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Home My WebLink About2251 FARADAY AVE; ; US090104; Permit10128/21, 9:16 AM US090104 Permit Data City of Carlsbad Flammable Liquids, Gases Permit No: US090104 Job Address: 2251 FARADAY AV Permit Type: FL Parcel No: 2120610400 Lot #: 0 Reference No.: Status: ISSUED Applied 9/29/2009 Approved: 9/29/2009 Issued: 9/29/2009 PC #: Inspector: Project Title: ABBOTT IBIS GENERATOR GENERATOR & AUTOMATIC TRANSFER SWITCH Applicant: Owner: CARLSBAD RESEARCH CENTER L L C 515 S FIGUEROA FL #16 LOS ANGELES CA Fees ($) Add'I Fees ($) [ Total ($) Balance L_ 123 0 123 0 Ill Bergelectric Corp. tractors & Engineers ABBOTT IBIS WO# 12027 GENERATOR AND AUTOMATIC TRANSFER SWITCH SUBMITTAL JULY 24, 2009 SUBMITTED TO: DBC CONSTRUCTION 9535 WAPLES STREET, SUITE 200 SAN DIEGO, CA. 92121 SUBMITTED BY: BERGELECTRIC CORPORATION 650 OPPER STREET j ESCONDIDO, CA 92029 PHONE: (760) 746-1003 650 Opper Street. Escondido, CA Tel (760) 746-1003 Fax (760) 746-4619 C 1048504 V 7 Bn 1/CITY ELECTFb WORKS KOHLERPOWER SYSTEMS SUBMITTAL DATA Emergency Generator System Abbott IBIS Prepared for: Rick Greewell Bergelectric 650 Opper St. Escondido, CA 92029 760-746-1004 Sales Representative Brett Harbach Phone 619-938-8200 x307 Project Manager Danny Ofria Phone 619-938-8200 x350 Prepared by Bay City Electric Works, Inc. 12208 Industry Road Lakeside, CA 92040 619-938-8200 619-938-8217 / FAX Service Facility 750 E. Central Ave. Unit #4 San Bernardino, CA. 92408 866-938-8200 .. 10EW#t11005 7/2009 .1rfltwI4(.] .] Riti tUiii It is imperative you submit your application to the AQMD/APCD immediately upon approval of submittals to avoid any complications. Engines cannot be started or commissioned prior to the issuance of your Authority to Construct and Startup Authorization by the governing air quality district. I Emergency Generator System Index Submittal Data Reference # Bill of Material Statement of Qualifications Bay City Electric Works Line Card Kohler 300REOZDD Generator 300REOZDD Specification Sheet G5-279 Alternator Data Sheet TIB-102 Generator Dimension Print AD V- 7001 Generator Set Controller Decision-Maker 3+ G6-30 Wiring Diagram GM39854 Schematic Diagram ADV-7101 Generator Accessories Circuit Breaker Specification G6-88 Battery Charger Specification Sheet G6-15 Battery Charger Wiring Diagram 233968 Battery Specification G6-16 Dry Contact Kit Wiring Diagram 328912 Silencer Specification G6-39 Voltage Regulator G6-58 Fuel Tank Enclosure Specification Sheet G6-40 Enclosure Dimension Print ADV-7002 Fuel Tank Specification Sheet G6-17 Subbase Fuel Tank Dimension Print ADV-7098 Transfer Switch Russell Specifications Miscellaneous Seismic Calculations (Sample) SDAPCD Registration Application APCD Form 16 SDAPCD ICE Application APCD Form 34A-J Engine Emissions Data EPA Certificate of Conformity CARB Certificate NFPA 110 Prototype Testing Certification K-896 8/03a Generator Start-up Request BCEW Start-up Notification K-625 Installation Checklist Startup Checklist Load Test Report BCEW Certified Test Record Sample Kohler Generator Five-Year Warranty Operating Instructions BCEW 1.7 BR TV ELECTFtC WORKS Bill Of Materials Abbott IBIS EMERGENCY GENERATOR SYSTEM BCEW #11005 Major system components Include: One (1) UL2200 Listed Kohler model 300REOZDD diesel powered generator set, rated for continuous standby duty at 300 KW, 0.8 PF, 375 KVA, 277/480 volt, 3 phase, 4 wire, 60 Hertz, 1800 RPM. Standard features of this model are shown in specification sheet G5-279, outdoor in weatherproof enclosure with a 368 gallon subbase fuel tank rated for 12 hours at rated load. One (1) Russell Model RTBDNB4004CEF Automatic Transfer and Bypass Isolation Switch, rated at 400 amps, 480 volt, 3 phase, 4 wire, 4 pole, in Nema I cabinet for indoor mounting. One (1) Four hour factory test per specification 16622. One (1) 1 year maintenance contract. Four (4) Caldyn Spring Vibration Isolators DETAILED INFORMATION Material Description Qty 300REOZDD Generator Set 1 GM13281-MA6 Air Intake, Std. Duty 1 333708 Voltage,60Hz,277!480V,Wye,3Ph,4W,0.8PF 1 GM58642-MA25 Alternator, 4UA13 1 GM19874-KA1 Decal, UL2200 Listing (Diesel) 1 222661 Nameplate Rating, Standby 130 Degree 1 GM41933-GA4 300REOZDD, 24V, 60HZ 1 GM52912-MA1 Skid & Mounting 1 GM1 4340-MA8 Controller, 16 Light,Dec3+,24V I GM41999-MA1 Control & Harness 1 GM41993-MA1 Unit Mounted Radiator 1 272747 Safeguard Breaker 1 GM38859-KP1 Bik Htr, 2500W,90/120V,1Ph w/Valves 1 324588 Battery,2/12V,95OCCA,Wet 1 REFERENCE: BCEW #10070 2 of 2 273744 Run Relay, 24V 1 347274 Failure Relay w/Harness, 1 Fault(RESTRICT) 1 GM42115-KA1 Pre Alrm Senders, NFPA-110 1 GM51004-KA1 Enclosure, Weather w/o Roof Mtd Silencer 1 GM50890-KA3 Neutral, 1313A. 4UA 1 GM33871-KA10 Silencer, Critical Roof Mounted 1 258811 Power Factor Test,0.8,3Ph Only 1 CTR Certified Test Report 1 GM50088 Warranty, 1 Year Standby 1 GM42472-KP Lit Kit, General Maint, 300REOZDD 1 343478 Flexible Fuel Lines 1 343514 Fuel Pressure Gauge 1 343513 Air Cleaner Restrict. Indic. 1 GM28625-KA8 Coolant in Genset 17 gals. 1 GM52117-KA1 Crankcase Emission Canister 1 GM19979-KA4 Rodent Guards,Non CSA,4UA 1 GM28621-KA13 Oil in GenSet - 38 qts. 1 GM38837-KA2 Double Wall Fuel Tank, 368 Gal. 4" Vent 1 GM29580 Additional Shipping Charges Accepted 1 226204 Inner Tank Leak Alarm 1 221665 Warranty, 2 Year Basic 1 GM50883-KA2 MTG, LCB, D-Frame, 400A, 4UA 1 GM51860-KA4 Covers, 4UA J-Box, D-Frame LCB 1 GM25953-KA1 Dry Contacts, 10SPDT,10A 1 GM52327-KA1 LCB, 400A, DGP, EL, 100% 1 GM38859-KA1 BIk Htr,2500W,90/120V,1Ph wNalves 1 PAD-292865 Battery Charger,Float w/Alarms,24V-10A 1 K 0 H L E R POWER SYSTEMS [-7 BR T V ELECT WORKS STATEMENT OF QUALIFICATIONS Dear Bay City Electric Works Prospective Customer, Bay City Electric Works has been a San Diego company since 1932 providing new emergency generator system solutions, generator parts & services, and generator rentals throughout Southern California. Our commitment to after sales support is unmatched with our factory trained field technicians' 200+ years of combined experience. All technicians operate from fully equipped/stocked service trucks that are efficiently dispatched via GPS tracking and are backed up by over $500,000 of spare parts at our service facilities. We maintain a 24-hour emergency service "hot-line" to assure a "live" response and are responsible for over 2000 installed generator systems for preventative service maintenance and trouble call support. Our customers include electrical and mechanical contractors, industrial plants, commercial facilities, data centers, hospitals, schools, city and county government facilities, military installations, the telecommunications industry, water and electrical utilities and our area's growing bio-technical industry. Major product lines represented include Kohler for standby, residential, mobile, and marine generators; Winco Corporation for portable generators; Kohler, Briggs & Stratton, Onan, and Tecumseh for industrial engines; Lincoln, Baldor, and Leeson for electric motors. Bay City Electric Works is the premier provider of standby electrical power systems solutions in Southern California and looks forward to working with you to support your power needs. Sincerely, Rodney C. Lee President & COO KOHLERROWER SYSTEMS 12208 Industry Road Lakeside, CA 92040 Phone-619.938.8200 Fax-619.938.8217 Service Facility: 766 S. Gifford Ave, San Bernardino, CA 92408 BRY1ITY KOHLER,. ELECTIC WORKS POWER SYSTEMS Dependence on technology requires an uninterruplible power source, whether you are a small buSiness, hospital, retail outlet, contractor, cellular communications site, bLlildi)lfj/taCility manager or even a homeowner. Maintenance Contracts Bay City offers maintenance contracts that are tailored to our customers' specific requirements. We offer Maintenance Services in accordance with manufacturers' recommendations to help your system operate at peak performance and efficiency. Test results