 6.20 3.10 12.59 6.49 .219 2 2:07 1.04 9.45 4.53 --2.91 1.46 4.02 2.01 (I.E.C.) ! C.801N 4.53 . 6.77 8.26 4.13 15.74 8.70 .297 3 2 .. 75 1.38 9.44 4.09 7.87 · 2.56 6.81 3.41 , 4.11 _ 2.06 C1001N 4.53 , 6.77 8.26 4.13 15.74 8.70 .297 3 2.75 1.38 9.44 4.09 7.87 2.56 6.81 3.41 4.11 2.06 C1251N 4.53 6.77 8.26 4.13 15 .. 74 8.70 .297 3 2.75 1.38 . 9.44 4.09 7.87 . 2.56 6.81 3.41 4.11 2;06 cM1soo I 10.74 I 17.75 I 16.45 I 8.23 I 16.92 I 10.42 I .406 I 2 I 1,5.35 I 7.68 I 9.44 I 2.75· I -I -I 9.05 .I 2.63 I 7.67 13.35 CM2000 I 10.74 I 17.75 I 16.45 I 8.23 I 16.92 I 10.42 I .406 I 2 I 15.35 I 7.68 I 9.44 I 2.75 I -I -I 9.05 I 2.63 I 7.67 I 3.35 CM250o I 10.74 I 17.75 I 16.45 I 8.23 I 16.92 I 10.42 I .406 I 2 I 15.35 I 7.68 I 9.44 I 2.75 I -I -I 9.05 I 2.63 I 7.67 I 3.35 HOLE STYLES I . ~ ! i •• I ,, i .!) I •,' --1 A (BACK OF I-- SIDE PANEL) I •G c=.i :tH -GH -tH ? OF BREAKER HANDLE HAND! . .E CUTOUT 7Jfu· 7R~ r-. : ~-+~~ . l_ i _j__J_ t !/! I _J ~ -4-+-+--, i I _l_j_ l -rr 1 _J 1 -4-+-4-i I I , -, _1_1 , t I I -~ I • I I I (n• ~ --I-' ' ~t-~------i<Zoc'kR~"l_fi·I+~ -+--t-~,--i---+--+-+-+--+-~ L-.±t. + 1~n~., 1-I _J -., t t : +~, ~F BREAKER . HANDLE STYLE 1 1~l)'LE 2} STYLE 3 SlYLE 4 . -B~ ? OF BREAKER HANDLE 8 I 7 I 6 I 5 't 4 I 3 I '7:::':---::--~---·------~--........_~------~ ,_ ---------------------- 2 2 I 11EY I OOE I REYISXlN Br ,i B I 9-8-94 IAWIE CF250N: DM "f" 4.31 WAS 3.92. DIii "L" 4.29 WAS 4.69. lllll "1" 1.28 WAS 1.68; FRAME CJ400N & CJ800N: DIii "l" 1.81 WAS 2.01; FRAME ct<800N A: CK1200N: DM "f" 2.91 WAS 6.81, DM "r(' 1.45 WAS 3.41, DIM "rt' 4.09 WAS 4.11. lllM ·r us wAS 2.06. !MRS C 1-14-97 (D-7) SQUARE D FRAME Sil£, "Q2lt' ADDED [49161] RSH D 9-11-98 (D-7) SQUARED FIWIE SIZE: "PIF."Pef"."PXF" ADDED [53692 D C f:1- B A 0) 0) 0) -..:=---~ KOHLERCQ ~ ~----l<IHElf.11 53044 USA. -=::: =~ ~~~~N~-=::.n~-= ~ x ± .-7 awe. NJ. mus CF IEDI m IMJnDI #IIE IIBDNm. "{--:::AIS l .,.lE ,.,. BREAKER, CIRCUIT :::! -IN1 ~ ~ ~ .. ~~-1-----1--=i----,=,-1 o::: ADV-5912 ! De ~ 1 I GENERATOR ACCESSORIES ) KOHLER®POWER SYSTEMS Float/Equalize Battery Charger ) ) ) ) 09001 CJ'} ICDHLER. -GEN:RAlORS MERNATPNAll.Y REGISTERfD D.C. A.C. OUTPUT INPUT 0 0 TYPE ABC TYPE ABC 25A 120VAC-7A 240YAC-5A POWER ON Specifications VOLTS Model No. Output Voltage PAD-292862 12 PAD-292863* 12 PAD-292864 24 PAD-292865* 24 Weight Dimensions -· (Lx D x H) * Includes optional alarm circuit board. 0 0 ' Output Amp!? 10 10 10 10 • Kohler automatic battery chargers feature two charging modes to keep lead-acid and nickel-cadmium batteries fully charged without overcharging. The battery charger automatic float-to-equalize operation maintains battery voltage with no manual intervention. • Temperature compensation feature prevents overcharging or undercharging battery at high/low ambient temperatures. • Current-limiting circuitry prevents battery charger from overload at low battery voltage and during a short circuit. Ten amp DC current limit eliminates crank disconnect during generator set exercise period. Number of Cells Lead Acid Ni-Cd Voltage Regulation 6 9 ±1% 6 9 ±1% 12 18 ±1% 12 18 ±1% 26 lbs. (11.8 k~) 10.67 X 5.63 X 16.63 in. (271 x 143 x 422 mm) NOTE: Complies with NFPA 11 O code requirements when equipped with optional alarm circuit board. Alarm board features low battery voltage, high battery voltage, and battery charger malfunction alarm contacts. G6-151/95g Automatic Float to Equalize When the battery loses its charge, the battery charger operates in the High Rate Constant Current Mode until the battery voltage rises to the preset equalize level. At the preset equalize level, the battery charger switches to the constant voltage Equalize Mode until the current required to maintain this voltage drops to 50% of the battery charger's high rate current. The battery charger then switches to the lower constant voltage Float Mode when the battery nears full charge. The battery charger continues to operate in this mode until AC input power disconnects or the current required to maintain the battery at the float voltage setting exceeds 6 amps. Temperature Compensation The battery charger compensates for battery temperature using a negative temperature coefficient. The battery charger provides temperature compensation of -2mv/°C per cell over the ambient temperature range of -40°C up to 60°C. The temperature compensation automatically adjusts the float and equalize voltage settings to prevent the battery from overcharging at high ambient temperatures and undercharging at low ambient temperatures. t! C: (]) (]) Cl,._ !t :5 -o ~ Cl >,.£ ,._ Cl (]) ,._ 'a_g roo Float Voltage Float Current Time- • High Rate Constant Current Mode Ill Equalize Mode 0 FloatMode -60 e ~ 40 ta ffi c. 20 ! ~ 0 ! -20 G6-151/95g Figure 1 ----------·----- I ---------J ----_,_ ----I 92 94 96 98 100 102 104 106 % of Nominal Charging Voltage Figure 2 ( ( ( ( • ) ) ) ) Standard Features • Ammeter and voltmeter indicate battery charging rate with 5% full-scale accuracy. POWER ON lamp indicates battery charger is operating. • AC input and DC output fuses prevent battery charger damage from abnormal overload and short-circuit conditions. • Operational temperature range is from -40°F (-40°C) to 140°F (60°C). Battery charger float and equalize voltage automatically adjust throughout the temperature range. • Reverse polarity protection circuitry prevents battery charger from energizing if improperly connected. • Internal terminal blocks for AC input and DC output/ sensing lead connections. • DC voltage regulation of± 1 % from no load to full load and AC input line voltage variations of ±10%. ') • UL listed/CSA certified . • Wall-mount, slotted enclosure with knockouts for customer conduit installation. • Reconnection blocks allow operation at 120 or 240 volts AC, single phase, 50 or 60 hertz. • Battery charger circuitry protected from AC line and DC load voltage spikes and transients. • Terminal block for remote battery sensing leads. • Automatic float-to-equalize operation with individual potentiometer adjustments. Charge up to 12 lead-acid or 18 nickel-cadmium battery cells. • No adjustments are necessary for lead-acid or nickel-cadmium batteries. • Oversized transformer and SCR heatsink allow constant current charging at 1 O amps up to the equalize voltage setting for fastest battery charging. G6-151/95g KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 920-565-3381, Web site www.kohlergenerators.com Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 10.67 [271] 7.00 [178] --------+-----~ D.C. A.C. OUTPUT INPUT 0 0 TYPEABC TYPE ABC 25A 120VAC-7A 240VA~ POWER ~\o -'--+!t--H-) ON c7 ,__ __ 7.00 [178] .25 [6] DIA. (2HOLES) CUSTOMER INPUT CONNECTIONS AC TERMINAL BLOCK NOTE: BATTERY CHARGER IS CONNECTED FOR 120 VOLT tlPUT AB STANDARD, WIRES MUST BE AEPOSmoNED AS SHOWNTOCONNECTT02-40VOLT INPUT, AC INPUT FUSE MUST BE CHANGEO TO AGREE AB SHOWN BELOW, FUSE SUPPLIED, ~ 120VAC 240VAC FUSE 7A, TYPE ABC 5A, TYPE ABC 5 10 0,,\,1\11,,1,,,,)5 \DC AMMETER A CUSTOMER OUTPUT CONNECTIONS DC TERMINAL BLOCK \ BATTERY SENSING CONNECTIONS IF CHARGER OUTPOr LEADS ARE LONGER T~ 15 FT., DISCONNECTTEAMINAL BLOCK JUMPERS AND RUN SEPARATE SENSE LEADS TO BATTERY. USE MINIMUM 18 GA. WIRE. BATTERY CONNECTIONS POS, &NEG, USE MIN.10GA,WIRE. NOTE: FOR DC CONNECTIONS, USE STRANDED COPPER WIRE, WJfN, 1D.5%%127CVINYLPIASTK:: INSULATION, UL STYLE 1016, CSA lYPE TEW, .500 DIA. X .219 DIA. [12.7 X 5.6] KEYHOLE 2PLACES -AC TERMINAL BLOCK DC TERMINAL BLOCK - @ ~ ~ ~ ~ + -+ SENSE OUTPUT @ ~ @ VIEW 8-8 CUSTOMER CONNECTIONS L5.63[143] - iii 0 0 I LV -N.O. CONTACTS, CLOSE ON LOW BATTERY VOLTAGE HV -N,O, CONTACTS, CLOSE ON HIGH BATTERY VOLTAGE CM -N.O. CONTACTS, CLOSE ON LOSS OF AC INPUT OR LOSS OF DC OUTPUT VIEW A-A OPTIONALALARM BOARD HVAOJ, LVl'DJ. Ll:03 r,;;] r;;:-7 LE01 0 i..:::J L..!.J 0 233966 ADV-5971 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 Co. generator distributor for availability. DISTRIBUTED BY: BAY CrrtttECTRIC WORKS, INC. 337:Si;Hancock St. Shn-Diego, CA 92110 (619) 298-6193 ©Kohler Co., 1992, 1993, 1994, 1995, 1999. All rights reserved. G6-151/95g ) ~ B • • I • o· c·· B A 8 '4J_J POWER ON 7 SCHEMATIC §0 ~~· ¥J(!] §0 ;(!] .. 0 -.. N:. ' • - cs N:. CONTROL cs BOARD Kl K2 K3 ~r~1~ 1§0 !l:!J H~I §0 OPTIONAL ALARM BOARD 6 TRANSFORMER AC! 1· Cl ACI I ~J· I + 2.'. ~- ' SCR POWER I I , JI I MODULE ·~· Bl] AC INPUT FUSE 120 VAC-7A 240 VAC-5A fl 120 V. INPUT 8 iJII ~ $ 6 AC2 G2 83 7 oJTPm FUSE f 25A N P I 84 Jgo -+ -+ 0000 SENSE !OOIPUT 6 5 4 3 2 llllffO.lE:I "'-"SOI "",: A I 2-1-93 l(C-S) N:. 4: DC fllS( S'IMIIOI.S RE1IISED RSH ' ,--------------------------------~----------------------------------'-----------------,--------------------, I · . I · , . I : DOOR : TRANSFORMER BACK PANEL . ! . . SCR MODULE : RIGHT SIDE I ,I .---r---,.___, r I I I I I I \· I I I I I I . I I .... 'm lM I I 1 I : ' I 1 I I I I I I I I I I I I I I I I I DC AMPS. l ~:cs I p N . (R~) (B\J() B3 I I I I I I I I I I I i I I I I I 240 VAC-5A I 120 VAC-7A 25A l ~ .~84..J_(RED). 1 2 83 : AC FUSE I I DC FUSE I ro-POWER AC TERMINAL 2 3 BLOCK ON AC2 (RED) ' G.2 ·! ACI I I I I r I I I' . l?l?l?l'f' l~l'f'J I I I I I r-t----+-(BU<) . I I I 111 t: I RED I 'DC -+ -+· 0000 ;x.nx.10UTPUT TERMINAL BLOCK ~~ ~[!] L...J.,-,-t--~ N (Eµ) 1125 ~ §0 ~[!] .. ~, + N:. ~ cs ~o I I I I . I ;[!]II ~r;;i ;r;L~ §0 I I CONTROL BOARD OPTIONAL ALARM BOARD L--------------------------------J-----------------------------------: -------------,--L-------------------- CUSTOMER INPUT CONNECTIONS 240 VOLT INPUT AC . TERMINAL BLOCK 7 t\_GROUNO I I t\_fROUNO "' ~ "' w s s ... 3: a: LUG :i: a: LUG m ;,: <:) m ;,: <.:> I I I I 5 4 3 NOTE: WHEN CHANGING AC INPUT VOLTAGE. THE AC INPUT FUSE MUST BE CHANGED TO AGREE AS SHOWN. INPUT 120 VAC 240 VAC FUSE 7A, TYPE ABC 5A, TYPE ABC T...=~ KOH[EI CQ c... c::: r ...-s ~ -.:.0 ·-:.s:, OJ ..lOCI!: JHit #NkD~ 1/r c:o«:Mt0R CM5l0N. tcOtUJlt,. • 5J04.4 U.S.A. .JX!: Ml ~,.,... =,~:c,~---~-=:u.~.= .x t. ao 7Wi,T. ~....-sorK10tCl"l-at'DIMl"....Jf' AUTO-FLOAT ~ a.tt ""' DIAGRAM, WIRING 2 I 1 12 VOLT ,:=_ w 2-11-92 _, 11 1 ,00... 23396,.awc ,-1 1 11 B T ER G JS 3-3-92 -A T Y CHAR ER ·-""" 3-11-s2....... ,........ 233967 I DJ D C B A I I . . . . . . .. · . . . . GENERATOR ACCESSORIES KOHLERePOWER .SYSTEMS Decision Monitor™ ·I 0 9001 u.s.A: Plant ISO Registered .~~ 1· I 1· I I 1· I I I I I I I I I 0 Surface Mount O~ O~ OMllm,NJ.T O~. OE 0~ O~ QLOW ML. . QCNU19'1111 o~ e IDHLER Flush Mount Oti'&ffl. O\!Dllmr O!Aml,IU.T 01:1.. O;x' 0~ O\rrll.,.,. o=• OA'Rl. OIi""°' Or=:1"' _. O• o--o-o- • IIDIUR 0'' 0 0 0 For Use with Decision-Maker TM 3+ ControHers • Annunciator panel monitors condition of standby generator set equipped with Decision-Maker™ 3+ controller. • The Kohler Decision Monitor™ alarm annunciator panel meets the standards of the National Fire Protection Association established in NFPA 99 for essential electrical systems for hospitals and also meets standards of the National Electrical Code, Section 700-7. • NFPA standards require· a storage-battery- powered remote annunciator. The remote · annunciator must operate In a location outside _of the generating room that is readily observed . by operating personnel at a workstation. The annunciator must give visual and audible warning of an alarm condition affecti_ng an emergency or auxiliary power source. • The Decision Monitor™ alarm annunciator panel mounts to either a desk or wall. It allows monitoring of the standby power system from a location remote of the generator set. Dry Contact Kit GB-1 8/95e ••••••••••••• , ....................... #· ....................... , •• , ..... ,~·-·-··-.. ········-··"'-•••••• ··-·· ............ , •••••• ..,_, ••• ,····· KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 414-565-3381, Web site www.kohlergenerators.com Fax 414-459-1646 (U.S.A. Sales), Fax 414-459-1614 (International) After July 26, 1997, use area code 920 instead of 414 · Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 . . For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Phone ·(65)264-6422, Fax (65)264-6455 Alarm Horn. Horn sounds U fault or prealarm condition exists except emergency stop, battery charger fault or low battery volts. The alarm horn can be silenced only with the generator master switch in the AUTO position. Alarm SIience Switch. Switch disconnects alarm during servicing. Generator master switch must be in the AUTO position (meets requirements of NFPA 110). Lamp Test Switch. Switch tests the annunciator indicator lamps. Prealarm High Engine Temperature. Lamp lights if engine coolant temperature approaches shutdown range. Requires prealarm sender group. Prealarm Low Oil Pressure. Lamp lights if engine oil pressure approaches shutdown range. Requires prealarm sender kit. Low Water Temperature. Lamp lights if optional engine block heater malfunctions and/or engine coolant ten,perature is too low (below 75°F [21 °C]) for 10-second start-up. Requires prealarm sender kit. Low Fuel. Lamp lights if fuel tank fuel level in tank approaches empty. Requires customer-supplied level switch. t,flgh Engine Temperature. Lamp lights if engine has shut down because of high engine coolant temperature. ~ow Oil Pressure .. Lamp lights if set shuts down _because. bf insufflcient oil pressure. · Emergency Stop. Lamp lights and engine stops if emergency stop is made. Requires' remote emergency stop switch. Overspeed. Lamp .lights if set shuts down because of overspeed condition. Battery Charger Fault. Lamp lights if battery ·charger malfunctions. Requires battery charger with alarm contact. · ' Low Battery Voltage. Lamp lights if battery or charging vqltage drops below preset level: Requires battery charger with alarm contact. · Auxiliary Fault. Lamp lights will flash immediately· if controller does not sense AG output ( except during first 1 O· seconds after start-up). Overcrank. Lamp will light and cranking stops if engin,e does not start after 45 seconds of continuous cranking or . 75 seconds of cyclic cranking. • Cranking stops and overcrank lamp lights after 15 seconds if starter or engine does not turn (locked · rotor).· . • Overcrank lamp flashes if speed sensor signal is not received for one second. · · Line Power. Lamp lights when commercial utility power is in use. Requires auxiliary contact in transfer switch. Generator Power~ Lamp lights when generator power is in use. Requires auxiliary contact in transfer switch. • Auxiliary lamp lights and engine stops 5 seconds after high oil temperature or low coolant level fault (if equipped) .. • Auxiliary lamp lights and engine shuts down immediately if overvoltage condition occurs (if equipped with overvoltage shutdown kit). • Auxiliary lamp lights if remote emergency stop switch is reset with generator master switch in the AUTO or· RUN position. System Ready. Lamp lights when generator master switch is in AUTO position and the system senses no faults. Generator Switch Not In Auto. Lamp lights when generator master switch is in RUN or OFF/RESET position. Overall Dimensions: Surface-Mount Remote Annunciator (L x D x H):. 8.69 x 2.38 x 5.00 in. {221 x 60 x 127 mm) Flush-Mount Remote Annunciator with Adapter Plate (L x D x H): 11.00 x 2.11 x 9.50 in. {279 x 54 x 241 mm) NOTE: The flush-mount kit will mount in'side a standard 12 x 8 x 4 in. (305 x 203 x 102 mm) Hoffman pull box. 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 Kohler Co. generator · distributor fo~ avallablllty. .~C-K-0h-ler_C_0.,-1e-e2-, -19-93-, 1-99-4,-19-95-. -Al-I rl-gh-ts-,e-se-rve-d.--------' G6-1 6/95e I I I 1· 1· I I I I I I I I I I I I I· I I I I I I I I I I I I I I I I I I I I ) / D C 8 OPTIONAL COMMON A/V ALARM CONNECTIONS ~ m- FOR REMOTE ANNUNCIATOR SEE-SHEET 2 OF 2 7 6 5 4 3 2 RlYI ll"1f: I ,RellSION e I 6-5-95 I {B-7) ,.,, 1M AOOED TO TERMINAi. 1>: #32 [42179] r-----------------------------------------------7 I JUNCTION BOX I r--::-----,--, r----------------------------------------------------------------------------------------7 I C I 10-9-961 SHEET 1 OF 3 W>S 1 Of 2 [45684] D I 3-31-97 / {B-4) INDICATOR PANEL ASSEIIBLY AOOED; (B-4~ C-2. 0-3) HIGH 111\TTERI' 'IOlTAGE •zr WIRING NlO€ll; {A=8} LEGam UPDAlE> [4_!1_781] DI'S 1 1 c NC NO OPTIONAL l OPTIONAL CUSTOMER CONNECTION KIT I 1 l_L1= COMMON I . 11 I FAULT I 0 o: co c,,a m en co o a ..-~ N IC) o t'l -I , ~ ·~ =~ Lrrfff 1~~-ff-~ffi-~m~m~-m~m~m~m~m~m~m~~~~m~m-lffi-M-ff-~-J 1 1' E 111-19..gn {A-2) "MICROPROCESSOR-PW!;" WAS "DEC 3+" ON 5PEC1RUII Tl1l£BlOCK [s26921 1-1 I NOTE: TRANSFER SWITCH TERMINAL DESIGNATIONS MAY VARY FROM THOSE SHOWN HERE. VERIFY THE CORRECT DESIGNATIONS USING THE APP- ROPRIATE TRANSFER SWITCH WIRING DIAGRAM. I I I ' I I I I OPTIONAL 1~1~1~, , 1 : ~ l'T'T'f' ~ 3 REMOTE START SWITCH (TERMINALS 3 AND 4, REMOTE START /STOP SWITCH OR ENGINE START CONTACTS ON TRANSFER SWITCH) rn-___,I / J I (TERMINAL 63, LOW FUEL LEVEL SWITCH LOCATED IN MAIN TANK OR 1 LOW FUEL PRESSURE SWITCH) BATTERY ' 111 I I I ~ I i ~GROUND I OPTIONAL B~TTERY I CHARGER CONNECTIONS , 111111111111 II ' I I i :t ::-~=::;~LT ~--~·HIGH BATTERY VOL1S '-,. '--- 1 11 l:•1' ~ _, ---------------------/ RELAY CONTACTS . OPTIONAL RUN L_ . t1 tJ tl !tj t1 tti11 tti1~ 1 g 2 ,;;,J,;;,NC· d,.,blld:, ---------------· -. -----------------------:-7 4~ 5~ 6~ + + + ·~ ': Pf-~--=~-~~=~--;;-~~ =-~--=~=-;~ --=--~ ~1~ i I , • • :,o ---11 ,11~141_ I_I ___ I_I ___ I ___ I l1 I 1, I ' L..J < c-< 0 0:: CO IXJ < CO N O> CX> CO O O :;j: c-< N I{) 0 l'l <O f I 1A 1 .OPTIONAL EMERGENCY STOP KIT CONNECTIONS RELAY I KIT I CONNECTIONS I I <'\I. 0 OU'> .... ~ C'il ._ t<'l ..-, "') CO a> U> ..-, ..-, ...,-U> f 1 1 ~ ~ --t-" " "' TB2 1 BLACK I 1 , r-7 1 ,---,,...---.---;-.. , I L---~----TT-------~i I I I r L---------Tt-------t--1 j l I L (70) BATTERY VOLTAGE PRESENT TERMINAL ID. DESCRIPTION I : (OPTIONAL LOCAL EMERGENCY STOP: g O ! I ONLY WHEN GENERATOR IS OPERATING. *1 EMERGENCY-STOP RELAY (K4) GROUND-------, ·: STANDARD ON DDC) 9A O 1 ------------------ +1A EMERGENCY-STOP RELAY (K4) COIL, NEGATIVE I I 4 l I r;::t:::;::j::;::t:::;i OPTIONAL 42A BATTERY VOLTAGE (FUSE PROTECTED) 1 l CONTROLLER BOARD 3 1 l~l(Qll(Qll ONE ISOLATED ALARM I 70~ g~~~:TOR IN COOLDOWN I L----------------------------,------------------------------r--=--=--=--=--=--::=--=--=--=--:;:.-=--=--=-::.-=-:---------J 1 ~~~~CJNECTIONS 8 70R GENERATOR RUNNING ir:---------------:-31 32A COMMON FAULT LINE 2 (ACTIVATED BY: E-STOP, I 1c:=====:=========== 1 I 7N A AUX, OS, LOP, HET, FAULTS) 1 . l INDICATOR PANEL l I I 3 REMOTE START GROUND L I ASSEMBLY 1 _j _ 9 4 A9 ~~~MtTt:TcJ~~~~y~~); GROUND=CONTINUOUS) __ --__ --__ --~~NTROL~E~ ~~~R BO~ _ --_ -· --_ _ L--=---==---=-=---=-~~ _ --__ _J. e-OUT;K1-m OVERSPEED (TYPICAL CONNECTION) CIRCULATING PUMP BLOCK HEATER CRANK MODE GROUND - 12 OVERCRANK INDICATOR 26 AUXILIARY INDICATOR L STANDARD 32 COMMON FAULT/PREALARM LINE 1 (ACTIVATED BY: HET, ·1 CONTROLLER HETP, LOP, LOPP, OS, LWf, OC, LF, AUX, AD, NIA FAULTS) 36 HIGH ENGINE TEMPERATURE INDICATOR 38 LOW OIL PRESSURE INDICATOR 39 OVERSPEED INDICATOR 56 AIR DAMPER INDiCATOR 60 SYSTEM READY INDICATOR 70 BATTERY VOLTAGE (RUN ONLY) 7N GRO.UND 80 NOT IN AUTO INDICATOR 35 LOW WATER TEMPERATURE . · LA N' 40 PRE-ALARM HIGH ENGINE TEMPERATURE INDICATOR L PRE-A RM FU CTION 41 PRE-ALARM LOW OIL PRESSURE INDICATOR-'------'' OPTION ADDITIONS 58 LINE POWER--------------, TRANSFER SWITCH 59 GENERATOR 'POWER -------~--~!--OPUON ADDITIONS 27 HIGH BATTERY VOLTAGE (ACTIVE LOW) ------, 48 EMERGENCY-STOP INDICATOR 61 BATTER'( CHARGER FAULT (ACTIVE LOW) 62 LOW BATTERY VOLTS (ACTNE LOW) 63 LOW FUEL (ACTIVE LOW) ----------' 1 P PRIME POWER OPERATION ----------, 2P PRIME POWER OPERATION r OPTION ADDITIONS 3P PRIME POWER OPERATION _ 1-NFPA OPTION ADDITIONS NO NCC ~--------------------------. -------i-i I 10 RELAY I I 1 DRY CONTACT KIT 1 I r-----------,-----+--+-'-l-+--+--1-~f--+-'--t--+--"f--+------------,---, I ·I ' INPUT . I ~ N -N ~ ~ m ID ~ ~ m Q i ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ I , I ·! I OUT K1 OUT K2 OUT K3 OUT K4 OUT K5 OUT K6 OUT K7 OUT KB OUT K9 UT .1<10-1 . • ...._ I 1 rn rn rn rn rn rn rn rn rn ±~1 I I I OVERSPEED OVERCRANK HIGH ENGINE LOW OIL LOW WATER AUXILIARY AIR PRE-ALARM PRE-ALARM EMERGENCY 1 I TEMPERATURE PRESSURE TEMPERATURE FAULT DAMPER HIGH ENGINE LOW OIL STOP 1 (TYPICAL CONNECTIONS) 1 PRIME POWER OPERATION CONTROL BOARD TB2 PLACE JUMPERS ACROSS TB2-1P TO TB2-2P, TB2-3P TO TB2-4P &: TB2-4. TO TB2-3. TO .POWER~ DOWN CONTROLLER PLACE GENERATOR MASTER SWITCH IN "OFF/RESEr. TO START GENERATOR, MOVE MASTER SWITCH TO "AUTO" POSITION. Ti.E"~ KOHLER CQ Jll0tt .MO NGD:I: vr ~ DMSl0M. KDtUJt. • 5l044. \I.SA .-:1: -DI) .-,a:fWt :r~~-:#°.'f:re!..:-=~~ .. JC :I: --71MX. HJ.,..,., ........ NGmON,...lallMD...:. L OPTIONAL TEN ISOLATED ALARM CONTACTS KIT CONNECTIONS TEMPERATURE PRESSURE I _J --------------------------------------------------~ a.1E """ DIAGRAM, 1 -PWH 1-24-95 INTERCONNECTION 4P PRIME POWER OPERATION --------~ * MUST HAVE JUMP.ER IF THERE IS NO EMERGENC'( STOP KIT "CONNECTIONS. 1-3 DEC 3+ ACCESSORIES ,_ JS 3-10-95 """/ / / I..... 328912A.c1wg 1• 8 I 7 '6 5 4 3 2Q-1600KW ..-!WI 3-15-95 ....,. ,-... 3Z_89~12 2 I 1 Dl1 D C B A en en en ~ (0 N >-0:: <( :::> z <( -, 8 I 7 I 6 WIRING HARNESS TO CONTROLLER BOARD TRANSFER SWITCH AUXILLARY CONTACTS MOUNTED ON TRANSFER SWITCH CONTACTOR ASSEMBLY. DO NOT APPLY ANY VOLTAGE TO THESE CONTACTS. NOTE: TRANSFER SWITCH 10.c::t-@- ·:a:=NO 11 12 · N NC 13 58 TERMINAL DESIGNATIONS MAY VARY FROM THOSE SHOWN HER~. VERIFY TH~ .CORR.ECT DESIGNATIONS USING THE APPROPRIATE TRANSFER SWITCH WIRING DIAGRAM. REMOTE ANNUNCIATOR ,Sf,~£,£,~~f,r,~r,s~i,1,r,£,fi re~~;~~~~~~~~m~mggz . . . OPTIONAL DECISION. MONiTOR CONNECTiONS ERMINAL ID. DESCRIPTION *1 *-1A 42A 2 70C 70R 32A EMERGENCY-STOP RELAY (K4) GROUND EMERGENCY-STOP RELAY (K4) COIL, NEGATIVE BATTERY VOLTAGE (FUSE PROTECTED) GROUND . GENERATOR IN COOLDOWN GENERATOR RUNNING COMMON FAULT LINE 2 (ACTIVATED BY: E-STOP, AUX, OS, LOP, HET FAULTS) 3 REMOTE START GROUND 4 REMOTE START (ACTIVE LOW) 9 CRANK MQDE (OPEN=CYCLE GROUND=CONTINl)OUS). STANDARD 1-CONTROLLER 9A CRANK MODE GROUND 12 OVERCRANK. INDICATOR 26 AUXILIARY INDICATOR 32 . COMMON FAULT/PREALARM LINE 1 (ACTIVATED BY: HET, HETP, LOP, LQPP, OS, LWT, OC, LF, AUX, AD, NIA FAULTS) HIGH ENGINE TEMPERATURE INDJCATOR 36 38 39 56 60 70 7N ·so 35 40 41 -58 59 48 61 62 63 1P 2P 3P 4P LOW OIL PRESSURE INDICATOR OVERSPEED INDICATOR AIR DAMPER INDICATOR SYSTEM READY INDICATOR BATTERY VOLTAGE (RUN ONLY) GROUND NOT IN AUTO INDICATOR ------------~ LOW WATER TEMPERATURE PRE-ALARM HIGH ENGINE TEMPERATURE INDICATOR L PRE-ALARM FUNCTION PRE-ALARM LOW OIL PRESSURE INDICATOR ___ __,! OPTION ADDITIONS . LINE POWER--------------~ TRANSFER SWITCH GENERATOR POWER ------------~r OPTION ADDITIONS EMERGENCY-STOP INDICATOR -----------, BATTERY CHARGER FAULT (ACTIVE LOW) L NFPA LOW BATTERY VOLTS (ACTIVE LOW) r· OPTION ADDITIONS LOW FUEL (ACTIVE LOW)------,.