highlighting any defects discovered and full reports .showing the work performed are provided. Trained Specialists Bay City offers you superior service and support for routine maintenance and emergencies. Our technicians are either factory trained and authorized, and/or have completed degrees in diesel-electric power generation. Our highly-trained technicians are on call 24 hours a day, seven clays a week. We are an authorized Kohler distributor and can service all makes and models of diesel- and gas-powered generators Preventive Maintenance Your generator power system needs periodic maintenance to keel) it in top condition and ready to operate when the lights go out. Batteries, engine oil, anti-freeze and belts deteriorate over time. Oxidation, corrosion, separation and fatigue can also take their toll. Oil changes, filter changes, fuel replacement, air cleaner inspection and anti-freeze checks are vital to sound operation. We use advanced test equipment to thoroughly test your generator against the original factory standards. Every effort will be made to ensure that if your equipment has a week component, it will be found and corrected. PM services are available on any make or model generatol Load Bank Testing Ensure your generator is ready for emergencies with our load Bank Testing. Durh p a crisis, people's lives and livelihoods are at stake. YOU need to know that your generator sys)fl will = unction properly and provide the lull load of power you need. Recjulw resistive testing is the only way you eon make sure Y0111 Power system will operate when you need it most. Facilities that are legally required to have standby power sources must perform load batik testing during commissioning. Warranty Coverage tVlriinlanniçj the warranty On 0 generator systOfll requ)res proper installation and maintenance. Count or Boy City to ensure your warranty provisiohls arc met. We keep a periilauent reco d of all service repairs performed, as (locumcutalion is typically requirea. BR YCITY ELECTtb WORKS Bay City is a premier distributor of emergency generator systems; automatic transfer switches and paralleling switchgear; mobile generator sets; portable generator sets, small engines and equipment, servicing Southern California. Services Power Generation Equipment Sales, Service and Installations - Authorized Kohler Distributor Generator and Power Distribution Rentals for Emergencies, Planned Outages and Special Events Turnkey Installed Mobile/RV Generator Sales and Service Generator Preventive Maintenance Agreements - Servicing Southern California Fuel Services - 24/7 Delivery, Testing and Fuel Polishing U ni nterru ptibl e Power Systems Small Engine and Equipment Sales, Service, Repair and RebiId, Kohler Expert Distributor Complete Turnkey Upgrade Projects Diflicul1;tohnd Parts Searcii Service 12208 Industry Road L.ni<ade, CA 920/53 619938.8200 FAX: 619.938.8216 /136 Gifford Avanuc Sari 13&.in&wdino. (TA 92'14O8 15 8200 b¼L3iii FAX: 619.938,8218 P(DWE ru vu vu h o vu. c L 3 1 3 Engine Generator Ratings Range 60 Hz Standby: kW 280-300 kVA 350-375 Prime: kW 255-270 kVA 319-338 Generator Set Ratings 130°C Rise 105°C Rise Standby Rating Prime Rating Alternator Voltage Ph Hz kW/kVA Amps kW/kVA Amps 120/208 3 60 300/375 1041 270/338 937 120/240 3 60 300/375 902 270/338 812 127/220 3 60 300/375 984 270/338 886 4lIA13W/ 139/240 3 60 300/375 902 270/338 812 41JA13 220/380 3 60 280/350 532 255/319 484 240/416 3 60 300/375 520 270/338 468 277/480 3 60 300/375 451 270/338 406 Model: 300REOZDD KOHLERYOWER SYSTEMS 208-600 V Diesel 5 9OOi Standard Features ' ) KOHLEP CmLLV''1Lt. • Kohler Co. provides one-source responsibility for the ArI generating system and accessories. The generator set and its components are prototype-tested, factory-built, and production-tested. The 60 Hz generator set offers a UL 2200 listing. The generator set complies with ISO 8528-5 requirements for transient performance. The generator set accepts rated load in one step. The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards. The 60 Hz generator set engine is certified by the Environmental Protection Agency (EPA) to conform to Tier 3 nonroad emissions regulations. A one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. Alternator features: The Fast-Response'" Ill wound field (WF) design alternator provides excellent voltage response and short-circuit capability using an auxiliary power brushless exciter. The unique Fast-Response '° II excitation system delivers excellent voltage response and short circuit capability using a permanent magnet (PM)-excited alternator. The brushless, rotating-field alternator has broadrange reconnectability. Other features: Controllers are available for all applications. See controller features inside. The low coolant level shutdown prevents overheating (standard on radiator models only). Integral vibration isolation eliminates the need for under-unit vibration spring isolators. An electronic, isochronous governor delivers precise frequency regulation. Electronic engine controls and a generator set microprocessor controller combine to deliver one of the most advanced control systems in today's market. 347/600 3 60 300/375 361 270/338 325 RATINGS: All three-phase units are rated at 0.8 power factor. Standby Ratirtgs: Standby ratings apply to installations served by a reliable utility source. The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this rating. Ratings are in accordance with tSO-3045'1, BS 5514. AS 2789. and DIN 6271 Prime Power-Ratings: Prime power ratings apply to installations where utility power is unavailable or unreliable. At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is availabie for one hour in twelve. Ratings are in accordance with ISO-8528/1, overload power in accordance with ISO.304611. OS 5514, AS 2789 and DIN 6271 For limited running time and base load ratings, consult the factory. Obtain the technical information bulletin (TIR.101( on ratings guidelines for the complete ratings definitions. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. GENERAL GUIDELINES FOR DERATiON: Altitude: Derate 0.5% per 305w (1000 ft.) elevation above 1525 m (5000 ft.) up to a maximum elevation of 3660 m (120005). Temperature: Derate 1.0% per 5.5C (10SF) temperature above 40C (104F(. For radiator cooling system capacity. derate 1.4CC (2 5'F) per 305 m (1000 ft.) elevation above 183 m (600 ft.). 05-279 (300REOZDD) 9/05c Specifications Alternator Manufacturer Kohler Type Wound field (WF) Permanent magnet (PM) Leads: quantity, type Voltage regulator Insulation: Material Temperature rise Bearing: quantity, type Coupling Amortisseur windings 4-Pole, Rotating Field Wound Exciter Field with Separate Excitation Power Winding Brushless, Permanent- Magnet 12, Reconnectable Solid State, Volts/Hz NEMA MGi Class H 130°C, Standby 1. Sealed Flexible Disc Full Voltage regulation, no-load to full-load Wound field (WF) alternator Permanent magnet (PM) alternator 550 controller (with 0.5% drift due to temperature variation) One-step load acceptance Unbalanced load capability Peak motor starting kVA: 480V 4UA13W/4UA13 ±0.25% Average ±2% Average 3-Phase Sensing, ±0.25% 100% of Rating 100% of Rated Standby Current (35% dip for voltages below) 980 Alternator Specifications NEMA MGi, IEEE, and ANSI standards compliance for temperature rise and motor starting. Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds. Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field. Self-ventilated and dripproof construction. Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life. Superior voltage waveform from a two-thirds pitch stator and skewed rotor. Fast-Response°° Ill wound field (WE) brushless alternator with auxiliary power brushless exciter for excellent load response. Fast-Response" II brushless alternator with brushless exciter for excellent load response. Application Data Engine Engine Specifications Manufacturer Detroit Diesel Engine: model, type S60, 4-Cycle Turbocharged, Charge Air-Cooled Cylinder arrangement 6, Inline Displacement. L (Cu. in.) 14.0 (855) Bore and stroke, mm (in.) 133 x 168 (5.24 x 6.61) Compression ratio 16.0:1 Piston speed, m/min, (ft/mm.) 604 (1980) Main bearings: quantity, type 7, Precision Half-Shell Rated rpm 1800 Max. power at rated rpm, kWm (BHP) 366 (490) Cylinder head material Cast Iron Piston: type, material Crosshead, Malleable Iron Crankshaft material Forged Steel Valve material: Intake Iron-Based Seat Exhaust Nickel-Based Seat Governor: type, make/model DDEC Electronic Control Frequency regulation, no-load to full-load lsochronous Frequency regulation, steady state ±0.25% Frequency Fixed Air cleaner type, all models Dry Exhaust Exhaust System Exhaust flow at rated kW, m3/min. (cfm) 81.9 (2895) Exhaust temperature at rated kW, dry exhaust, °C (°F) 507 (944) Maximum allowable back pressure, kPa (in. Hg) 10.2 (3.0) Engine exhaust outlet size, mm (in.) See ADV Drawing Engine Electrical Engine Electrical System Battery charging alternator: Ground (negative/positive) Negative Volts (DC) 24 Ampere rating 40 Starter motor rated voltage (DC) 24 Battery, recommended cold cranking amps (CCA): Qty., CCA rating each Two, 950 Battery voltage (DC) 12 Fuel Fuel System Fuel supply line, mm. ID, mm (in.) 13 (0.50) Fuel return line, mm. ID, mm (in.) 8 (0.31) Max. lift, engine-driven fuel pump, m (ft.) 2.1 (6.8) Max. fuel flow, Lph (gph) 329 (86.8) Fuel prime pump N/A Fuel filter: quantity, type 2, Primary/Secondary Recommended fuel #2 Diesel Lubrication Lubricating System Type Full Pressure Oil pan capacity, L (qt.) 30 (32) Oil pan capacity with filter, L (qt.) 36 (38) Oil filter: quantity, type 2, Cartridge Oil cooler Water-Cooled G5-279 (300FREOZDD) 9/05c Application Data Cooling Radiator System Ambient temperature, 'C ('F) * 50 (122) Engine jacket water capacity, L (gal.) 22.7 (6.0) Radiator system capacity, including engine, L (gal.) 45.4 (12) Engine jacket water flow, Lpm (gpm) 363 (96) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 140 (7945) Heat rejected to air charge cooler at rated kW, dry exhaust. kW (Btu/min.) 90.7 (5160) Water pump type Centrifugal Fan diameter, including blades, mm (in.) 965 (38) Fan, kWm (HP) 22 (30) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H20) 0.125 (0.5) * Weather housing reduces ambient temperature capability by 5'C (9"F). Operation Requirements Air Requirements Radiator-cooled cooling air, m3/min. (scfm)t 561 (19800) Combustion air, m3/min. (cfm) 31 (1105) Heat rejected to ambient air: Engine, kW (Btu/min.) 51.8 (2949) Alternator, kW (Btu/min.) 24.3 (1382) t Air density = 1.20 kg/m3 (0.075 1bm1ft3) Diesel, Lph (gph) at % load Standby Rating 100% 96.1 (25.4) 75% 76.5 (20.2) 50% 51.9 (13.7) 25% 27.6 (7.3) Diesel, Lph (gph) at % load Prime Rating 100% 85.9 (22.7) 75% 65.5 (17.3) 50% 43.9 (11.6) 25% 24.6 (6.5) Controllers Decision-Maker' 550 Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Programmable microprocessor logic and digital display features. Alternator safeguard circuit protection. 12- or 24-volt engine electrical system capability. Remote start, remote annunciation, and remote communication options. Refer to G6-46 for additional controller features and accessories. LM IiI.I uu. Decision-Maker " 3+, 16-Light Controller Audiovisual annunciation with NFPA 110 Level I capability. Microprocessor logic, AC meters, and engine gauge features. 12- or 24-volt engine electrical system capability. Remote start, prime power, and remote annunciation options. Refer to G6-30 for additional controller features and accessories. G5-279 I300RE0ZDDI 9105c Overall Size, Lx W x H, mm (in.) Weight (radiator model), wet, kg (lb.): f 3500 x 1250 x 1941 (137.8 x 49.2 x 76.4) 2903 (6400) L IP KOHLER CO. Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Standard Features Alternator Protection (standard with 550 controller) Battery Rack and Cables Electronic, lsochronous Governor Oil Drain Extension Available Accessories Enclosed Unit .3 Weather Housing Open Unit EJ Exhaust Silencer, Hospital (kit: PA-354905) 3 Exhaust Silencer, Critical (kit: PA-354880) 3 Flexible Exhaust Connector, Stainless Steel Cooling System .3 Block Heater .3 Radiator Duct Flange Fuel System .3 Flexible Fuel Lines .3 Fuel Pressure Gauge 3 Fuel/Water Separator with Prime Feature 1:j Hand Primer Pump 1:1 Subbase Fuel Tanks 3 Subbase Fuel Tank with Day Tank Electrical System 13 Battery 13 Battery Charger, Equalize/Float Type 13 Battery Heater Engine and Alternator 13 Alternator, Wound Field (WF) 13 Alternator, Permanent Magnet (PM) 13 Air Cleaner, Heavy Duty 13 Air Cleaner Restriction Indicator 13 Alternator Strip Heater 3 Bus Bar Kits 13 Crankcase Emission Canister 13 CSA Certification 3 Line Circuit Breaker (NEMA1 enclosure) 13 Line Circuit Breaker with Shunt Trip (NEMA1 enclosure) 13 Rated Power Factor Testing .3 Rodent Guards .3 Safeguard Breaker (not available with 550 controller) 13 Skid End Caps 3 Voltage Regulation, 1% 13 Voltage Regulator Sensing, Three-Phase Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Paralleling System 13 Voltage Regulator Relocation Kit Maintenance and Literature 13 General Maintenance Literature Kit 13 Maintenance Kit (includes air, oil, and fuel filters) 13 NFPA 110 Literature 13 Overhaul Literature Kit 13 Production Literature Kit Controller 3 Common Failure Relay Kit 13 Communications Products and PC Software (550 controller only) 13 Customer Connection Kit 13 Dry Contact Kit (isolated alarm) 3 Engine Prealarm Sender Kit 13 Remote Annunciator Panel 13 Remote Audiovisual Alarm Panel 3 Remote Emergency Stop Kit 13 Remote Mounting Cable 3 Run Relay Kit Miscellaneous Accessories U I I Dimensions and Weights 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: © 2005. 2006: 2007 by Kohler Co All rights reserved. G5270 (300IREOZOO) 9105c KOHLER. TIB-1 02 POWER SYSTEMS TECHNICAL INFORMATION BULLETIN Alternator Data Sheet Alternator Model: 4UA13 Frequency: 60 Hz Speed: 1800 RPM Leads: 12 (6 Lead, 600 Volt) kW*_(kVA) Class B Class F Class H 80°C 90°C 95°C 105°C 130°C 125°C 150°C Voltage Power L-N/Lt Phase Factor Connection Continuous Lloyds ABS Continuous Standby Continuous Standby 139/240 3 0.8 Wye 275.0 285.0 290.0 300.0 300.0 300.0 300.0 277/480 (343.8) (356.3) (362.5) (375.0) (375.0) (375.0) (375.0) 127/220 3 0.8 Wye 272.0 283.0 288.5 300.0 300.0 300.0 300.0 254/440 (340.0) (353.8) (360.6) (375.0) (375.0) (375.0) (375.0) 120/208 3 0.8 Wye 272.0 283.0 288.5 300.0 300.0 300.0 300.0 240/416 (340.0) (353.8) (360.6) (375.0) (375.0) (375.0) (375.0) 110/190 3 0.8 Wye 245.0 259.0 266.0 280.0 280.0 280.0 280.0 220/380 (306.3) (323.8) (332.5) (350.0) (350.0) (350.0) (350.0) 120/240 3 0.8 Delta 264.0 278.0 285.5 300.0 300.0 300.0 300.0 (330.0) (347.5) (356.9) (375.0) (375.0) (375.0) (375.0) 347/600 3 0.8 Wye 275.0 285.0 290.0 300.0 300.0 300.0 300.0 (343.8) (356.3) (362.5) (375.0) (375.0) (375.0) (375.0) * All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Submittal Data: 139/240 Volts, 0.8 PF, 1800 RPM, 60 Hz, 3-Phase, 130°C Rise Symbol Per Unit Ohms Symbol Value Typical Resistances Typical Time Constants Phase Resistance 0.020 0.003 Armature Short Circuit Ta 0.018 sec. Rotor Resistance 13.854 2.128 Transient Short Circuit T'd 0.185 sec. Typical Reactances Transient Open Circuit T'do 2.184 sec. Synchronous Typical Field Current Direct Xd 3.417 0.525 Full Load IfFL 29.57 amps Quadrature Xq 1.178 0.273 No Load IfNL 8.3 amps Transient Typical Short Circuit Ratio 0.391 Unsaturated X'du 0.328 0.050 Harmonic Distortion Saturated X'd 0.289 0.044 RMS Total Harmonic Distortion 2.7% Subtransient Max. Single Harmonic 7th Direct X"d 0.133 0.020 Deviation Factor (No Load, L-L) 4.3% Quadrature X'q 0.139 0.021 Telephone Influence Factor <50 Negative Sequence X2 0.136 0.021 Zero Sequence Xo 0.011 0.002 Insulation Material Class per NEMA MG1-1.66 H Phase Rotation ABC TIB-102 4UA1360Hz 12/08j 1 4UA13, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL ALTERNATOR EFFICIENCY* 100 98 96 94 92 0-0 86 84 801I,lrI,ITluI,IlIlI,!I,!TI 50 70 90 110 130 150 170 190 210 230 250 270 290 310 Output (kW) 4UA13, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 40 , 35 30 25 0 I# I I I I I I 0 200 400 600 800 1000 1200 Locked Rotor kVA * All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. 