--------'· PRIME POWER OPERATION-----------, PRIME POWER OPERATION PRIME POWER OPERATION OPTION ADDITIONS PRIME POWER OPERATION-----------' * MUS1"____1-0VUlJMPER IF .THERE IS_'____IIJQ_ EMERGENCY STOP KIT CONNECTIQNS. 8 I 7 -I 6 I 5 6 REMOTE ANNUNCIATOR DRY CONTACT BOX MOUNTED AT GEN 4 I 3 I 42 2 39 12 36 38 26 60 80 41 48 61 62 63 35 40 I 6 I 6 I 6 I 6 I 6 ! 6 ! 6 I 6 I 6 ! 6 ! 6 ! 6 ! 6 I 6 I 6 ! 6 ! INPUT <( N -N N ~ ~ 'SI" l"l'S!"t!)<Ol'-000> ~ ~ ~ ~ ~ ~ ~ 0 -N l"l st" ~~~~~ 2 I R<VI °"TE I ll£I/ISION BY I; A I 6-5-95 i(B-7) t>D. NIA A00EO TO TERYNAI. ID. #32 [421791 RN B I 10-9-96 !SHEET 2 OF" 3 WAS 2 OF" 2 [4_~ KAR C ~1-19-971 (A-2) "MICROPROCESSOR-Pt.US" WAS "DEC 3+" & (B-7) "REMOTE NINUNCIATOR' WAS "DECISION MONfTOR" ON SPECTRUM Tlll.El!t.OCK [52692] KAR JN-rN-i--N-r-N-i-N~N-i-N-i--N-i-N-i--N-i--N-i-N-i-N l I~ ~I~ 0Tu 01~ 01~ 01~01~ 0T~ 01~ 01~ 01~ 01~ (S)_I~ 0\ 01 K14 K, 1 . 1 K2 -~rK3 1 K4 1 KS I K6 1 K7 1 KS I K9 . 1 K10. 1 K11 1 K1~ 1 1 K13 39 N 12 36 38 26 60 80 41 48 61 62 63 , 35 40 '• . . . . I I I I I I CUSTOMER SUPPLIED WIRES #N & #428, WIRE REQUIRE 100 FT. -18-20 GA. 500 FT. -14 GA. 1000 FT. -10 GA. SIGNAL WIRES 18-20 GA. TO 1000 FT. T-1 NOTE: IF ADDITIONAL LOAD IS ADDED RESIZE N & 428 AS REQUIRED J J _; J ~42Bt5 ~P : ©=o--:-p ·©=o---,-N NOTE: FBA-1 ANNUNCIATOR FUSE BLOCK 10 AMP CONTRACTOR TO HARDWIRE "p" TO BATTERY POSITIVE ENGINE CONNECTION, AND "N" TO BATTERY NEGATIVE ENGINE CONNECTION. USE WIRf.-HARNESS PROVIDED AND CUT & TERMINATE AS REQUIRED. . ! ACCESSORIES N Utfl.ESSClnOllffSCSPECW'CO-;~~~..a<s J0CX:t .oio #INCUS± 11r KOHLERCQ COERATOR OMSION. KOHLER. WI SJ04.4 U.S.A. .D: ± .OXt SUIW'M;t ~ ~~~~NC>,..~~~~-= Jt :!: .0.0 7-.x. H.1.~-0FCCSIC?40k....cNllONMCll£SDIIIID:> -=:ALS °"TE mu: DIAGRAM, ..;_ PWH '1-24.:95 INTERCONNECTION D I- C 1::,- B I- <X) A 0). ' 0) T'"' C, c-. :r. · (.) a: <( DEC 3+ ·14 RELAY DRY CONTACT/DECISION 20-loOOKW MONI.T.~R KIT JS ~ DAH 3-10-95 ~ / / 00 tlQ. 3289128.dwg s,ar 2-3 ·• :3-1s-95'"""'" -..,, 328912 D cJ ~ 1 5 'f 4 3 2 T 1 · DI C 8 A J3 U> ~-, CX) r') ,,-; l ----(/) a:: 0 0 ;5 1->-X..J <( a:: 0 u0 mo 5~,-~ Z..JO~ zW-~< <{0:: za o-,.Oa:: t--o..._, 7 ..J w z <( a. a:: ·w LL (/) ....... ~O> a:: tO I-• IX) Otn I-----· CX) r') .-5 _l l-2.66 [68]-l--3.38 [86] NOTE - lll.219 [6} ~ ~ THIS VIEW SHOWN AS SEEN FROM FRONT. WITH FRONT PANEL REMOVED = I frjl 0~ o=.=: O~rAU.., 0~ -0~ 0~ o--o=-~ ,:::1 """"""" """""' N 0~ 0~ 01:::r' 0~ 0 N 0 <O o-nn 0-.m o...,._. -0:'i':MAO lli -i-~ """"'o-,._ .-o= .§: O> ---: --------8.69 [221)------- SURFACE MOUNT NOTES:- THE SURFACE MOUNT KIT WILL MOUNT TO A STANDARD 4" SQUARE ELECTRICAL BOX. FOR SURFACE MOUNT KIT, DISASSEMBLE BOX AND REMOVE BACK PLATE. ROUTE WIRING THROUGH OPENING IN BACK PLATE AND ATTACH TO TERMINAL 6 STRIP. MOUNT BACK PLATE TO BOX IN WALL AND REASSEMBLE BOX. 8 7 I 6 C C ~ t- -l 2.38 [60] 1-- 5 <O N r') C! 4 I 3 ....... (/) ...J a:: 0 w 0 < z !;;:~xi:! <( -oo a. 0 mo 3~,-~ 0:: w z oz LL zW<{:;j: (/) <(fl::~:::;: z---<( 0, o-.i-o~ 0:: lO t--u-...-I-- ,4.22 [107] OCXl ,_e + l I ~ U> :!!.. CX) I l0112t~J21J21J21Ji:?.ll2U21J2JJ21J;?JJ;?JJ;?JJ21J;?JJ21ti?Jl2tl0 ,,, ,,-; r-1--?.53 [ 64-'] 3.38 !ll.219 '[6] ~ 0 ~ NOTE - THIS VIEW SHOWN AS SEEN FROM FRONT. WITH FRONT PAN~L REMOVED F 13.50 [343) . 2.59 [66]--i------8.32 [211]--~----,-- 2 IIEYI °"" -i _., .,\ :1 r----------------------------,-----~ I r.===============~ I I I 1 o~ o=.: o=,--o~ 1 ......,.. 8". (~ 0 .C 7 2.11 [54] 'm .,. IO .I 0~ 0'-"""'-0""'""""'" 0__,. I l ....,... '""""" ..._,.... """"' I I· 0""'·"" 0-o-0"'51lN -1 ~ IB ! J -~ ~ ~ 0 -st" '° -st" I ·"""""""' ..,.. -_, .,_ -I 1 o--o"""""" o"""""'"' o~ 1 <» " I • su,aQ-I I MNM I I ~o= I I !,!::==============::::A I I I L __ · _________________________ J _____ _ ~ N ~ <O C! N -, ---------11.00 c2191 \ 1-I 1.25 p21 SURFACE MOUNT CONVERTED TO FLUSH MOUNT NOTE: THE FLUSH MOUNT KIT WILL MOUNT INSIDE A STANDARD HOFFMAN 12X8X4 PULL BOX. WHEN CONVERTING SURFACE MOUNT REMOTE ANNUNCIATOR TO FLUSH MOUNT USING ADAPTER PLATE. FIRST DISASSEMBLE BOX AND REMOVE BACK PLATE. THEN ROUTE WIRING THROUGH OPENING IN BACK PLATE AND ATTACH TO TERMINAL STRIP. REASSEMBLE BACK PLATE TO FRONT PLATE USING EXISTING THREAD FORMING SCREWS. LOOSELY ATTACH SIDE ADAPTER BRACKETS TO BACK PLATE USING EXISTING THREAD FORMING SCREWS. LOOSELY .ATTACH SIDE ADAPTER BRACKETS TO ADAPTER PLATE USING /16-32 NUTS. CENTER REMOTE ANNUNCIATOR IN ADAPTER PLATE AND TIGHTEN HARDWARE. MOUNT FLUSH MOUNT REMOTE ANNUNCIATOR KIT INSIDE PULL BOX USING BLACK # 10-32 SCREWS SUPPLIED. 5 4 3 4X !ll.219 [6] NOTE: DASHED , LINES SHOW RECOMMENDED WALL OPENING IF BOX IS MOUNTED FLUSH TO WALL WITHOUT USING PULL BOX. SURFACE & FLUSH MOUNT REMOTE ANNUNCIATOR WITH 14 RELAY ORY CONTACT KIT 2 ~~,c:c,,,:a-;\:=s-:.:-oa .m.t: _.. ......cl.Cl:t:1/r KOHLERCQ . C01E1WOR OM510N. llOHl.Dl. • 53044 USA. ..-:t ... ~-=-~.:m~~--=~~·:.= .s :I:..... 7--M.L~Of"~Ol"""""°'#lllltllll(:IIIOIWO). ~ ...,,: ..., DIMENSION PRINT JJC JMS OAH 2-9-94 2-11-94 , ..... ~· 2-11-94 AOV5957.a.c; ,-· t-1 A0V-5957 ID A I N@tl®§ ., I I I I I I I ti I I I I I I " I • • Model: GLN/GLS/GTN/GTS Contactor KOHLER®POWER._SYSTEMS Automatic Transfer Switch~s ~9001 -~RS 1NTERNATJOti6.l.l.Y REGISTERED . 0 • -0 " ----0 'lllf.""a"",.. ~ . D =;-=--tiiir mHLER. "®-POWER SYSTEM ::o @ TRANSFER SWITCH . Shown with S340 controls and optional accessories Co·ntactor Ratings* Specifications Max. Switch Rating Max. Application (Amps) Voltage Voltage 40,80, 100,200 250 ··240_ ·.'' 480 40,80, 100,150 600 600 225,260,400 600 · .. '480 600 Standard Features • UL 1008 listed and CSA certified. • Complies with transient tests in accordance with NEMA and IEEE . standards. • Current ratings from 40 to 400 amps (250 volt maximum switches only though 200 amps) • 100% equipment rated and can be applied at the rated current without derating in open or enclosed configurations. • Rated for all classes of load, both inductive and noninductive . • Available in 2-, 3-, or 4-pole configurations. • Available in NEMA types 1, 12, or 3R enclosures or as open units. • Model GLN, GLS, GTN, and GTS switches are available with S340 solid-state controls. Model GLS switches are available with M340 microprocessor electrical controls. See specification sheets G 11-7 4 or G11-75 for electrical control features and available options . • Model GTN and GTS switches have 250-volt maximum contactor power switching devices which are UL listed and CSA certified at 240 VAC. • Model GLN and GLS switches have 600-volt maximum contactor power switching devices which are UL listed at 480 VAC and CSA certified at 600VAC. • Transfer time less than 50 milliseconds. • Auxiliary position contacts: one closed on normal switch position and one closed on emergency switch position (model GLN and GLS switches only; model GTN and GTS switches do not have auxiliary contacts as a standard feature). • Ambient operating temperature range -4° to 167°F (-20° to 75°C). • Ambient storage temperature range -22° to 185°F (-30° to 85°C). • Humidity range 5% to 95% noncondensing. .. Withstand and Closing Current Ratings (WCR), Maximum Current In RMS Symmetrical Amperes When Coordinated With Current-Limiting Fuses Molded-Case Circuit Breakers (CB) Any Specific Manufacturer's Max. Manufacturer's (See the Following Tables) Fuse Max.CB Size Size Cycles WCR (Amps) Class WCR (Amps) WCR @60Hz 22,000 200,000 400 J, RK1, or 10,000 400 30,000 1.5 RK5 22,000 200,000 J 50,000 100,000 600 RK1 or RK5 35,000 800 3.0 · 200,000 J 42,000 . * Current ratings listed are based on UL 1008 standards. 250-volt maximum switches are UL 1008 listed at 240 VAC maximum. 600-volt maximum switches are UL 1008 listed at 480 VAC maximum and CSA certified at 600 VAC maximum. G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b Contactor Ratings With Coordinated Circuit Breakers Withstand and Closing Current Ratings (WCR) for Model GTN and GTS Switches (250 V Maximum Contactors) Rated 40-200 Amps at 240 VAC Maximum Appllcatlon Voltage when Coordinated with Specific Manufacturer's Circuit Breakers as Appllcable to UL and CSA Standards Specifications Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RMS Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FCL, FB Tripac 100 Cutler-Hammer/ FD,FDC,HFD 150 Westinghouse HJD, JD, JDB, JDC 250 HKD, KD, KDB, KDC, u\ Tripac, LCL, DK 400 FC, FH, Fl 100 Square D KA, KC, KH, Kl 250 u\, LC, LE, LH, LI, LX, LXI 400 CED6,ED6,HED4,HED6,ED4 125 40-200 250 240 22,000 CFD6,FD6,FXD6,HFD6 250 I TE/Siemens CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, 400 ! SHJD6,SJD6 TB1 100 SEL, SEP, TEL, THED, THLC1 150 General Electric TFK,TFL,THFK,THLC2 225 SFL, SFP, TFJ 250 SGL4, SGP4, TB4, THJK4, THLC4, T JJ, T JK4, 400 TLB4 G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b • • - • ) • Contactor Ratings With Coordinated Circuit Breakers, cont'd. Withstand and Closing Current Ratings (WCR) for Model GLN and GLS Switches (600 V Maximum Contactors) Rated 40-400 Amps at 480 VAC Maximum Application Voltage when Coordinated with Specific Manufacturer's Circuit Breakers as Applicable to UL and CSA Standards Specifications Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RMS Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FDC,HFD 150 Cutler-Hammer/ HJD, JDC 250 Westinghouse HKD, KD, KDB, KDC, LA Tripac, LCL 400 FC, Fl 100 Square D KC, KH, Kl 250 LA, LC, LE, LH, LI, LX, LXI 400 CEDS, HED4, HEDS 125 40-150 30,000 I TE/Siemens CFDS,FDS,FXDS,HFDS 250 CJDS, HJDS, HHJDS, HHJXDS, JDS, JXDS, SCJDS, 400 SHJDS,SJDS TB1 100 SEL, SEP, TEL, THLC1 150 General Electric TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, T JJ, T JK4, 400 TLB4 JDC, HJD 250 Cutler-Hammer/ CHKD, HKD, KDC, LCL, LA Tripac 400 600 480 Westinghouse CHLD,CLDC,HLD,LDC 300-600 NB Tripac 300-800 KC,KI 250 Square D LC, LE, LI, LX, LXI 600 ME, MH, MX 800 CFDS, HFDS 250 CJD6,HHJD6,HHJXD6,HJD6,SCJDS,SHJD6 400 225-400 50,000 !TE/Siemens CLD6,HHLD6,HHLXDS,HLD6,SCLDS,SHLD6 600 CMD6, HMD6, HMXD6, MD6, MXDS, SCMD6, 800 SHMD6, SMD6 SFL,SF~TFL,THLC2 250 SGL4, SGP4, TB4, THLC4, TLB4 400 General Electric SGL6, SGP6, TBS, T JL4V, TKL4V, T JL 1 S-6S 600 SKL8, SKPB, SKHB, TBS 800 CF250L, CF250H 250 CJ400L,CK400H,CJ400H,CK400N 400 Merlin Gerin CJ600H 600 CKB00H, CKB00N 800 G11-73 (Model Gl:.N/GLS/GTN/GTS Contactor) 5/99b ' Contactor Ratings With Coordinated Circuit Breakers, cont'd . Withstand and Closing Current Ratings (WCR) for Model GLN and GLS Switches (600 V Maximum Contactors) Rated 40-400 Amps at 600 V Maximum Appllcatlon Voltage when Coordinated with Specific Manufacturer's Circuit Breakers as Applicable to CSA Standards Specifications Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RMS Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FDC,HFD 150 Cutler-Hammer/ HJD, JDC 250 Westinghouse HKD, KD, KDB, KDC, LA Trlpac, LCL 400 Fl 100 Square D KA, KH, Kl 250 LA, LC, LE, LH, LI, LX, LXI 400 CED6 · 125 40-150 22,000 CFD6,HFD6 250 !TE/Siemens CJD6, HJD6, HHJD6, HHJXD6, JDS, JXD6, SCJD6, 400 SHJD6, SJD6 TB1 100 SEL, SEP, TEL, THLC1 150 General Electric TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, T JJ, T JK4 400 600 600 KOC, LA Tripac, LCL 400 Cutler-Hammer/ CLDC, LDC 300-600 Westinghouse NB Tripac 300-800 Kl 250 Square D LI, LXI 600 CFD6 250 CJD6,HHJD6,HHJXD6,SCJD6 400 !TE/Siemens CLD6,HHLD6,HHLXD6,SCLD6 600 225-400 42,000 CMD6, HMD6, HMXD6, SCMD6, SHMD6 800 THLC2 250 . SGL4, SGP4, TB4, THLC4 400 General Electric SGL6, SGP6, TBS 600 SKLB, SKP8, TB8 800 CF250L 250 Merlin Gerin CJ400L, CK400H 400 CK800H 800 G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b -- • I - • • I ) • Design Features Transfer Switch Design • All switches are factory-wired, fnterconnected, and tested prior to shipment. • Switches use front-connecting lugs. Contactor Design • Contactors offer high-speed transfer, 50 milliseconds or less, including relay operating time for all ampacities exclusive of controller time delays. • Contactors are of double-throw, inherently interlocked design. • Contacts are readily accessible from the front for easy inspection. • Main shaft auxiliary contacts operate only with the main contacts and provide a positive indication of the switch position. • Current-carrying parts are silver plated or are of a silver alloy. Alloy contacts, which provide resistance to welding, sticking, and voltage drop, are shaped to give concentrated contact pressure for positive circuit continuity. • The single coil is momentarily energized during transfer, providing long, dependable life. • Switching mechanisms are lubricated for life. • All switches have self-wiping contacts. • 4-pole switches use break last make first neutral switching. Ratings • All models are 100% equipment rated and can be applied at the rated current without derating. • All switches are rated for a maximum of30% tungsten load. However, 40 to 225-amp, 600-volt maximum switches applied at 240 VAC or less .are acceptable for up to 100% tungsten load. • Switched neutral contact ratings correspond to the line-switching contacts. • Auxiliary contacts rated 20 amps, 250 VAC. Standards • All models are UL 1008 listed. • All switches meet transient overvoltage impulse withstand tests and voltage surge withstand capability in accordance with ANSI/IEEE 037.90-1978. • Switches are suitable for emergency and standby applications without modification. • All NEMA enclosure types meet the requirements of NEMA standard publication number ICS6, and UL standards 1008, 508 (ANSI 033.76), and 50. Application Data UL-Listed Solderless Screw-Type Terminals for External Power Connections Switch Normal, Emergency, and Load Terminals Rating Cables per Range of Wire Sizes (Amps) Pole (Copper or Aluminum) 40 #14to#6AWG 80 1 #14 to #1/0 AWG 100 1 #14 to #2/0 AWG 150 #8 to #3/0 AWG 200 1 #8 to #3/0 AWG (copper only) 225-400 1 #4 AWG to 600 MCM 2 #1/0 AWG to 250 MCM Weights Specifications Nominal Weight lbs. (kg) NEMA Type 1 Enclosed Amps Poles 2 40-200 3 4 2 225-400 3 4 129 (58.5) 132 (59.9) 135 (61.2) 213 (96.6) 218 (98.9) 225 (102) Dimensions Specifications Amps Complete ATS Enclosed Unit Dimensions*, in. (mm) Height Width Depth NEMA Type 1, S340 or M340 Controls 40-200 35.75 (908) 25.72 (653) 14.15 (359) 225-400 47.09 (1196) 26.02 (661) 15.41 (391) NEMA Type 12, S340 or M340 Controls 40-200 38.50 (978) 30.00 (762) 17.15 (436) 225-400 50.50 (1283) 36.00 (914) 21.41 (544) 40-200 225-400 40-200 225-400 Specifications Amps 40-200 225-400 (2 pole) 225-400 (3 pole) 225-400 (4 pole) NEMA Type 3R, S340 Controls 37.96 (964) 25.72 (653) 47.09 (1196) 26.02 (661) NEMA Type 3R, M340 Controls 37.96 (964) 25.72 (653) 50.50 (1283) 36.00 (914) 15.48 (393) 15.41 (391) 15.48 (393) 21.41 (544) Open Unit Contactor Only Dimensions, in. (mm) Height Width Depth 11.00 (279) 9.00 (229) 4.86 (123) 12.03 (306) 15.63 (37) 13.93 (354) 7.13 (181) 15.83 (402) * Dimensions for units with NEMA type 12 and 3R enclosures include permanent mounting tabs or lifting eyes. See the submittal drawings for more information. G11-73 (Modal GLN/GLS/GTN/GTS Contactor) 5/99b Model Numbers 250 Volt Maximum Transfer Switch with Solid-State Controls*t Specifications S340 Electrical Controls Poles Amps Automatic Nonautomatlc 2 40 GTS-1 xx231-0040 GTN-1 xx231-0040 80 GTS-1 xx231-0080 GTN-1 xx231-0080 100 GTS-1xx231-0100 GTN-1xx231-0100 200 GTS-1 xx231-0200 GTN-1 xx231-0200 3 40 GTS-1xx341-0040 GTN-1 xx341-0040 80 GTS-1xx341-0080 GTN-1xx341-0080 100 GTS-1 xx341-01 00 GTN-1xx341-0100 200 GTS-1 xx341-0200 GTN-1 xx341-0200 xx Voltage and Frequency Code 61: 110 Volt, 50 Hz 62: 120 Volt, 60 Hz 63: 220 Volt, 50 Hz 64: 240 Volt, 60 Hz 67: 190 Volt, 50 Hz 68: 208 Volt, 60 Hz * Models listed in this table are UL listed and CSA certified at 240 volts and below. t Models listed In this table have NEMA type 1 enclosures. The model number changes from xxx-xxxxx1 to xxx-xxxxx0, xxx-xxxxx2, or xxx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R enclosures respectively. 600 Volt Maximum Transfer Switch with Solid-State Controls*t Specifications S340 Electrical Controls Poles Amps Automatic Nonautomatlc 2 40 GLS-1 xx231-0040 GLN-1xx231-0040 80 GLS-1 xx231-0080 GLN-1 xx231-0080 100 GLS-1xx231-0100 GLN-1xx231-0100 150 GLS-1 xx231-0150 GLN-1xx231-0150 225 GLS-1 xx231-0225 GLN-1 xx231-0225 260 GLS-1 xx231-0260 GLN-1 xx231-0260 400 GLS-1 xx231-0400 GLN-1 xx231-0400 3 40 GLS-1 xx341-0040 GLN-1 xx341-0040 80 GLS-1 xx341-0080 GLN-1 xx341-0080 100 GLS-1xx341-0100 GLN-1xx341-0100 150 GLS-1 xx341-0150 GLN-1xx341-0150 225 GLS-1 xx341-0225 GLN-1 xx341-0225 260 GLS-1 xx341-0260 GLN-1 xx341-0260 400 GLS-1 xx341-0400 GLN-1xx341-0400 4 40 GLS-1 xx641-0040 GLN-1xx641-0040 80 GLS-1 xx641-0080 GLN-1 xx641-0080 100 GLS-1xx641-0100 GLN-1xx641-0100 150 GLS-1 xx641-0150 GLN-1 xx641-0150 225 GLS-1 xx641-0225 GLN-1xx641-0225 260 GLS-1 xx641-0260 GLN-1 xx641-0260 400 GLS-1 xx641-0400 GLN-1 xx641-0400 xx Voltage and Frequency Code 53: 220 Volt, 60 Hz 60: 600 Volt, 60 Hz 62: 120 Volt, 60 Hz 63: 220 Volt, 50 Hz 64: 240 Volt, 60 Hz 65: 550 Volt, 60 Hz 66: 480 Volt, 60 Hz 68: 208 Volt, 60 Hz 71 : 380 Volt, 50 Hz 72: 380 Volt, 60 Hz 73: 416 Volt, 50 Hz * Models listed in this table are UL listed at 480 volts and below, CSA certified at 600 volts and below. • - • t Models listed in this table have NEMA type 1 enclosures. The model 1 number changes from xxx-xxxxx1 to xxx-xxxxx0, xxx-xxxxx2, or xxx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R enclosures respectively. • G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b • - ) ) • 600 Volt Maximum Transfer Switch with Microprocessor Controls*t Specifications M340 Electrical Controls Poles Amps Automatic 2 40 GLS-5xx231-0040 80 GLS-5xx231-0080 100 GLS-5xx231-0100 150 GLS-5xx231-0150 - 225 GLS-5xx231-0225 260 GLS-5~?1-0260 . 400 GLS-5xx231-0400 3 40 GLS-5xx341-0040 80 GLS-5xx341-0080 100 GLS-5xx341-0100 150 GLS-5xx341-0150 150 GLS-5xx341-0150 - 225 GLS-5xx341-0225 260 GLS-5xx341-0260 400 GLS-5xx341-0400 4 40 GLS-5xx641-0040 80 GLS-5xx641-0080 100 GLS-5xx641-0100 150 GLS-5xx641-0150 - 225 GLS-5xx641-0225 260 GLS-5xx641-0260 400 GLS-5xx641-0400 xx Voltage and Frequency Code 53: 220 Volt, 60 Hz 60: 600 Volt, 60 Hz 62: 120 Volt, 60 Hz 63: 220 Volt, 50 Hz 64: 240 Volt, 60 Hz 65: 550 Volt, 60 Hz 66: 480 Volt, 60 Hz 68: 208 V9lt, 60 Hz 71 : 380 Volt, 50 Hz 72: 380 Volt, 60 Hz 73: 416 Volt, 50 Hz * Models listed in this table are UL listed at 480 volts and below, CSA certified at 600 volts and below. t Models listed in this table have NEMA type 1 enclosures. The model number changes from xxx-xxxxx1 to xxx-xxxxx0, xxx-xxxxx2, or xxx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R enclosures respectively. --.,,,, .. L .., G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 920-565-3381, Web site www.kohlergenerators.com Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 . Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service·outlet In U.S.A. and Canada Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 Record the transfer switch model number in the boxes below. The transfer switch model number defines characteristics and ratings as explained in the accompanying chart. Model Controls I• 1LJ 1 ~ 1 ~ 1 s 1 -~ Voltage and Frequency Poles 1~·~11iJ Wires Enclosure Current Rating LJLJ I • I w w-~ ~ ~ ~ Kohler~ Part Number Key This chart explains the Kohler® transfer switch model numbering system. The sample model number shown is for a Model GTS automatic transfer switch that uses a 250-volt maximum contactor power switching device with S340 solid-state electrical controls rated at 240 volts, SAMPLE MODEL NUMBER GTS-164231-0200 60 hertz, 1 phase, 2 poles, and 3 wires In a NEMA type 1 enclosure with a current rating of 200 amperes. Not all possible combinations are available. Switch Classification or Family G: Model GLN/GLS/GTN/GTS contactor-type transfer switch Power Switching Device Characteristics T: 250-volt maximum contactor, 40-200 amperes L: 600-volt maximum contactor, 40-400 amperes Operation Classification S: Automatic N: Nonautomatic Electrical Controls (Logic Controller) 1 : S340 solid state 5: M340 microprocessor Voltage and Frequency (other codes possible) 53: 220 Volts, 60 Hz 60: 600 Volts, 60 Hz 62: 120 Volts, 60 Hz 63: 220 Volts, 50 Hz 64: 240 Volts, 60 Hz 65: 550 Volts, 60 Hz 66: 480 Volts, 60 Hz 68: 208 Volts, 60 Hz 71 : 380 Volts, 50 Hz 72: 380 Volts, 60 Hz 73: 416 Volts, 50 Hz Number of Poles and Phase 2: 2 pole, 1 phase 3: 3 pole, 3 phase 4: 3 pole, 1 phase 6: 4 pole, 3 phase Number of Wires 3: 3Wire 4: 4Wire Enclosure O: Open unit 1: NEMA type 1 2: NEMA type 12 3: NEMA type 3R Current Rating . Numbers indicate the current rating of the switch in amperes DISTRIBUTED BY: BAY CITY ELECTRIC WORKS, INC. 3375 Hancock St. San Diego, CA 92110 (619) 298-6193 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 Co. generator distributor for avallabllity. © Kohler Co. 1998, 1999. All rights reserved. G11-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b I I • ) ) ) ) I Model: GLN/GLS/GTN/GTS S340 Controls KOHLER®POWER SYSTEMS Automatic Transfer Switches ~22ao1 -GEN:RAtORS INTERNATIONAllY REGISTERED 0 • 0 • NORMAi. EMEA8ENCV SWITCH NOT IN AUTO P08ITION 0 Of'F AUTO ENGaNE \ 1 STAR_! a }EST CAUTION: AFTER '!ESTIS COMPlETED RETUAN SWITCH TO AUTO P08ITION. AUTO + 0 IIVPAll8TIMEDELAY EMEACIENCYTO NORMAL + WARNING