2 4UA13 60 Hz 12/08j TlB-102 4UA13, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 1000 100 I I 10 I 0.1 I 0.01 -I- 10 100 1000 10000 100000 Armature CUrrent, Amps Alternator Damage Curve 3 Phase Symmetrical - Line-to-Line 1 Phase ft Line-to-Neutral 1 Phase TIB-102 4UA13 60 Hz 12/08j 3 4UA13, 60 Hz, High Wye Connection SHORT CIRCUIT DECREMENT CURVE 1000 100 10 U) C 0 C.) C) Cl) 0.1 I 0.01 + 10 100 1000 Armature Current, Amps Alternator Damage Curve 3 Phase Symmetrical - - Line-to-Line 1 Phase ft Line-to-Neutral 1 Phase 4 4UA13 60 Hz 12/08j TIB-102 40A13, 60 Hz, 600 V Connection SHORT CIRCUIT DECREMENT CURVE 1000 100 10 I - I 0.1 0.01 -I- 10 100 1000 I VVJV Armature Current, Amps Alternator Damage Curve 3 Phase Symmetrical - M Line-to-Line 1 Phase ft Line-to-Neutral 1 Phase TIB-102 4UA1360Hz 12108j 5 C OV OL z Li UI < - 0 on W _J Ii) 0 a o Z u)L <0 - : IiJ(,Z LI u)0 mu) u,U)0Ld L - L00 0)6 rm LI z 62 z NlN3d0 31103 100T1'i 1601 L60PlJ 119I I z _______ .1 co [J 'ir [oL9] 1111______I TifflfjH __ j 0 [t) £ZL ° . r° [t-) 9L I1. 0 In 06 [ot'gd i6L 13 .i [cs) 8911 - UJ ijliflo 1SflX3_ [Q$'6] 1001 OE (MIS o) F [lP] 901 [90 LI 161 I —— I3INI 13fl [c991] 199 00 0 OL 00 0 ij9d96Lh <Z. L \ • 1LJAZ b U li GL— I IrrAIjF oc [o g) 091 \ - N ° In In ,t3 mE3 I In I a [c1] occ [l6) z1—I [699) OLI I sw —[goczI cg— 113 0 0 FLEXIBLE EXHAUST CONNECTOR SEE (FLANGE DETAILS) FOR DIMENSIONS. FLEXIBLE EXHAUST CONNECTION THERMOSTAT BLOCK HEATER CONTROL BOX BLOCK HEATER KIT 172 [6 [i CI 75 [2,951 M6-l.0O 0 (16 PLACES) 07 L0. o RADIATOR DUCT FLANGE KIT 45. D.B.C. 8 022 [0.87] 0343 [010.50) 0.0. 4 . 0 , 29 . 11 ' [011.751 5 (06.05] MIN. (FLANGE DETAIL) 8-(NOM. PIPE SIZE) 45• I 022 [0.87) 0279 [011.001 0.0. Ic 0154 [06.05] MIN. 0241 [09.50] D.B.0 (FLANGE DETAIL) I 6-(NOM. PIPE SIZE) I Al 81 07 '"MOU L0. 0- 740 [29.13]I I 90-105V AC POWER CORD LGTH. 1829 [72.0] 2 PLACES CONNECT TO BATTERY l CONNECT TO BATTERY p. 230 MODEL 4UA9/W 250/275 MODEL AUAIO/W BATTERY CHARGER 250/300/50 MODEL 4UA13/F'/W 350/400 MODEL 4t1A166/BW RECONNECTABLE IMS RECONNEC1ASLE & 800V ALTERNATORS DDC SERIES 60 DIESEL I 3 1 2 1:] METRIC CAD FILE Generator Controller Industrial Generator Set Accessories KOHLERYOWER SYSTEMS Generator Set Controller 090.01 V) KOHLER C E — IV ItCt rib F—_"EMERGENC o crzo 4 J VD VM1 c Decision-MakerTh 3+ Controller General Description and Function The generator set controller provides system control, monitoring, and diagnostics for optimum performance. The generator set controller provides both analog AC meters and engine gauges and 16-light annunciation of shutdowns, warnings, and status events. Standard Features Supports Modbus® RTU (Remote Terminal Unit) communication protocol via RS-485 networks. Supports CANbus J1939 communication protocol for ECM engines Contains microcomputer-based logic with a ROM (read-only memory)-based control algorithm. Features upgradeable software for new system functionality. Provides overspeed protection, cooldown mode, and a selectable crank mode. Provides audio and visual alarms. Features analog meters and engine gauges. Meets the National Fire Protection Association requirements of NFPA 99 and NFPA 110 with additional accessories. NFPA 110, Level 1 requirements typically apply to health care facilities; NFPA 110, Level 2 requirements apply to less-critical applications. Uses conformal coated circuit boards for environmental durability. Modbus'° is a registered trademark of Schneider Electric. G630 10/07k I GD UPPER METER SCALES \\\\\L\\.il.ldlILllLLLb1!f/// \\L\L\lL\VlhI.11l.11lhhIi//// 0!F \ HERTZ A-C VOLTS A-C AMPERES L1.42 AMPS LU-LU (\ VOLTS LOWER METER ecALos i1 VOLTAGE EMERGENC'T 50000 I '1 STOP Li TEMPERATURE (J TEMPERATURE (i FAULT L) VOLTAGE '1 ADJURE ONLY \1 peeo. a steo 0 RPOUU 0 DAMPER (_ :: :: ty \Y // $42 KOHLER 0 ED ED I I I I I Decision-Maker'" 3+, 16-Light Controller Controller Features General Specifications Power source with circuit protection: 12- or 24-volt DC Power draw: 220 milliamps in system ready mode (or 200 milliamps without panel lamps) Humidity range: 5% to 95% noncondensing 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) Standards: CE Directive NFPA 99 NFPA 110 UL 508 Dimensions—W x H x D, 461 x 247 x 297 mm (18.15 x 9.71 xli .68 in.) Hardware Features AC interlock to prevent starter reengagement with engine running Battery (DC) circuits are fuse protected Controller mounts locally or remotely up to a distance of 12 m (40 ft.) and viewed from one of four positions LEDs for visual annunciation Gauges and meters for system data Communication Features Supports Modbus® RTU (Remote Terminal Unit) via RS-485 (Comm. module GM32644-KA1 or GM32644-KP1 required) Supports Modbus® TCP (Transmission Control Protocol) via Ethernet (Converter GM41143-KP1 required) Supports CANbus J1939 communication protocol Modbus a a registered trademark of Schneider Electric. NFPA Requirements In order to meet NFPA 110, Level 1 requirements the generator set controller must monitor and display specific engine/generator safety indications and shutdowns Engine functions: Overcrank shutdown High engine temperature shutdown High engine temperature warning * Low water (engine) temperature warning * Low oil pressure warning * Low oil pressure shutdown Overspeed shutdown Low fuel (level or pressure) warning * Low coolant level (auxiliary fault) shutdown High battery voltage warning * Low battery voltage warning * Air damper indicator General functions: Battery charger warning * Master switch not-in-auto Lamp test Audible alarm silence * Requires optional input sensors on some generator set models G6-30 10/07k Standard Features Sixteen LED indicating lights for status, warnings, and shutdowns Status indicators: Air damper (red) (if equipped)* Master switch not-in-auto (red) System ready (green) Warning indicators: Auxiliary (multiple function)(red) Battery charger (red)* Fuel, low—level or pressure (red)* Pressure, low oil (yellow)* Temperature, low water (engine) (red)* Temperature, high engine (yellow)* Voltage, high battery (yellow)* Voltage, low battery (red)* Shutdown indicators: 0 Auxiliary (multiple function)(red) Emergency stop (red)* Low fuel (utilizes auxiliary indicator)(red); 125RZG model only Level, low coolant (utilizes auxiliary indicator) (available with radiator-mounted generator set models only) Overcrank (red) Overspeed (red) Temperature, high engine (red) Pressure, low oil (red) Underfrequency (utilizes auxiliary indicator) (red) Panel illumination lamps (2) Analog gauges, 51 mm (2 in.): Pressure gauge, oil Temperature gauge, engine cooling system Voltmeter, DC battery Analog meters, 89 mm (3.5 in.): AC ammeter, 2% of full-scale accuracy AC voltmeter, 2% of full-scale accuracy Frequency meter, 0.5% of full-scale accuracy Running time meter Switches and standard features: Horn, alarm (with silencing switch) Mode, prime power via jumper selection Potentiometer, generator output voltage-adjusting (front panel mounted, ±5% of nominal voltage) (350-2000 kW models have adjustment on voltage regulator in junction box) Shutdown, overvoltage protection Switch, latch-type emergency stop (standard on most 200-2000 kW generator set models) Switch, lamp test Switch, meter range selector Switch, run, off/reset, auto (engine start) generator set master Timer, engine cooldown, (5-minute fixed) Eight DIP switches for control and communication: O Cooldown disable Crank mode select for continuous or cyclic cranking. The cranking provides up to 30 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 750 rpm (25 Hz). Engine communication setting (2) Modbus® addresses (bit 0, bit 1, bit 2) Overspeed protection selection of 60 Hz for 50 Hz models or 70 Hz for 60 Hz models Terminal strips: Terminal strip connections for 2-wire remote start Terminal strip connections for 2-wire (series connection) remote emergency stop Terminal strip connections for remote annunciator Terminal strip connections for remote dry contact kit Terminal strip connections for prime power feature (prevents battery drain when not in use and no battery charger connected) LEDs on circuit board for troubleshooting diagnosis O Crank fault O Emergency stop Overvoltage fault 0 Run operation * Requires optional kit or user-provided device to enable function and lamp indication. 