TO INSUREAIWNST SHOCK OR BURNS, DJSCONNECT ALL SUPPLY SOURCES BEFORE WORKING ON THIS SWITCH Standard Features • Solid-state electrical controls for Model GLS, GLN, GTS, and GTN transfer switches. • Normal source voltage sensing, adjustable from 65% to 130% (factory setting 88%) of nominal for pickup and from 50% to 130% (factory setting 70%) of nominal for dropout. Voltage monitored line-to-line for all phases of 3-phase switches. • Voltage sensing pickup for emergency source, adjustable from 40% to 130% (factory setting 85%) of nominal. Monitors one phase only. • LED diagnostic aids to indicate circuit status and monitor function completion. • Two-position test switch to simulate a normal power source failure. Not supplied if optional accessories KA-6 (2-or 3-position) or KA-7 (4-position) test switches are specified. • Time delay engine start (TOES) fixed at 3 seconds. • Time delay normal to emergency (TONE) adjustable from 0.6 to 60 seconds (factory setting 0.6 seconds). • Time delay emergency to normal (TDEN) adjustable from 1 to 30 minutes (factory setting 1 minute). S340 control panel shown with optional accessories • All printed circuit boards conformally coated for environmental protection. ,, .. : " • Controls ambient temperature range -40° to 158°F (-40° to 70°C). • Controls humidity range 5% to 95% noncondensing. G11-74 (Model GLN/GLS/GTN/GTS, S340 Controls) 5/99a Accessories All accessories are UL listed and CSA certified unless otherwise specified. All KA-accessories are installed on switches with NEMA type 1 enclosures unless otherwise specified and all PA-accessories are loose accessories. Some KA-accessories may have additional suffixes that specify such things as the transfer switch voltage, frequency, phase, amperage, or other enclosure types. Automatic Accessories The following accessories are available for automatic transfer switches. Pilot Lights, Contactor Position O KA-12-C Green lamp indicates contactor in normal position. 0 KA-12-D Red lamp indicates contactor in emergency position. Pilot Lights, Source Available 0 KA-12-G White lamp indicates normal power is available. 0 KA-12-H White lamp indicates emergency power is available. Plant Exerciser 14-day programmable solid-state digital timer sets the generator set exercise schedule. Timer temperature range -10° to 160°F (-23° to 71 ° C). Do not order accessory KA-1 0-F Preferred Source Switch with this accessory. 0 KA-23-W Plant exerciser runs the generator set unloaded. 0 KA-23-X Plant exerciser runs the generator set loaded. 0 KA-23-Y Plant exerciser includes a two-position selector switch that determines if the generator set runs unloaded or loaded. Auxiliary Contacts, Relay, Source Available Relays operate when one phase of the power source is available. Relays have three sets of isolated SPDT form C contacts each rated 10 A@ 2!3 VDC; 10 A@ 120 VAC, 0.8 PF; 6 A @ 240 VAC, 0.8 PF; and 3 A @ 480/600 VAC. 0 KA-14-C Relay operates when normal power is available. 0 KA-14-D Relay operates when emergency power is available. Auxiliary Contacts, Main Contactor Shaft Position Main shaft auxiliary contacts operate with the transfer switch main contacts and provide a positive indication of transfer switch position. Each additional set of contacts provides one contact closed when the load is connected to the normal source and one contact closed when the load is connected to the emergency source. Each contact is rated 20 amps, 125/250 VAC. Order only one of the following choices. 0 KA-15-N One additional set of contacts for 600-volt maximum switches. 0 KA-15-P One additional set of contacts for 250-volt maximum switches. 0 KA-15-R Two additional sets of contacts for 250-volt maximum switches. Battery Chargers 2-amp maximum charge rate with automatic adjustable float. 0 KA-24-xxA 12 VDC battery charger. 0 KA-24-xxB 24 VDC battery charger. xx Voltage-and frequency-dependent code. Source Monitor, lnphase Monitor/Synchronism Check Relay Controls the transfer of loads to prevent inrush currents from exceeding normal starting currents and tripping circuit breakers, and to prevent damage to loads. Monitors one phase of the normal and emergency power sources and permits transfer only when power sources are near synchronism. If the voltage of the power source supplying the load drops below a bypass pickup setting, a circuit allows immediate transfer to the alternate power source. If both power source voltages fall below a pickup prevention setting, transfer is inhibited to prevent transfer to an unacceptable power source. 0 KA-34-A lnphase monitor permits transfer when power source voltage waveforms have a phase difference within :1:15 degrees and a frequency difference within :1:3.0 Hz. Approximate 2.0 second time delay after powerup of inphase monitor before enabled. Inhibit circuit prevents transfer when power sources are moving away from synchronism. The bypass pickup and pickup prevention setting is 70% of nominal. 0 KA-34-B Synchronism check relay permits transfer when the power source voltage waveforms have a phase angle difference below a phase angle setting for approximately 50 milliseconds. Phase angle setting is adjustable from ± 5 to ± 30 degrees, factory setting ± 10 degrees. The bypass pickup setting is 71-75% of nominal. The pickup prevention setting is 68-72% of nominal. Time Delay Engine Start (TDES) TDES delays the starting of the generator set when the normal source fails. TDES helps to prevent nuisance starting of the generator set and begins timing when the normal source fails. 0 KA-2-A TDES adjustable 5 to 20 sec. Factory set at 5 sec. 0 KA-2-F TDES adjustable 20 to 240 sec. Factory set at 20 sec. 0 KA-2-G TDES adjustable 0.5 to 5 sec. Factory set at 0.5 sec. Time Delay Engine Cooldown (TDEC) TDEC delays the opening of the engine start contacts after transferring the load to the normal source to allow an additional time for the generator set engine to cool down before the generator set engine controller's cooldown timer, if equipped, begins timing. TDEC starts timing after the load is transferred to the normal source. 0 KA-4-D TDEC adjustable 1 to 30 min. Factory set at 5 min. Time Delay Override Switch 0 KA-8-C Switch bypasses time delay emergency to normal (TDEN) and allows manual transfer at any time after the normal power source is restored. Test Switches, Automatic Operation, 2-and 3-posltion This accessory replaces the standard test switch. 0 KA-6-F Two-position key-operated test switch interrupts normal power source sensing to simulate a normal power source failure when the switch is in the TEST position. Momentary TEST position, maintained AUTO (automatic) position. 0 KA-6-M Three-position test switch permits three modes of operation. TEST WITH LOAD position simulates a normal power source failure. TEST WITHOUT LOAD position closes the engine start circuit but does not transfer the load. AUTO (automatic) position returns the switch to automatic operation. Momentary TEST WITH LOAD position, maintained AUTO (automatic) and TEST WITHOUT LOAD positions. G11-74 (Model GLN/GLS/GTN/GTS, S340 Controls) 5/99a • ( • ( • ) ) ) l Automatic Accessories (continued) Test Switches, Automatic Operation, 4-position A four-position test switch with white light permits four modes of operation: TEST, AUTO, OFF, and ENGINE START. The OFF position de-energizes the control circuitry and opens the engine-start circuit. The transfer switch does not operate nor does the engine start on power source failure. The TEST position simulates a normal power failure. The AUTO position returns the transfer switch to automatic operation. The ENGINE START position closes the engine-start circuit. The switch transfers only if the normal power source fails. A white lamp lights in all modes except the AUTO position. Momentary TEST, maintained AUTO, OFF, and ENGINE START positions. 0 KA-7-D Four-position test switch for NEMA type 1 enclosures. 0 KA-7-H Four-position test switch for NEMA type 3R and 12 enclosures. Meters Meters are mounted in the enclosure door but are not available on models with NEMA type 3R or 12 enclosures. Meters included on open units are for NEMA type 1 applications only. 0 KA-18-G Frequency meter, analog, one phase of emergency only. 0 KA-18-J Voltmeter and ammeter, analog. Allows the display of all. line-line voltages for the emergency and ·normal sources. Displays all line currents for the load. Load-Shedding Contacts 0 KA-35-G Load-shedding contacts allow the controller to disconnect loads prior to transfer in either direction. 2 NO and 2 NC contacts operate an adjustable time (0.6 to 60 sec.) prior to transfer in either direction and reset immediately after transfer. Specify up to three KA-35 accessories with the transfer switch. Each contact is rated 10 A @ 28 VDC; 10 A @ 120 VAC, 0,8 PF; 6 A @ 240 VAC, 0.8 PF; and 3 A @ 480/600 VAC. Manual Operation Switches with Override A two-position key-operated auto/manual selector' switch selects automatic or manual operation. An override circuit causes automatic transfer to an available power source ifthe manually-selected power source fails and the other power source is available. 0 KA-29-P Pushbutton manual operation from emergency to normal. 0 KA-29-T Pushbutton .manual operation from emergency to normal and from normal to emergency. Area Protection Relay 0 KA-26-D Allows automatic operation when a customer-supplied external contact is closed. Upon contact opening the transfer switch starts the generator set and transfers the load to the emergency power source when available until the area protection contact closes again. An override circuit allows the switch to transfer the load to normal power if emergency power fails. Operating voltage 12 VAC, maximum external contact circuit resistance approximately 12 ohms. Logic Protection Fuse 0 KA-28-A Fuse protection for nonessential.circuitry. Used with accessories KA-6, 7 12, 14, and 23. Use one KA-28-A per protected accessory. Nonautomatic Accessories If any of the following accessories are specified, the switch becomes nonautomatic as defined by UL 1008. The model number changes from GTS/GLS to GTN/GLN to reflect that the transfer switch is nonautomatic. Test Switches, Manual Operation, 2-position This accessory replaces the standard test switch. A two-position test switch simulates a normal power source failure when the switch is in the TEST position. Maintained TEST position prevents automatic retransfer to the normal power source when the emergency power source fails. Maintained AUTO (automatic) position. 0 KA-6-D Two-position, maintained test switch. 0 KA-6-H Two-position, maintained, key-operated test switch. Manual Operation without Automatic Override A two-position keyed selector switch selects automatic or manual operation. Does not automatically transfer to an available power source when the manually selected power source fails. 0 KA-29-G Pushbutton operation from emergency to normal and pushbutton operation from normal to emergency. 0 KA-29-J Pushbutton operation from emergency to normal. Engineering Special Accessories The following are available only on engineering specials. · Preferred-Source Switches A preferred-source switch selects either the normal or emergency power source as the preferred source, which is the source the switch always transfers to if acceptable. 0 KA-10-B A two-position selector switch selects the preferred source. For use with either two commercial power sources or one commercial power source and one generator set. 0 KA-10-D A two-position selector switch selects the preferred source. For use when both power sources are generator sets. 0 KA-10-F A 14-day programmable solid-state digital timer alternately selects the preferred source on a timed schedule. Do not order accessory KA-23 Plant Exerciser with this accessory. For use when both power sources are generator sets. 50/60 Hz. Dead Bus Relay Provides automatic operation when a customer-supplied external contact is open. Contact closure causes the switch to transfer the load to the normal source, whether normal power is available or not, using emergency source power. Makes the switch nonautomatic. Requires accessory KA-15 (two contacts closed when the contactor is in the emergency position). 0 KA-54-A Dead bus relay. G11-74 (Model GLN/GLS/GTN/GTS, S340 Controls) 5/99a KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Loose Accessories The following accessories are provided as kits that may require installation. Neutral Lug Assembly 0 PA-362151 For 40-100 amp switches. 0 PA-362152 For 150-200 amp switches. 0 GM10400-KP1 For 225-260 amp switches. 0 GM10401-KP1 For 400 amp switches. Transient Voltage Suppression ANSI C62.41-1980 protection from transient voltage surges produced by lightning and other sources. Protection module features metal oxide varistor (MOV) design and is typically connected to the normal power source terminals. 0 PA-294538 For 40 amp switches. 0 PA-294530 For 80-100 amp switches. 0 PA-294531 For 150 amp switches. 0 PA-294532 For 200-400 amp switches. Transient Voltage Suppression with Avalanche Diode Silicon avalanche diode provides protection from transients of shorter duration. 0 PA-294539 For 40 amp switches . . · 0 PA-294556 For 80-100 amp switches. 0 PA-294557 For 150 amp switches. 0 PA-294558 For 200-400 amp switches. Literature O G11-73 Model GLN/GLS/GTN/GTS transfer switch spec sheet. O G11-74 Model GLN/GLS/GTN/GTS, S340 controls spec sheet. 0 TP-5991 Model GLN/GLS/GTN/GTS transfer switch operation and installation manual. 0 TP-5993 Model GLN/GLS/GTN/GTS, S340 controls operation and installation manual. 0 TP-5612 S340 controls service manual. 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 Co. Kohler® Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455 Other Options Export Boxing Available only on models with NEMA type 1 enclosures. D Export boxing. Other Enclosures Model GLN/GLS/GTN/GTS transfer switches are also available in NEMA type 12 or 3R enclosures. The transfer switch model number is changed as follows: Gxx-xxxxx1 becomes Gxx-xxxxx2 or Gxx-xxxxx3 respectively. D NEMA type 12 enclosure. D NEMA type 3R enclosure. DISTRIBUTED BY: BAY CITY ELECTRIC WORKS, INC. 337 5 Hancock St. San Diego, CA 92110 (619) 298-6193 generator distributor for availability. @ Kohler co. 1998, 1999. All rights reserved. G11-74 (Model GLN/GLS/GTN/GTS, S340 Controls) S/99a • I 8 D C B A I· 7 I I I I I I I I '· I I I I I I I I I I I i I l I I 6 . 406 [10.3] WIDTH OF SLOT NEUTRAL ASSEMBLY (IF REQUIRED) ci:' ~ ~ i I g -------- I I I· I I -+-I ~ ....... .-, ,....... <O 0, "<j-!') NN ............ ¢.531 [13.5] HOLE ~ 15] TYP. i---1-4.17 [106] [21] TYP. (150 AMP) . 3.91 [99] (150 AMP) 15.41 [391]-· ,....... ~,....... IX) <O ~ L-1 ...... I!) !') N ~ . " 5 4 11------25.52 [648]------i I : 26.02 [661] 3.89 [99] TYP. , ! 18.25 [464] • 1 . a: • ~ 'ro' 0 ~ ...... "<j- N -.t= -I ~ z 0. I ~ «i' <( 0, :::;; ~ w ~ 3 ...... 0, M 0 I{) " r--"<j-0, ...... 0 "<I; (0 !') @} 3 CONDUIT ENTRY AREA 2 EVI ~ I E¥m* lnl~ -5-10-99 IEW DRAWING [58629) JS A 6-9-99 ~-21 GENERIC 1lll£ BLOCK -'DOEll & MODEL DESIGNATIONS ~ra>: [590351 IB!W SIZE OF UL LISTED SOLDERLESS SCREW lYPE TERMINALS FOR EXTERNAL POWER CONNECTIONS .. D C SWITCH RATING I I (AMPS) 225-400 RANGE OF AL-CU WIRE SIZE I B TWO #1 /0 AWG TO 250 OR ONE #4 TO 600 MCM 1· I NOTE: 1. NUMBERS IN [ ] ARE MILLIMETERS. 2. DIMENSIONS ARE FOR REFERENCE ONLY. 3. REFER TO OPERATOR'S MANUAL PRIOR TO INSTALLATION AND OPERATION OF THE SWITCH. 0) Acr, (j) T""" T...=~--ICOHLERCQ g .Jlld ..ot0 --..s:t: 1/r COCEMlOI IM5DI,, 1C1H11,, WI 5.10C4 1J.S.A. , Jll:;t. .mo _.AOt,_ MS ............ IBM.ISIINDC::0.,-uny-W MODEL G GLS GTS ~,. --r-. --:..",.::::,::::::,.wi:.=,:---z , , .~:t: V •-I I· . 225-40b AMP. , -= .. n: DIMENSION PRINT :::, re-------------_ • . M-340 NEMA 1 ONLY ,-JS s-10-99 J _, __ . -, :·· · . 8-· .. _ I · 7 . S 340 · NEMA 1 NEMA 3R -Ni s-25-99 ::_ 114 •:: NN6472J111G ,.., 1-1 z -~ ·.-· _·· . -~ . C ---•• ~--6 I 5 "'( 4 I 3 I • : 2 ·-:-Ni 5-25-°i I' A~V 6472 I DG ~-,i.:--..-~---------------. --~---- I I I I D I I I I C I I I I B I I I I I Al 1· ,I 8 FROM NORMAL SOURCE 7 6 lS 22 lS 21 1S 20 5 4 3 TO LOAD 19 . I I I i--1 r:=:-:=::'. 4 (EA .------n ---+-------+------1----+--+-----------' .---t-----76 ----------+------I----+--+-------------' SIA A ASIA StAA S1AA SIA. 18 19 12 11 4 PIA 1' 1' PIA PIAT P1AT P1AT NA NB NC 79 78 SE1 _cfT,lNO SIA ;::--s1A , P1Ati1Ar 74 1s 1s n 1a 79 ~r=+ ~r ~r 12 1'3 ·T4 ,,15 S3A1 S3A~ SJA+ SJA+ ~1-- ~ 61 ~~~--~-'-----364--+----il ~~r.-@--365--+----{1 ~ SIA PIA S2B P2B 6 NR 9 I -I 9 NR 3 7 ER 4 P2B S2B PIA SIA SCE2 c' I ~15~5--(3f----<f-#-)) P2B J, (( -j ~>---<~ ~~4>--45~1~ B SIA 't PIA 1' 2 SIA SIA SIA '" f '" f '" l EC i EA EA • S2B ,g- SCNt SIA PIA S2B P2B 4 NR 7 P2B t 7 NR 1 6 ER 9 P2B S28 PIA SIA SCE1 I '=' Eft 'T---<•<-"--<~ » « lf->>-<<---j-,>-•->•> T n C NO NO C ~ UNDER *~ LED 1 CIRCUIT I SN SE2 ~ f'rn ·l'isi T6 T7 7;;;: Tt "r" "r" s1AlNO I,j 1.stA S3A,l 19 re rs T7 14 10 13 1 1 l l l PtAj P1A1' jPtA P3A.i S3A S3A S3A S3A I · 9 • B 5 2 18 17 16 P3A. 1' P3A.1' P3A. '1-P3A. @@)@ 4 NR1 7 A 24VDC ~>r--<~> r (OfF !)E!AY) B 12 VllC ~~A 63 UNDER WLT,IGE UNDER fR£QU£NCY CIRCUIT J' 5~ 2 ~1 i><TE I _,_ lerl~ B 5-12-119 (C--S) SEI WAS TS, C WIS NO, NO WIS C; (B-8) 172 WIS 72. 384 W>S__ 64. 365 WIS 8S;(C-8) SCH! WIS SCN2. C NO, NO WIS C, SN WAS TS, SEZ ADDED, NO WIS 16 a: 18, C WJS 19; (D-6) SCN2 WIS SCH!, C WIS NO, NO WAS C; (D-4) S<:E2_ WIS SCEI, NO WIS C, C WJS NO:_ !<:-:4) SCEI WAS SCE2. NO WIS C, C WIS _NO: (C-1) NJXIUAAY CONTI AllOEI)_ [5862!1) I JS FROM EMERGENCY SOURCE !. EFR!2 t-<~~~· AUXILIARY CONTAClS . A4 69 ~ 1 TOES 7 5~1--------<«-I ~)>----1( C NO ~~ OPTIONAL [ A4 ~ ::::r-[ A4 J C NO 58 PtJ r:-57 [ A3 ~--::::.1---~r A3 J ----1<; ~ - S1Ai iS1A ~ ENGINE srARJ-TERMINALS (ON CONi:ACTOR) .J.mEliQ A3,A4 -AUXILIARY CONTACT BR -BRIDGE RECTIFIER C( #) -CAPACITOR EfR -EMERGENCY FREQUENCY 'RELAY ER -EMERGENCY RELAY ET -·EMERGENCY TRANSFORMER -D(#) -DIODE J -JUMPER LED(#) -LIGHT EMITTING DIODE iilR -NORMAL RELAY NR1 '-NORMAL •RELAY 11 NT -NORMAL TRANSFi'.lRMER R(#) -RESISTOR . SE -SWITCH, LIMIT -EMERGENCY POSITION ~g~ = gg~~g: gg:t g~:~g = ~~~~NCY SN -SWITCH. LIMIT -NORMAL. PosmoN TDES -TIME DELAY ENGINE START TS .:._ TRANSFER SWITCH (CONTACTOR) V(#) -VARISTOR 0 -CpMPONENT CONNECTION • -INTERNAL COMPONENT CONNECTION © -TERMINAL BLOCK TERMINAL # ~-PRIMARY "TRANSFORMER 1-SSY. TERMINAL BLOCK l'.'i:?J -SECONDARY TRANSFORMER ASSY. TERMINAL BLOCK (@ -TERMINAL BLOCK TB1 W/TERMINAL # I--LEAD NUMBER eje -CAM OPERATED CONTACT ,-;;'( -' INDICATOR LAMP ~ R-RED -<H- W -WHITE G -GREEN SI# ~II \_ \_ PLUG NUMBER PIN NUMBER SOCKET NUMBER D C B I I I l '---NOTE: A~ I 11IIE DEIAY /.. EMERGENCY "/lONORIW. S1B j_ ,l ,l ~ CIRCUrr 1 ,l 1111 2 3 4 -5 11 15· 16 17 J 8 I 7 r 6 ..... c~~ I -5 ~ * L£D 3 TIME DElAY NORMAi. lO EMERGENC'( CIRCUIT '8 9 18 19 7 EFR 4 rl H 4 DIAGRAM SHOWN WITH "NORMAL" ENERGIZED AND CONTACTOR IN THE NORMAL POSITION 'T..:::=-'--:=.-KOHLER CQ .:ad;~=.n:1:,ir :nE:1:=:,~:..a~~- ' .XIC: ± .mo ~ ,_. IIUSl' IOr IE USED D:CEPr IN CXIIII:IIDN mH IIDUI UL-Mlllt. MOD~L G, GLS :..:.,::,, 7--· _All.~DFDellllClt~.W:-- StB ~0-40Q AMP _,, ""TE 21 zo s 1. 600V CLASS .... GFR s-28-91! S-340 -.UC ·&-~ ... NONE 100-362172.llWC 1-I 1 I FOR INTERCONNECTION DIAGRAM SEE 362164 --:-AH a-3--1111 """"' r• 362172 l DJ 3 I 2 I 1 O> T"" 0 C"') w z ::> --, I I I D I ii I I I C I I I I B I I I I I A I I 8 7 6 TRANSFER SWITCH (TS) ,--------------------------------7 ~ I rop 2 I I ~ s ,~------, t R &O --n -. 0 1 I.!. .!. .!. o'.!. I .!. -. I~ I I a. n. ~ e:,. ~ I e:,. I e:,. e:,. I I I U) I I ~ TSR -liN -...-..N ' -I-"' .,, _ "' _ .... z,... .., .,, e:,. o I I ~-A I ,-.. LAt LB t! ,-..LC I +If) NO f-NO I~ I i I I + ~z I c=1 c&;N2. NO +NO I ~ I I I . SN M I ~ TSS °< O CC <I I 'T T I r-;,i 1 NA (SCN1-C} I g g I 1 .t ' 1 ·1 ~ ~ I 11321 1 I~ ~ I I I I J, J, ~--74 (P1-22} 1130 I I t:;. t:;. 17 (PHO} I I I FA {SCEl-C}-J T }-EC (SCE2-C} : . lcSCE, j_cSCE2 T::1 T: +~ : J~: ?EA 1EB ?Ee I TNO JNO· l J I I ~ ,... ~ .I ~ "' "', -, I I ,~ ..... '° ..... ..... ' I I I I .• I -.-I 0: CL a: ...... a: ~ ~ I ~ ~ ~ I e:,. ~ I"' "' I ~ .ffl rrl .,-.. -:-I ~'--;--------"-r-.-L ·---~ I L _____________ ·--------------~ a, I -& ~ "' I ~ ~ !ci BTB3 ENGINE START CONNECTION 8 P1 ©®00 ~7 t§5 58 ·@EC~} (iji/(fj!}0 • 11 . . Na@@) ··@,~i~}@1@ -) 1~?/tiJf@ ~t}OcEf® 7 . P1 CONNECTIONS PIN #1 1 (SCE1-NO} l 2 2 (TsR-B) 3 33 (SCN1-NO) 4 NC (Ts-NC) 5 5 (TSR-A) 6 ·EC (TS-EC) 7 FA (TS-EA} 8 58 (TB3-3} 9 57 (TB3-4) -10 17 (SE2-C) 11 NB (TS-NB} 12 NA (Ts-NA) 13 16 (SE2-NO) 14 18 (SN-NO) 15 15 (SCN2-NO) 16 46 (SCE2-NO) 17 EB (TS-EB) 18 76 (Ts-LA) 19 77 (Ts-LC) 20 N/C • 21 75 (SE1-NO) 22 74 (SE1-C) 23 N/C 24 .N/C 6 5 4 ,-----------7 I TRANSFQRMER I ASSEMBLY I (TA) I I TBS I I T1 (P3-1) I I T2 (P3-3) I I T3 (P3-6) I I T4 (P3-7) I I TS (P3-4) I T6 (P3-5) I T7 (P3-2) I I T8 (P3-8) I I N(~-~ I I I I I I I I I I I I EB (JH7) I I EC (J1-6) I I TB4 I L __________ _J 3 2 Rf.YI .,.TE I _. B l5-12-99ISHEET 2 Of 2 AOOED_[58829] MAIN LOGIC BOARD (MLB) TIME DELAYS VOLTAGE ADJUST DO DO D DO NORMAL TO EMERGENCY EMERGENCY TO NORMAL DROP-OUT PULL-IN P3 I NR1 I ACCESSORY BOARD (AB) P2 = §@ P2 CONNECTIONS PIN #1 1 (J1-1) 2 5 (J1-5) ar If JS D e3 CON!::jf;CllONS PIN #1 T1 (TB5-T1} @4@® [:J @s®e@ EFR EJBEJ 0011 I, l 3 15 (Jl-15} IC 4 46-(J1-16) I 2 T7 (TB5-T7) 3 T2 (TB5-T2) 4 T5 (TB5-T5) 3@6c§9c§). 5 T6 (TB5-T6} 6 T3 (TB5-T;5} 7 T4 (TBS-T-4-) 8 T8 (TB5-T8} TB1 9 N (TBS-N) '::.:' io ;:;: I() ,-.. "' ..... 'in' I I I "' ai I "' g, m ;;; m Ct t. t:;. (0 "' IC> "' .... I ,-.. (0 '° (0 -.., .., .., J1 J1 CONNECTIONS 00@4 PIN #1 1 (P2-1) 1 2 33§ l 2 2 (P2-5) s· t§@e 3 33 (P2-6) ,0 EC FA<§ 4 NC (TB4-NC) 9'1@1@18 5 5 (P2-2) @: 17, · NB .NA : 6 EC (TB4-EC) ®1Ci~i@1@ 7 EA (TB4-EA) 8 58 (TB2-58) 7@J1@1®b 9 57 (TB2-57) 10 17 (TB2-17) 1Y?J@ub 11 NB (TB4-NB) 12 NA (TB4-NA)' 13 16 (TB2-16) 14 18 (TB2-18) 15 15 (P2-3) 16 46 (P2-4) 17 EB (TB4-EB) 16 76 (TB6-76) 19 77 (TB6-77) 20 N/C 21 75 (TB6-75) 22 74 (TB6-74) 23 N/C 24 N/C FOR SCHEMATIC 5 4 3 4 1 · ®0· 5 2 (J1-2) 6 33 (J1-3) -= _j -~ TB2 60 59~58 57 56 55 54 53.29·27 20 19 18 17 16 I o o o o o op o_o o o AUTO/TEST SWITCH (ATS) i;-g_ 0 '° I ~~ ~s,;;;-10 O> I I 1 11 33 ---333 10 ,-.. 