06-30 10/07k KOHLER CO. Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Selected Decision-Maker T"'3+ Accessories U Common Failure Relay remotely signals auxiliary Remote Emergency Stop Panel immediately shuts the fault, emergency stop, high engine temperature, low generator set down from a remote station. oil pressure, overcrank, and overspeed via one single- pole, double-throw relay with 10 amp at 120 VAC, j Prealarms warn of low water (engine) temperature, 10 amp at 28 VDC contacts. approaching low oil pressure, and approaching high engine temperature. Kits for gas-fueled models include a low fuel EJ Controller Cable, 12 m (40 ft.), enables remote pressure switch. mounting of the controller. LI 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. EJ 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 450-2000 kW models. rj 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. IJ 10 Amp Float/Equalize Battery Charger with Alarm Feature warns controller of battery charger fault, high battery voltage, and low battery voltage. UJ 6 Amp Float/Equalize Battery Charger has automatic 3-stage charging with indicator LEDs. Durable potted assembly for full waterproofing and shockproofing. UL 1236 listed. FJ Controller-Mounted Emergency Stop Switch shuts down generator set immediately in emergency situations. Use the generator set master switch for normal shutdowns. Standard on most 200-2000 kW generator set models (see respective generator set specification sheet for details). J Remote Audiovisual Panel warns the operator of fault shutdowns and prealarm conditions. Common fault lamp and horn with silence switch. Li Remote Serial Annunciator Panel enables the operator to monitor the status of the generator from a remote location. Maybe required for NFPA99 and NFPA 110 installations. Uses Modbus® RTU (Remote Terminal Unit), an industry standard open communication protocol. U Communication Module GM32644-KA1 or GM32644-KP1 is required when using the remote serial annunciator (RSA) and/or Modbus®/Ethernet communications. u 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. Run Relay provides a three-pole, double-throw relay with 10 amp at 250 VAC contacts for indicating that the generator set is running or shut down. U Modbus®/Ethernet Converter GM41143-KP2 for network communications. Modbus5 is a registered trademark of Schneider Electric. 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 Kohier® generator set distributor for availability. © 1995, 1995, 1997. 1999, 2000. 2002, 2003, 2005, 2007 by Kohler Co. 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AMMETER 9CA - 6611201 CIOIROING ALTERNATOR DV- BOTTCRY VOLTMETER COt. - CI€CII OICIME IDIOT CT(#) - CURRENT 154457010*211 CWES - CITY 110120 00011110 SOLENOID CTS - COOLANT TEMPERATURE 1040(0 Cit - COOLANT TEMPERATURE 0.44510 0(f) - DIODE ORB - 010541. 401.14CC REGULATOR (90 - 0100€ 810CR 08006 (CM - CIAOIIE CMJTROI. MODULE gy - FUSE - EMERGENCY 5100 SWITCH HR -00.0110100 AZ - FREQUENCY METER ION - INDICATOR PANELAESEMR1.Y KS - AIJXLIHRY RUN BOAT K20 - 02*1111 BOAT 10. -LOW COOLANT 10901.001104 LOT -LOW 00001012090201000 SNITCH 95* -11*00*01. SPEED ROAST 110.1 - METER SCALE LAMP 106CR 113.0 - 810120 SONIC LIIAO UPPER OPG - 01. PRESSURE CUICE 010 - OIL PRESSURE GENDER PLUG PANEL LAMP P110 - PERMANENT MAGNET GENERATOR RSWNSIL 154451095100 501 - STOP 8)51000 UCIIT SF0 - 511002011*40 BREAKER SM - STARTER 1101011 55 - STARTER 0010*20 STAT - 27*1011 SW(f) - 540101 103 - CT/MOlES SCALE TERMINAL 10.0CR 194 - N.C. 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(1102*12) QCON4 — 511-114116 (1102012)1 I I Ln GOD r AM SIDE SIDE ) L P1 CONNECTiONS PIN fT 71 (1120-5) 2 N/C 3 70 (1011-70) 4 N/C - 3 14*4 () B N/C 7 N/C 8 N/C N N/C 10 31* 31* (LOt.) 11 11/C 12 lAO (1120-9) 13 N/C 14 N/C 15 N/C IN N/C 17 N/C 111 N/C IN N/C 20 N/C 21 N/C 22 N/C 23 N/C 24 3011 (tOT) IT 11441021001100 DOT 1014000 GENERATOR CTT CT2 CT3 - II 10.2) QCONA SN-CRoW (OGLES) J 19 70 TN I TO ENGINE r SHEET2 Ic EE AM - A.C. AMMETER 409 - AUTOMATIC VOLTAGE REGULATOR RCA - BATTERY CHANCING ALTERNATOR 00 - BATTERY VOLTMETER ca - CHECK ENGINE LIGHT - CURRENT TRANSFORMER Cit - COOLANT TEMPERATURE GAUGE CTS - COOLANT TEMPERATURE SENDER ORES - CITY WATER COOUNS SOLENOID D() - DIODE CRC - ENGINE BLOCK GROUND ECM - ENGINE CONTROL MODULE (55 - EMERGENCY STOP SWITCH - FUSE GNU - CONTROLLER 800 GROUND HR - HOUR METER HZ - FREQUENCY METER RSI.IL(#) - INSUUNK IPA - INDICATOR PANEL ASSEMBLY 65 - ECU CONTROL BOAT (20 - CR4810 RELAY LCL - LOW COOLANT LEVEL SWITCH ICY - LOW COOLANT TEMPERATURE SWITCH lISA - MANUAL SPEED ADJUST MOU. - METER SCALE LAMP LOWER MOW - METER SCALE LAMP UPPER OPG - OIL PRESSURE GAUGE 01'S OIL OIL PRESSURE SENDING UNIT P(5) - PLUG PL(5) - PANEL LAMP P.T.S - POTENTIAL TRANSFORMERS SCON(#) - QUICK CONNECT DEL - STOP ENGINE LIGHT SELSW - SELECTOR SWITCH SPIT - SAFEGUARD BREAKER SM - STARTER MOTOR 05 - STARTER SOLENOID STAY - STATOR SW(5) - SWITCH TBIA. IBID. 1142 - CONTROU.ER BOARD TERMINAL BLOCK TBS - CT/METER SCALE TERMINAL BLOCK 1144 - A.C. FUSENLOCK 11411 - SAFEGUARD BREAKER TERMINAL BLOCK 1612 - JUNCTION 900 TEBMINAI. BLOCK IBIS - FTJSEBLOCK VADJ - VOLTAGE ADJUST NM - AC. VOLTMETER 'B Z B IA t A-2-WJJi OTTOM BOTTOM PET SIDE SIDE (48 -CON (TO3-CT).9_ M — B (TB3-C3) U lRG(TB4U)92 * )± IS I9BRG(I48-(+)()X * —MO (TBA-VB)9!Z 19 M - RED )T5AvA)o1 ->1- I::SIRl (>- - WON --S F OIT. 6111 (o( SELSW 230-400 KW ((DEC V SERIES 60 TIER III DECISION-MAKER 3+ CONTROLLER 10-30 & 600 VOLT. W/SPUT ACTIVATOR CONTROLLER/METER BOX TO STAT (FRII] SEE DWG. 01435941 OR STAT/P.T.S (RAt) Co (IOU-CR) SEE ORG 01435942 —CT (T011-CT) - C2 -.C2( çTRII I TO3IG3 CD Cl CO BR STFIXW TO TO ANTI (PS) [P611] SEE 0140. GM35941 OR 400 (P40) (WFE) SEE DING. 01435942 7 IiIB —5FO I (OPTiONAL> NOTE WHEN SAFEGUARD BREAKER IS NOT USED CONNECT CT WIRES DIRECTLY TO TRIT AND WIRE 16 DIRECTLY 10 TNT T-70 CTI CT2 CT3 NOTE CURRENT TRANSFORMER DOT OR •H1 TOWARD GENERATOR i CONTROLLER BOARD TBIA DLDD1DDDDO DDQD TBIB 21 "ouuuucrnuu LL_ PIN 111 71 (K20-s) A/C N/C . I IA A/C - MOTE 1000 6194 WIT DM1. I I TAPE __ WI• v (loll-Do) I • N/C 5 IAN (CRC) B N/C . IS (O3) IS N/C 17 N/C 18 N/C ) 3. 7 N/C IN N/C ON/C. 20 N /C ( RN/C. 21 N/C 11 10 STA (LCD) 22 N/C Ti N/C 23 N/C - I U i2 ICR (510-0) 24 220 (LCI) >GN0 BV II C I (PA 167 Q T-2 36 T27 _J I 41)T1FU1RC ZWESSU110 I) ----------------------------------------- - r r Ii 12 0 2241 33 II 38111161DB F 24111TO152 IA 4A14121163 S1 1 I 247 J ENS I (OPTIONAL) JUNCTION BOX CO (192-cR) Cl (IRS-Cl) —CD (193-C2) —CS (153-0) (Cow) - TO 2 1611 ,-7N O (P2-1) W41 (9R*)) op. 