10 ,-.. (0 I() I() --- 60 (TB2-60) ~ 61 (TB1-61)___j ,....~Tr .... -1CD Q <" S .!. 1;;;'i' , 1 T T ~~ '-3 5.. ~ ~ ~ t-t--CIITwU> , U> r,,.. --!:::":'-'~r:--, ...... ,-.. ~ 0 0 0 0 0 0 76· 77 78 79 BO 81 I TB6 0 0 _Q_Q O 0 .l.E!illill i A3.A4 -AU~IUARY CONTACT AB -ACCESSORY BOARD ATS -AUTO/TEST SWITCH J(#) -CONNECTOR (JACK) <: MLB -MAIN LOGIC BOARD P(f) -CONNECTOR (PLUG) . SCE -SWITCH, LIMIT -COIL CLEARING ~ EMERGENCY SCN -CONTACT, COIL CLEARING -NORMAL SE -SWITCH. LIMIT -EMERGENCY POsmoN SN -SWITCH, LIMIT -NORMAL POSITION· TA -TRANSFORMER ASSEMBLY TB(#) -TERMINAL BLOCK TS -TRANSFER SWITCH (CONTACTOR) TSR -TRANSFER SWITCH ~RECTIFIER~ TSS -TRANSFER SWITCH SOLENOID POINT TO POINT CODE: LEAD NUMBER (DEVl<;:E TO-POSITION ON DEVICE) T-=-"-~ KOHLER CQ ,:au.~:0:1:vr . THl5~~~:.0~~- MODEL G', GLS :'; = --:""'".:'. --:._~~~-.:,~"""' 225-40() AMP -::,:,_. :TE ... WIRING DIAGRAM, S-340 -JS s-,2_ INTERCONNECTION 600V CLASS -cww 5-17 99 ... NOIE ,--36216411.DWG ..... 2 2 I DIAGRAM SEE 3_6~ 172 -_ Ni s-zo-gg ,... r '"!-3621 64 j Dj 2 I 1 B 0) Am 0) ...... 0 ('t) w z => -, I I .. I .I I I 1 .. I ·1 I I I I I I I I. I I Kohler Standby/Prime Generator Set Test f:>rogram Testing is an·integral part of quality assurance. In keeping with our uncompromising commitment to quality, safety, and · reliability, every Kohler standby/prime power generator set undergoes an extensive series of prototype and production testing. Prototype Testing Prototype testing includes the potentially destructive te~ts necessary to verify design, proper fu_nction of protective devices and safety features, and life expectancy. Kohler's prototype test program satisfies · the requirements of NFPA-110 and also includes the following tests: • Generator temperature rise per NEMA MG1-22.40 and 16.40. Standby and prime ratings of the generator are established during this test. • Maximum power test to assure that the prime mover and generator have sufficient capacity to operate within specifications. • Generator overload test per NEMA MG 1-22.41. • Steady-state load testing to ensure voltage regulation meets or exceeds ANSI C84.1, NEMA MG1-16.47.2, 16.48.2.4, and 22.48 requirements and to verify compliance with steady-state speed control specifications. • One-step, full-load testing and staircase testing to · verify that transient speed control· meets or exceeds .specifications. Transient load tests per NEMA MG1-16.48.2 to verify specifications of transient voltage regulation, voltage dip, voltage overshoot, recovery voltage, and recovery time. . Production Testing In production, Kohler standby/prime generator sets are built to the stringent standards established . by the prototype program. Every_ Kohler unit is fully tested prior to leaving the factory. Production testing includes the following: • Stator and exciter winding high-potential test on all generators. Surge transient tests on . stators for generators 180 kW and larger. Continuity and balance tests on all rotors. • One-step, full-load pickup tests to verify that the performance of each generator, regulator, and governor meet Kohler's published specifications. • Motor startin!;I tests to evaluate capabilities of generator, exciter, and regulator system. This test, per NEMA MG1 -16.48.5, includes one-step load pickup of full rated load at 0.3 (lagging) power factor. • Three-phase symmetrical short-circuit test per NEMA MG1-16.45 · and 22.45 to demonstrate short circuit performance, mechanical integrity, ability to sustain short-circuit current, and functioning of the generator circuit breaker to protect the ·generator. • Harmonic analysis, voltage waveform· deviation per NEMA MG1 -22.43. to confirm that the generator set is producing clean voltage within acceptable limits. • Fuel consumptiohtests at25%, 50%, 75%, and 100% of rated load. • Torsional analysis to verify nonexistence of harmful torsional effects at·synchronous speeds ± 10%. • Generator cooling tests and cooling air flow tests· to verify maximum operating ambient temperature and fan design. · • Endurance testing followed by inspection for failure and defects, and analysis·of any failed components to determine ·design, workmanship, or component problems. • Acoustical noise intensity and sound attenuation effects tests. ' • Regulation and stability of voltage and frequency are tested anc:f verified at no load, 1/4 load, 1/'4, load, .3/4 load, full rated. load, and maximum load. • Voltage·, amperage, frequency and power output ratings verified by 30-minute full-load test. • The proper operation. of all controller logic circuitry, prealarm warnings, and shutdown functions is tested and verified. - • Generator sets ordered with switchgear are tested as complete systems at full load with their accompanying · switchgear and transfer switches. ~ Any defect or variation from spedfication discovered during testing if? corrected and retested prior to approval for shipment to the customer. ' Kohler offers additional testing at the customer's request. These optional tests include customized load testing for specific application, witness testing, and a broad range of MIL-STD-705 testing. KOHLER. POWER SYSTEMS· G18·5612/93 KOHLER CO. GENERATOR DIVISION, KOHU;R, WI 53044 U.S.A. I I I· ·1 I I I 1· I.· 1·. I ·KOHLER .GENERATORS,· CUST P.O. 5317 BAY CITY JA~ 16 IEC'D Certified Generator Set Test Record . Model ......,60 ...... R ...... E_.._O ...... ZJ.__ _____ _ Serial N 1.:1 mber -=-06"'""9-=2 ....... 60 ...... 6 ______ _ . . Specification Number .._P,_,A__.-: 1'"""8.,.._94 ....... 2=..i.7 .......... ____________________ _ Type of Fuel Pll;SE;L Engine Seri~I ..... JO __ 4 ..... 0-.4 .... 5 ..... T __ 86 ...... 5~9.-.0 .... 6 _____ _ Volts-Amperes -Watts Hertz 1 Light 209. ----62.3 ·1./4 Load· 210. · 42.00 15276. 62.0 · 112 Load 210. 84.00 · 30552. 61.6 3/4 Load · 209.-126.00 45610. 61.1 ... Full Load 208. 169.00 60883. 60.0 1·. :· . · · · Power Factor ..,_1 '-""-><---,---------------------1 Altitude _6....,0 ...... Q._' ________ Temperature ""'"'68.._.,0_· _______ _ 1· 1·. I I .. I I Tested by --3493 Date Tested --12/16/2000 We hereby certify that the results listed were developed during the actual factory test of ·.-. the generator set indicated. . · · · .--~.1~· Certified Correct KOHLER CO., KOHLER WISCONSIN I I I I I I I I I I I I I I I I I I I Installation Checklist This docym~nt is generic in content and some items may not apply to specific applications. Read a~d understand all safety precautions found in Operation and Installation Manuals. Make the following installation checks before initial start-up: NOTE: Us~ this form as a general guide, along with any applicable codes or standards. Comply with all applicable codes an_d standards. Improper installation voids warranty. O 1. Is equipment installed in a qedicated, fire proof room or outdoor weather housing? O 2. Is battery-powered emergency lighting installed in equipmentroom? The outdoor weather housing should have a ·battery-powered drop cord or flashlight. O 3. Is there adequate clearance available on all sides allowing ease of l'!laintenance? O 4. Is mounting base(s) constructed per installation guidelines and leveled? O 5. Was the generator-to-engine a·lignment performed after attaching skid to mounting base? Generator sets with two-bearing generators require alignment. O 6. Is there a minimum of 6 in. (152 mm} clearance between engine and floor? O 7. Is there a<;iequate heating for equipment room or outdoor weather housing? O 8. Is there adequate incoming and outgoing air (louver motors adjusted and with correct voltage applied}? O 9. !s radiator duct flange sized per guidelines and connected? O 1 o. Is the cooling system filled and purged of air (50/50 antifreeze/water}? O 11. Is the correct level of specified oil in crankcase? O 12. Is there an adequate/dedicated fuel supply? O 13. Are flexible sections installed in cooling water lines? O 14. Are manually operated fuel and cooling water valves installed which allow manual operation.or bypass of ·solenoid valves when used? · .-· O 15. Are flexible fuel lines installed between engine and fuel piping? O 16. Are fuel tanks and piping installed in accordance with applicable codes and standards? d 17. Is there adequate fuel transfer tank pump lift and is pump motor correctly wired? O 18. 1$ the specified gas pressure available at fuel regulator inlet? O 19. poes gas solenoid .valve function? O 20. Is the exhaust line sized per guidelines and have flexible connector(s}? Is flexible connector(s} straight. O 2·1. ls.there an exhaust line condensate trap with drain installed? O 22. I~ the exhaust line installed with recommended downward outgoing incline? lj 23. Is the specified silencer installed with hangers and mounts tight? O 24. Is the exhaust line free of excessive bends and restrictions? Is the back pressure under specified limit? O 25. l's the exhaust line protected from entry by rain, snow, and animals. O 26. Is an approved heat-isolating thimble(s) installed at points where exhaust lines pass through combustible wall(s) or partition(s)? .,, O 27. · Does the exhaust system outlet location prevent entry of exhaust gases into buildings or structures? O 28. poes battery(ies) have specified rating and voltage? O 29. Is battery(ies} filled with electrolyte and connected to battery charger? O 30. Is battery charger AC circuit connected and is battery charger operational? O 31. Is battery(ies) installed with adequate ventilation? O· 32. Do the engine starting cables have adequate length and gauge? O 33. Are engine starting cables connected to battery(ies)? O 34. .Arf! Qenerator set load conductors of proper ampacity and correctly connected to circuit breakers and/or emergency side of transfer switch? . O 35. Are load conductors, engine starting cables, battery charger cables, and remote annunciator leads installed in separate conduits? O ~6. Do~s nameplate voltage/frequency of generator set and transfer switch match normal/utility source ~ng~ . O 37. ls-transfer switch AC conductors correctly connected (Normal to NL 1, NL2, NL3; Emergency to EL 1, EL2, EL3; Load to L,L 1, LL2, LL3}? Verify lead designations using the appropriate wiring diagrams. O 38. Is trM'sfer switch mechanism free of binding? NOTE: Disconnect all AC sources and operate manually. O 39. Is all ·other wiring including customer added options connected per instructions? O 40. !s equipment room clean with all materials not ·related to the emergency power supply system removed? O 41. Is equipment room protected with a fire extinguishing system? · O 42. is the equipment protected from lightning damage? · O 43. Is ~he earthquake protection adequate for equipment and support systems? I I I. I I I I I I I· I I I I I I I I I Start-up Procedure . This document is generic in content and some items may not apply to specific applications. Read and und~rstand .all safety :precautions found in Operation and Installation Manuals. Perform the following start-up checks: O 1. Open all water and fuel valves. Remove radiator cap to eliminate air in cooling system. 