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(P37-43) INSUL6 ¶3 N/C (CAVITY PLUG) 30 N/C (CAVITY PLUG) 47 N/C (CAVITY PLUG) 64 BUY (BAIT A-(-)) 4 V14 (10612-3) 31 N/C (CAVITY PLUG) 48 N/C (CAVITY PLUG) AS '185 (3813-Fl) - - - _2 1 5 '115 (N3-87) 32 N/C (CAVITY PLUG) 49 N/C (CAVITY PLUG) 68 '1068 (1013-Fl) 020 (P27_AA)__C:)___UPlINs_IL ¶6 N/C (CAVITY PLUG) 33 N/C (CAVITY PLUG) 50 PVC (CAVITY PLUG) 67 BUY (BAIT A-(-)) 514P (24V ONLY) II N/C (CAVITY PLUG) 34 N/C (CAVITY PLUG) SI N/C (CAV11Y PLUG) 69 BUY (6671 A-(-)) GRN (P23 SULl_GpN )P3D) (EDO)— ft __TEL (P30-C)— (SS)-1 1 --UNIAS GO UNINS - - 56-20160 (QCON4)-9 ---O20 )P3O-E) — ) 12)-------- -----70 (TBli 7o)_ç wHumca I 230-400 KW 7 DECISION—MAKER 3+ CONTROLLER — DIAGRAM. WIRII 230— — a — (O 0-30 & 600 VOLT, W/SPUT ACTIVATOR DDEC V SERIES 60 TIER III _____________ 400 SERIES 60 KOHLER ALTERNATOR a 9-II-061 - GM398 Generator Accessories Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Line Circuit Breakers 20-2250 kW 09001 Standard Features The line circuit breaker interrupts the generator set output during a short circuit and protects the wiring when an overload occurs. Use the circuit breaker to manually disconnect the generator set from the load during generator set service. Circuit breaker kits are mounted to the generator set and are available standard with load-side lugs or bus bars and neutral bus bar. Kohler Co. offers a wide selection of molded-case line circuit breaker kits including single and dual configurations for each generator set. Four types of line circuit breakers are available: Single Circuit Breaker Kit with Neutral Bus Bar 20-300 kW Model Shown Magnetic trip Thermal magnetic trip Electronic trip Electronic with Ground Fault Circuit Interruption (GFCl) trip In addition, line circuit breakers are offered with 80% and 100% ratings (thermal magnetic available only in 80% rating). Single line circuit breaker kits allow circuit protection of the entire electrical system load. 14--Mll W • Dual line circuit breaker kits allow circuit protection of selected priority loads from the remaining L 0 0 0 electrical system load. Dual Circuit Breaker Kit with Neutral Bus Bar S Line circuit breakers comply with the following codes 20-300 kW Model Shown and standards unless otherwise stated. UL 489 Molded Case Circuit Breakers UL 1077 Supplementary Protectors UL 2200 Stationary Engine Generator Assemblies G6-88 10/07b Line Circuit Breaker Types Magnetic Trip The magnetic trip features an electromagnet in series with the load contacts and a moveable armature to activate the trip mechanism. When a sudden and excessive current such as a short circuit occurs, the electromagnet attracts the armature resulting in an instantaneous trip (UL 1077 circuit breakers). Thermal Magnetic Trip Thermal magnetic trip contains a thermal portion with a bimetallic strip that reacts to the heat produced from the load current. Excessive current causes it to bend sufficiently to trip the mechanism. The trip delay is dependant on the duration and excess of the overload current. Elements are factory- calibrated. A combination of both thermal and magnetic features allows a delayed trip on an overload and an instantaneous trip on a short circuit condition. Electronic Trip These line circuit breakers use electronic controls and miniature current transformers to monitor electrical currents and trip when preset limits are exceeded. Electronic with Ground Fault Trip The ground fault trip feature is commonly referred to as Ground Fault Circuit Interruption (GFCI). Models with GFCI compare current flow in phase and neutral lines, and trip when current unbalance exists. Ground fault trip units are an integral part of the circuit breaker and are not available as field-installable kits. The ground fault pickup switch sets the current level at which the circuit breaker will trip after the ground fault delay. Ground fault pickup values are based on circuit breaker sensor plug only and not on the rating plug multiplier. Changing the rating plug multiplier has no effect on the ground fault pickup values. 80% Rated Circuit Breaker Most molded-case circuit breakers are 80% rated devices. An 80% rated circuit breaker can only be applied at 80% of its rating for continuous loads as defined by NFPA 70. Circuit conductors used with 80% rated circuit breakers are required to be rated for 100% of the circuit breaker's rating. The 80% rated circuit breakers are typically at a lower cost than the 100% rated circuit breaker but load growth is limited. 100% Rated Circuit Breaker Applications where all UL and NEC restrictions are met can use 100% rated circuit breakers where 100% rated circuits can carry 100% of the circuit breaker and conductor current rating. The 100% rated circuit breakers are typically at a higher cost than the 80% rated circuit breaker but have load growth possibilities. When applying 100% rated circuit breakers, comply with the various restrictions including UL Standard 489 and NEC Section 210. If any of the 100% rated circuit breaker restrictions are not met, the circuit breaker becomes an 80% rated circuit breaker. Accessories U Alarm Switch The alarm switch indicates that the circuit breaker is in a tripped position caused by an overload, short circuit, ground fault, the operation of the shunt trip, an undervoltage trip, or the push-to- trip pushbutton. The alarm resets when the circuit breaker is reset. U Auxiliary Contacts These switches send a signal indicating whether the main circuit breaker contacts are in the open or closed position. U Bus Bars (units without circuit breakers installed) Bus bar kits are available on alternators with leads for connection to the generator set when circuit breakers are not ordered. Bus bar kits offer a convenient way to connect load leads to the generator set when a circuit breaker is not present. U Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. U Lockout Device (padlock attachment) This field-installable handle padlock attachment is available for manually operated circuit breakers. The attachment can accommodate three padlocks and will lock the circuit breaker in the OFF position only. J Neutral Lugs Various neutral lug sizes are available to accommodate multiple cable sizes for connection to the bus bar only. EJ Overcurrent Trip Switch The overcurrent trip switch indicates that the circuit breaker has tripped due to overload, ground fault, or short circuit and returns to the deenergized state when the circuit breaker is reset. U Undervoltage Trip, 12 VDC or 24 VDC The undervoltage trips the circuit breaker when the control voltage drops below the preset threshold of 35%-70% of the rated voltage. U Shunt Trip, 12 VDC or 24 VDC A shunt trip option provides a solenoid within the circuit breaker case that, when momentarily energized from a remote source, activates the trip mechanism. This feature allows the circuit breaker to be tripped by customer-selected faults such as alternator overload or overspeed. The circuit breaker must be reset locally after being tripped. Tripping has priority over manual or motor operator closing. U Shunt Trip Wiring Connects the shunt trip to the generator set controller. 66-88 10/07b Line Circuit Breaker Specifications 80% Rating Circuit Breaker 100% Rating Circuit Breaker Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Style 20-60 4P/40 30-100 Magnetic, UL 1077 E (480 V max.) Magnetic, UL 1077 with 12 V shunt trip Magnetic, UL 1077 with 24 V shunt trip 40-150 Thermal magnetic H 175-250 Thermal magnetic J 60-180 4S/4V 30-100 Magnetic, UL 1077 E (480V max.) Magnetic, UL 1077 with 12V shunt trip Magnetic, UL 1077 with 24 V shunt trip 40-150 Thermal magnetic H 175-250 Thermal magnetic J 300-400 Thermal magnetic L 600 Electronic D Electronic GFCI 700-600 Thermal magnetic M 800 Electronic 800 Electronic GFCI 200-300 4UA 40-150 Thermal magnetic H 175-250 Thermal magnetic J 300-400 Thermal magnetic L 600 Electronic 0 Electronic GFCI 700-800 Thermal magnetic M 1000-1200 Thermal magnetic P 800-1200 Electronic 800-1200 Electronic GFCI 350-900 (small ext. box) (no 5M4044) W/leads 300-400 Thermal magnetic L 600 Electronic D Electronic GFCI 700-800 Thermal magnetic M 1000-1200 Thermal magnetic P 800-1200 Electronic P Electronic GFCI 350-900 (large ext. box) (no 5M4044) * 4M/5M w/leads 1600-2500 Thermal magnetic R Electronic Electronic GFCI 1000-2250 and 900 kW with 5M4044 (large ext. box) *± 5M/7M w/bus bars 1200-2500 Thermal magnetic R Electronic Electronic GFCI C. B. Alt. Ampere Frame Gen. Set kW Model Range Trip Type Style Electronic 20-60 4P/40 150-400 D Electronic GFCI Electronic 150-400 ____________ D Electronic GFCI 60-180 4S/4V Electronic 600-800 P Electronic GFCI Electronic 150-400 D Electronic GFCI 200-300 4UA Electronic 600-1200 P Electronic GFCI Electronic 350-900 (small ext. box) (no 5M4044) 4M/5M w/leads 150-400 D Electronic GFCI 600-1200 Electronic Electronic GFCI Electronic 350-900 (large ext. box) (no 5M4044) *-;• 4M/5M w 1600-2500 R Electronic GFCI 3000 Electronic NW /leads Electronic GFCI 1000- 2250 and 900 kW with 5M4044 (large ext. box) 5M/7M wfbus bars 1200-2500 Electronic GFCI RElectronic 3000 Electronic NW Electronic GFCI Circuit Breaker Lugs Per Phase (Al/Cu) Frame Size Ampere Range Wire Range E (480 V max.) 30- 100 Up to two wire terminals fitting 10-32 or 1/4-20 stud H 40-150 One #14t03/0 175 One l/0to4/0 200-250 One 3/0 to 350 kcmil L 300-400 One #1 to 600 kcmil Al D 150-400 One #2 to 500 kcmil Al One #2 to 600 kcmil Cu 600 Two 2/0 to 350 kcmil Al Two 2/0 to 500 kcmil Cu M 700-800 Three 3/0 to 500 kcmil P 600-800 Three 3/0 to 500 kcmil 1000-1200 Four 3/0 to 500 kcmil R 1600-2500 (8) lugs per phase rated for (1) #4-600 kcmil or (2) 1/0-250 kcmil NW 3000 Available as front or rear facing circuit breaker on junction box. Front facing circuit breakers are not available on the 600-2000REOZM, 600-2000REOZMB, and 400-800RZW models Front facing circuit breakers for 450/50OREOZVB models are available for units with standard air cleaner and not with heavy-duty air cleaner. The 5M4044 is a 4-bus alternator and has bus-type mounting. G8-88 10/07b A generator set with a single circuit breaker installed typically feeds a single transfer switch and then a distribution panel. This allows protection of the entire system. KOHLER CO. Kohler, Wisconsin 53044 USA Phone 920-565-3381 Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Line Circuit Breaker Applications Single Circuit Breaker Installations Dual Circuit Breaker Installations A generator set with dual circuit breakers installed is used to segregate critical loads. Typically, one circuit breaker will feed a main transfer switch with noncritical loads and the other circuit breaker will feed a second transfer switch that feeds critical loads. First Second /0 Line C.B. Line C.B. ol 10 1 IATS1 IATS Distribution Distribution Panel Panel To Remaining To Priority Load(s) Building Loads Dual line circuit breaker configuration where first circuit breaker can trip allowing second circuit breaker to continue supplying power to priority load(s). Dual Circuit Breaker Combinations First Second Alternator C. B. Frame C. B. Frame Model Size Size Comments 4P/40/45/ H 4V/4UA j - 4S/4V/4UA L - 4P/4Q/4S/ D - 100% rating, standard or 4V/4UA GFCI M - 4S/4V/4UA 100% rating, standard or - GFCI 4P/40/4S/ H H 4V/4UA J H or J 4S/4V/4UA L H, J, or L 4P/4Q/ 4S/4V D H. J, L, or D 100% rating, no GFCI 4UA D J H, J, L, or D Primary or sec. available as _________ 100% rating, std. orGFCl 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 Kohlere generator set distributor for availability. First Second Alternator C. B. Frame C. B. Frame Model Size Size Comments 4S/4V M H, J, L, or D 100% rating, no GFCI 4UA M H, J, L, or D D available as GFCl 45/4V P H, J, L, or D 100% rating, no GFCI P H,J,L,orD P and/or 0 available as 4UA GFCl P P 100% rating, no GFCI Dual circuit breaker 4M/5M/7M All - configurations available as Engineered Specials DISTRIBUTED BY: C 2007 by Kohler Co. All rights reserved. G6 B810107h Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Float/Equalize Battery Charger 09001 Standard Features A1IOfiN11 LUI LSt 0 WARNING 61 D.C. A, C. OUTPUT INPUT o a \DCPWMETER TYPE ABC TYPE ABC 25A 120 VAC-7A 240 VAC-5A POWER 0 1O5 W 25 0 1•• 9 ____ 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. The ten amp DC current limit allows the battery charger to remain connected to the battery during engine cranking. Battery charger complies with NFPA 110 code requirements when equipped with optional alarm circuit board. Alarm board features low battery voltage, high battery voltage, and battery charger malfunction alarm contacts. Specifications Loose Battery Charger Kit No. Installed Battery Charger Kit Nos. NFPA 110 Alarm Outputs Output Number of Cells _______ Voltage Amps Lead Acid Ni-Cd PAD-292862 - No 12 10 6 9 PAD-292863 Yes PAD-292864 GM28562-KA2, -KA4 No 24 12 18 PAD-292865 GM28562-KA1 -KA3 Yes AC Input Voltage, Frequency 120/240 VAC, 50/60 Hz DC Voltage Regulation ±1% Weight (battery charger without mounting brackets) 11.8 kg (26 lb.) Dimensions, Lx D x H (battery charger without mounting brackets) 271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.) Note: Installed battery charger kits are available on selected generator set models. See your authorized distributor for availability. 66-15 5J05i 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. - Equalize Voltage Float Voltage 50% of High Rate 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. Time — O High Rate Constant Current Mode 0 Equalize Mode fl Float Mode Figure 1 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. Figure 2 G615 5/O5 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°C (-40°F) to 60°C (1400F). 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 10 amps up to the equalize voltage setting for fastest battery charging. Note: The battery charger will discharge the engine starting battery(ies) when the battery charger is connected to the battery(ies) and is not connected to an AC power supply. To prevent engine starting battery(ies) discharge, install battery charger relay kit GM39659. G615 /OSi KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381 Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada, phone 1-800-544-2444 Singapore 619159 Kohl erPowerSystems.com Phone (65) 6264-6422, Fax (65) 6264-6455 10.67 [271] - 7.00 [178] .500 DIA. X.219 DIA. [12.7 X 5.6] KEYHOLE 2 PLACES 5.63 [143] WARN RcL._............J .A. CU U) OR D.C. A.C. OUTPUT INPUT 0 5 0 () \DCMWNTEfl TYPE ABC TYPE ABC 25A 12000C.-7A 240 SAC-bA POWER 5 20 20 I . Cr:.- .... AC ____ TERMINAL - . BLOCK 2356 -.II:B cm AU) DC TERMINAL BLOCK SENSE 1 OUTPUT VIEW B—B A CUSTOMER CONNECTIONS LV - N.C. 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 7.00 [178] .25 [6] DIA. (2 HOLES) CUSTOMER INPUT CONNECTIONS CUSTOMER OUTPUT CONNECTIONS AC TERMINAL BLOCK DC TERMINAL BLOCK 120 VOLT INPUT 240 VOLT INPUT BATTERY SENSING CONNECTORS _____ 000000 1500000 IF CHAUGER OUTPUT LEADS ARE LONGER THAN 15 FT., / / " \DISCONNECT TERMINAL BLOCK JUMPERS AND RUN SEPARATE r NSE LEADS TO BATTERY. SE MINIMUM 1000. WIRE. I USE GRD . [GOD ,—UATTERYCONNCCSETNS 0 5 0 0 5 0 II II / POS.A NYU. IJSF I I MII&100A.WIRE. NOTE: BATTERY CHOWDER IS CONNECTED 0 FOR 120 VOLT INPUT AS STMIOARD. WIRED MOOT BE REPOSITIONED AS - - DENSE OUTPUT SHOWN TO CORRECT TO 225 VOLT INPUT. AC INPUT FUSE MUST BE CHANGED TO AGREE AS SHOWN BELOW. FUSE SUPPLIED. I NOTE: FOR DC CONNECTIONS INPUT FUSE USE STRANDED COPPER WIRE, 00v 105%1ZIC VINYL PLASTIC 20 VAC 10, TYPE ABC INSULATION. UL STYLE TOTS, 220 VAC 50, TYPE 000 233980 Availability is subject to change without notice. Kohler Co. reserves the right to change the design or Specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler generator set VIEW A-A OPTIONAL ALARM BOARD RU ADJ. LV ATE. LEDD ..- LED' c) 0 LjL10 ® ADV-5971 DISTRIBUTED BY: Bay City Electric Works 12208 Industry Road Lakeside, CA 92040 619-938-8200 distributor for availability. 91 1992. 1993.1994:19W 1999.2003; 2005 by Kohler Co. All rights reserved. G6-15 5f05i III LJ E1 io 90 'C OPTIONAL BOARD I L ALARM BOARD NOTE WHEN CHANGING AC INPUT VOLTAGE, THE AC INPUT FUSE MUST BE CHANGED TO AGREE AS SHOWN BELOW. INPUT FUSE 120 VAC 7A, TYPE ABC 240 VAC BA. TYPE ABC I IA Dl I 7 SCHEMATIC 90 82 82 83 141 G21 a Ii 50 lj CN 90 o CO0L OPTIONAL BOARD ALARM BOARD 6&I 240 VAC-5A 120 VAC-7A 25A DC AMPS. 1::-i AC FUSE DC FUSE BACK PANEL T RIGHT SIDE SFORMER SCR MODULE FF 91 1 DC VOLTS POWER ON TRANSFORMER 4 '' 0TR11~— G2 CP r — 5CR Ii I 2 (RED) (eLK) P N __ _____ 2 fl MODULE B D 83 C OUTPUT FUSE 25A AC INPUT FUSE 120 VAC-7A 240 VAC SA n Al 120 V. INPUT I C TERtNAL [Io: ( I I RED) - I )__ L BLACK—. B4 RED TERNA ------------------------------ DC CUSTOMER INPUT CONNECTIONS 120 VOLT INPUT 240 VOLT INPUT àOóoô AC ôôo 2 5 4 s TERMINAL 2 S 4 5 iCl 0 l CKio 1 ! ?