0 2. Prime fuel system. O 3. Turn on water/oil heaters and fuel lift pumps. O 4. Place generator set master switch In the OFF/RESET position. Observe Not-in-Auto lamp and alarm, if equipped on controller. O 5. Press lamp test, if equipped on controller. Observe lamp indications. O 6. Open generator set main line circuit breakers, safeguard breaker, and/or fuses (depending upon model). O 7. Turn down speed potentiometer (electrical governor) or speed screw (mechanical governor).* O· a. Verify presence of lube oil in turbocharger, if equipped. See engine and/or generator set operation ma'.nual. O 9. Place generator set master switch to. RUN position. Allow engine to start and run for several seconds. O 10. Place generator set master switch to OFF/RESET position. O 11. ~estart generator set. Verify sufficient oil pressure; Check for oil, Water, and exhaust leaks. O 12. Check battery charger ammeter for battery charging indication. · O 13. With safeguard circuit breaker closed, adjust engine speed to 50 or 60 Hz if equipped with electrical governor and 52.8/63 Hz if equipped with mechanical governor.* O 14. If speed is unstable, adjust per appropriate engine and/or governor manual.* O 15. Adjust AC output voltage to match lor;id voltage using voltage adjusting potentiometer or switch. See generator set operation manual. O 16. Allow engine to reach normal operating watertemperature. O 17. Adjust thermostatic valve for correct operating temperature on city water-cooled models. ,0 18. Manually overspeed the engine to cause an engine shutdown (68-70 Hz on 60 Hz models and 58-60 Hz on 50 Hz models). Place generator set master switch to OFF/RESET position.* O 19. Check coolant level, add coolant as necessary, .and replace radiator cap. Verify that all hose clamps are tightand secure. O 20. Restart generator set. Check generator set phase sequence on three-phase models. Sequence must match ·normal source and load. O 21. Verify engine low oil pressure and high water temperature shutdown by grounding the appropriate switch and/or leads. · O 2~. Check qvercrank shutdown by closing fuel valve and grounding ignition coil secondary cable at distributor on gas/gasoline models. O 23. Close generator main line circuit breaker or replace fuses. Apply normal source to transfer switch. O 24. Start generator set and chtaP.k voltage and frequency on emergency side of transfer switch. O 25. Stpp generator set and place generator set master switch in the AUTO position. D 26. Place transfer switch in TEST.position (load test or open normal sourc·e circuit breaker). NOTE: Obtain permission from building authority before proceeding for this procedure tests transfer switch operation and connects. building load to generator set power. O 27. Readjust frequency to 50 or 60'Hz with total building loads. O 28. Release transfer switch test switch br close normal circuit breaker. Transfer switch should retransfer to normal source after appropriate time delay. . O ~9. Allow generator set to run and shut down automatically after appropriate cool down time . . 0 30. Set plant exercise to customer's required exercise period. O 31. Verify that all options on transfer switch are adjusted and functional to the customer's requirements. d 32. If possible, run building loads on generator set for several hours or perform load bank test if required. Q 33. Make sure the customer has the correct engine/generator set and transfer switch operation and maintenance manuals. Instruct the customer in proper operation and maintenance of the new emergency power supply system. O ~4. Fill out start:up notification at this time and send white copy to the Generator Service Dept. include warranty form if applicable. . O 35. Verify that all wire connections from generator set to transfer switch and optional accessories are tight and, secure. * Some· models with electronic engine contr'ols may limit or prohibit adjusting engine speed. Consult the· engine oper(;ltic,n, and/or ehgine service manual for additional information. I I I I I I I I I I I I I I I I I I I BA V CITY ELECTRIC WORKS, INC. Date:_/_/_ Customer: ___________ _ Engine·----------S/N_· ________ _ Spec#·---------- Hrs Volts AMPS L1 L2 L3 - ,, ,. ,, ., '> ' TEST REPORT FREQ. - ,, Repair Order (RO) #: __ _ Model·---------- S/N·~-------~- Spec #·----------------- °lo Water Oil LOAD Temp. Pres. - Remarks ~ I I I I I I I I I I I I I I I . I I I I Stationary Standby & Prime Power One-Year o~ 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 t~e period Indicated below, each product to ba free from defects In materials and workmanship. Repair, replacement, or appropriate adjustment at Kohler Co.'a 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 lnstructlori manuals. 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 Generator Set & Accesaorles Prime Power Generator Set 6 kW Warranty Coverage• One (1) year or 2000 hours (whichever occurs first) from date of Initial start-up or Larger One (1) year or 2000 hours (whichever occurs first) from date of Initial start-up • Some restrictions may apply. Contact your Kohler D1.atrlbutor/Oealertorfull details, The Following WIii Not Be Covered By Warranty: 1. Normal engine wear, routine tune-ups, tune-up parts, 5, Original Installation charges and start-up costs. adjustment,, and periodic ,ervlce. 6. Starting batteries and the following related expenses: 2. Damage caused by accidents, Improper Installation or a, L.abor charges related to battery service, handling, faulty repairs not performed by an authorized service representative, or Improper storage, b, Travel ·expense related to battery service, 3. Damage caused by operation with Improper fuel or at 7, Engine coolant heaters, heater controls, and circulating speeds, loada, c;ondltlona, modifications, or Installation pumps after the first year. contrary to published specifications or recommendations. 8. Rental of equipment during performance of warranty 4, Damage caused by negligent maintenance such as: repairs. a. Failure to provide specified type and sufficient 9. Repair shop labor without prior approval from Kohler Co, quantity of lubricating oil. Warranty Department. b, Failure to kttp air Intake and cooling fin areas clean, 10, Engine fluids such as fuel, oil, or coolant/antifreeze. C, Failure to properly service air cleaner. 11, Shop supplies such as adhesives, cleaning solvents, d. Failure to provide sufficient coolant and/or cooling air, rags, etc, e. Use of other than factory-eupplled or-approved repair 12. Expenses Incurred Investigating performance complaints parta and/or procedures. f, Failure to perform scheduled maintenance as 1,mless the problem Is caused by def~ctlve Kohler prescribed In supplied manuals. materials or workman.ship. g, Failure to regularly exerclae the ~enerator set under 13. Maintenance Items such as fuses, lamps, filters, spark load (stationary applications only , plugs, loose or leaking clamps, adjustments, etc. A Start-Up Notification FQrm must be on file at Kohler Co. A Start-Up Notification Form must be completed by Seller and received at Kohler Co. within 60 days after the date of Initial start-up. Standby syatems not registered within 60 days of start-up will automatically be registered by Kohler Co. using the Kohler Co. ship date as the start-up 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 U.S.A. . . KOHL.ER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL., OR CONSEQUENTIAL DAMAGES OF ANY KIND, Including but hot limited to Incidental, consequential labor costs, Installation charges, telephone charges, or transportation charges In connection with the replacement or repair of defective parts, This ls our exclusive written warranty. Wt make no ~ther express warranty, nor Is anyone authorized to make any on our behalf, ANY IMPLIED OR STATUTORY WARRANTIES, 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 glvia you specific legal rights, and you may also have other rights that vary from state to state . KOHLER. POWER SYSTEMS KOHLER CO, Kohler, Wisconsin 53044 Phone. 920-565,3381, Web site www.kohlergeneratora.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1814 (International) For the nearest sales and service outlet In U.S.A. and Canada Phone 1,B00,544·2444 TP-5374 4/98 " 1000 100 10 1 0.1 1 10 -.. l 'd 8989'0N Short Circuit Decrement Curve 41>10, Low Wye or · Delta connectlon, 60 Hz l I I i I I l . I ! I \ . l , f l ~! l ! ! I '\. l I' '-I f I "\ I ' -j • II ,,. • ' • \. ,.,.. ~~, I " ~ta I . ... . I "' ... I W\ I •\ ... I '1 \ l ,, • I ii I .. !\ 'l 100 1000 ARMATtJru; CORBENT (amps} I I 10000 Alternator car.nap curve ----· Aliunator rated wrrcnt 3 phuei syrninetrlcal LlllllwLlni: l~b -.. ·Lwe 10 Neutnl lph 69Zv 86Z 619 8373 A1l8 AY8 f > ,; I ," Notes. 1) 2) The emergency exit lighting and egress illumination is not dependant upon the performance of the optional stand-by generator. ( This project shall comply with the 1998 edition of the California Building Code (Title 24), which adopts the 1997 USC and the 1996 NEC. CIRCUIT DIRECTORY PANEL .... EM CIR CIR I R&D -R0DEG FREEZER 2 SPACE 3 FREEZER#l 4 SPACE 5 COOLER#2 6 SPACE 7 FREEZER#3 8 SPACE 9 FREEZER#4 10 SPACE I I COOLER#5 12 SPACE 13 FREEZER #10 -20DEG 14 SPACE 15 FREEZER #9 -8ODEG 16 SPACE 17 FREEZER#l2 -80DEG 18 SPACE 19 FREEZER#l4 20 SPACE 21 FREEZER#l5 22 SPACE 23 FREEZER#l6 24 SPACE 25 FREEZER#!! 26 SPACE 27 SPACE 28 SPACE 29 SPACE 30 SPACE 31 SPACE 32 SPACE 33 SPACE 34 SPACE 35 SPACE 36 SPACE 37 SPACE 38 SPACE 39 SPACE 40 SPACE 41 SPACE 42 SPACE f~U.Tl1 ER FORD RD. G6/,/ e..t...4-n:, I'<.... L6C-4-T[D ;J 5iG:IJ ~ l./6C-762.-8 -ro 6£-wtouiJrGi) .i,\&:it.~ ~ . ' PAR\(lhlG-LOT 1'1()' '( -··-··--"---' ····---------· -·--·-·····-------- ! 1 l ' ' .. ,1...- I\ ( \ '" N I ,l i : ll ---NEW 6,1 Dll SC.RJ:E.N WALL c, F 6 Pt..1 T r:.tJC.£. 6lOC-K. • -7 I -<j· ----------EX l ST It~ GI F\ ! , S H I_ · ... ,_ , ~-- v'iCINITY MAP ii.i_r_f_ .JN f OR :MA-T J oV'.i C)'iJ.N£R,.,St:. Q-'810 ~en e S!TE...ADIJll!lfH:S; -1.l.. S-.l Rt-\Tl+E-12.K'.SR.l) (t{) c..AP-L.S 6A-f)1 CA <f z.008 ·,, Q-BIOGENE 2155 Rutherford Road Carlsbad, Ca. Back-up Generator Single Line Diagram \ 2" EMT w i ( 4 )310 rawN \ Kohler GLS-168341-0225 Transformer 22SA 3 Pole 4801277 X 120/208 Volt • 35,000 AIC -~ Atutomatic Transfer Switch I (Existing) I I (New) I . -1 400amp 200a 120/208v 1201208v 0 Panel Panel "EM" (Existing) (ExistinR) II 200ACB - Main Switchgear I (Existing) I . 1200 amp 480/277 volt II ~ I ToSDG&E I Kohler 60REOZJ Diesel Generator set \ #2 CU 7 Strand bare I 1201208V ZODA 3PHASE I • I Ground Rod I 10,000 AIC (New) I ~ 11. J. Ogden Elettrlt -:rSl 130B OGDEN -OWNER ~ SOPHISTICA i'ED LIGH11NG AND POWER CONTROL PHONE: (760)1,-34-1834 Lie# CIO FAJI.: (760}04-1607 1308 BASSWOOC AVENIJE CAftl.ESAO, !:A 9200! 4408.60 E-MAIL 00G!E2@AOLCOM hl PA&€iL (658) Wq -'13 'f I ) .;