=, GROUND GROUND FS LUG 5 LUG I I I 0000 AUTO-FLOAT 24 VOLT BATTERY CHARGER 1 9 Industrial Generator Set Accessories KOHLERPOWER SYSTEMS System Batteries 09001 Typical Overall Dimensions - W - Kohler Co. selects batteries to meet the engine manufacturer's specifications and to comply with NFPA requirements for engine- cranking cycles. Heavy-duty starting batteries are the most cost-effective means of engine cranking and provide excellent reliability in generator set applications. Batteries are rated according to SAE standard J-537. All batteries are 12-volt and have lead-calcium or lead-antimony plates with sulfuric acid electrolyte. Most generator set battery kits offer dry-charged or wet-charged batteries. Tough polypropylene cases protect against life-shortening vibration and impact damage. Removable cell covers allow checking of electrolyte specific gravity. Battery Specifications Battery Post Layouts A—C and Styles 1-2 A 40 1 80 o Positive, 17.48 dia. Negative, 15.88 dia. B ____________ 15.88 height 31 Post 1:9 taper C1 24F7 2 °I 12.7-19.1 height 3/8-16 UNC-2A thread Notes: Dimensions are in mm; 25.4 mm equals 1 inch. BCI group numbers shown in italics. Order stud kit 254427 to convert from Style 2 to Style 1. G6-16 2/09w Use the tables to find the Battery Kit Number and Charge Type for your model and then go to the System Batteries Specifications table on the last page for battery specifications. Batteries are for applications below and above 0°C (320F). Gas Models with 12-Volt Engine Electrical Systems Models Charge Type Battery Kit Number 25RZGB Wet PA-256985 30RZG Wet PA-256985 30RZGB Wet PA-256985 35RZG Wet PA-256985 45RZG Wet PA-256985 50RZGB Wet PA-256965 60RZG Wet PA-256985 8ORZG Wet PA-256985 100RZG Wet PA-256985 125RZG Wet PA-256985 150RZGB Wet PA-256985 Diesel Models with 12-Volt Engine Electrical Systems Models Charge Type Battery Kit Number 1OREOD/REODBt Wet PA-256985 10REOD/REODBt Dry PA-225290 1OREOZD/REOZDBt Wet PA-256985 10REOZDIREOZDBt Dry PA-225290 I5REoD/REoDBt Wet PA-256985 15REOD/REODBt Dry PA-225290 15REOZD/REOZDBt Wet PA-256985 15REOZD/REOZDBt Dry PA-225290 20REOD/REODBt Wet PA-256985 20REOD/REODBt Dry PA-225290 20REOZD/REOZDBt Wet PA-256985 20REOZD/REOZDBt Dry PA-225290 20ROZJB Wet PA-256985 20REOZJB Wet PA-256985 20REOZJC Wet PA-256985 30REOZJB Wet PA-256985 30REOZJC Wet PA-256985 40REOZJB Wet PA-256985 40REOZJC Wet PA-256985 50REOZJB Wet PA-256985 50REOZJC Wet PA-256985 60REOZJB Wet PA-256985 60REOZJC Wet PA-256985 BOREOZJB Wet PA-256985 SOREOZJC Wet PA-256985 80REOZJD Wet PA-256985 100REOZJB Wet PA-336692 100REOZJC Wet PA-256985 IOOREOZJD Wet PA-256985 125REOZJB Wet PA-336692 125REOZJD Wet PA-336692 I50REOZJB Wet PA-336692 150REOZJD Wet PA-336692 180REOZJB Wet PA-336692 180REOZJC Wet PA-336692 t Service kit GM40633 may be required when the original battery is replaced. See Service Bulletin SB-658. Gas Models with 24-Volt Engine Electrical Systems Models Charge Type Battery Kit Number 400RZW Dry GM22297-KP1 400RZW Wet GM34404-KP1 600RZW Dry GM22297-KP1 600RZW Wet GM34404-KP1 800RZW Dry GM22297-KP1 800RZW Wet GM34404-KP1 Diesel Models with 24-Volt Engine Electrical Systems Models Charge Type Battery Kit Number Single Starter Motors 50REOZJB Wet PA-336071 60REOZJB Wet PA-336071 80REOZJB Wet PA.336071 BOREOZJC Wet PA-336071 80REOZJD Wet PA-336071 100REOZJB Wet PA-336071 100REOZJC Wet PA-336071 100REOZJD Wet PA-336071 125REOZJB Wet PA-336071 125REOZJD Wet PA-336071 135REOZJC Wet PA-336071 150REOZJB Wet PA-336071 150REOZJC Wet PA-336071 15OREOZJD Wet PA-336071 18OREOZJB Wet PA-336071 180REOZJC Wet PA-336071 1 BOREOZJD Wet PA-324588 200REOZJB Wet PA-336071 200REOZJC Wet PA-324588 200REOZJD Wet PA-324588 230REOZDB Wet PA-324588 230REOZDD Wet PA-324588 230REOZJB Wet PA-336071 230REOZJD Wet PA-324588 250REOZDB Wet PA-324588 250REOZDD Wet PA-324588 250REOZJC Wet PA-324588 250REOZJD Wet PA-324588 275IREOZDB Wet PA-324588 275REOZDD Wet PA-324588 275REOZJD Wet PA-324588 275REOZV Wet PA-324588 300REOZDB Wet PA-324588 300REOZDD Wet PA-324585 300REOZV Wet PA-324588 350REOZDC Wet PA-324588 350REOZDD Wet PA-324588 350REOZVC Wet PA-324588 400REOZDC Wet PA-324588 400REOZDD Wet PA-324588 400REOZVC Wet PA-324588 550REOZV Wet PA-324588 600REOZM Wet PA-324588 600REOZM Wet PA-354065 600REOZMB Wet PA-324588 600REOZMB Wet PA-354065 600REOZV Wet PA-324588 06-16 2/09w KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPower.com Phone (65) 6264-6422, Fax (65) 6264-6455 System Batteries Specifications Battery Kit Number Charge Type* Battery Part Number Battery Oty. per Kit BCI Group Size Battery SAE Dimensions mm (in.) L W H Cold Cranking Amps at -18°C (0°F) Minimum Reserve Capacity Minutes at 27°C (80°F) Minimum Battery Post Layout and Style 324586 2 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 185 B/2 GM14225-KP3I: Wet 256984 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 120 C/i GM22297-KP1 Dry GM22349 2 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 A/1 GM28546-KP1 Dry GM22349 4 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 All GM34404-KP1 Wet GM34399 2 SD 527.1 (20,8) 282.4 (11.1) 276.4 (10.9) 1150 400 Ni GM34405-KP1 Wet GM34399 4 8D 527.1 (208) 282.4 (11.1) 276.4 (10.9) 1150 400 Ni PA-225290 Dry 225289 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 130 C/1 PA-256985 Wet 256984 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 120 C/1 PA-324588 Wet 324586 2 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 185 8/2 PA-324589 Dry 324587 2 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 200 8/2 PA-336071 Wet 256984 2 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 120 C/1 PA-336692 Wet 324586 1 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 185 8/2 PA-354065 Wet 354147 4 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 700 170 B/2 PA-354066 Dry 354148 4 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 700 150 8/2 * Charge type: Dry-charged batteries do not contain electrolyte. Supply and add electrolyte per instructions enclosed with each kit. Wet-charged batteries contain electrolyte and have removable covers. This battery kit contains three batteries, two batteries for the 24-volt engine starting system and one battery dedicated to the engine ECM. 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® generator set distributor for availability. Bay City Electric Works 12208 industry Road Lakeside, CA 92040 619-938-8200 © 2001. 2002. 2003, 2004, 2005, 2006: 2007: 2008, 2009 by Kohler Co. All rights reserved. G6-16 2/09w JUNCTION BOX I 1 5060IWL. 1mxaoOT (loan] I OPTIONAL OPTIONAL CUSTOMER CONNECTION KIT 4.-n-ON I F 4-41*0 ICIUL004 NOTE A I56N6) STE NOTT N (50040] It Lii collw"RELAY KIT .- NOTE: TRANSFER SWITCH TERMINAL OESIGNA11O OUT K1 MAY VARY FROM THOSE SHOWN HERE. VERtI CONSCECYONS THE CORRECT DESIGNATIONS USING THE APP- ,j I ROPRIATE TRANSFER SWITCH WIRING DIAGRAM. OPTIONAL REMOTE (TERMINALS 3 AND 4, REMOTE I I START START/STOP SWITCH OR ENGINE START OPTIONAL SWITCH CONTACTS ON TRANSFER SWITCH) COMMON A/V (TERMINAL 63, LOW FUEL LEVEL SWITCH ALARM CONNECTIONS I LOCATED IN MAIN TANK OR 32 J LOW FUEL PRESSURE SWITCH) BATTERY — I I I I - - - __1__a.GROUND OPTIONAL BATTERY I -_ I CHARGER CONNECTIONS - 6) BAIT. CHARGER FAULT BATTERY VOLTS FOR REMOTE ((OH BATTERY VOLTS ANNUNCIATOR — - - — - - — - - 27 SEE SHED 2 OF 2 —ILL I - - - RELAY CONTACTS - - - - - - — 4- 2 4 OPTIONAL 11 ô RUN ; CONNECTIONS :i Gg ED IN OPTIONAL EMERGENCY KIT CONNECTIONS TB2 BLACK i_.---------. P0) BATTERY OLTAGE PE SENT ________________ I I I STANDARD ON DDC) R I I I II I 2 GROUND I I ----------------------------------------------------------------------_______ TA EMERGENCY-STOP RELAY K45 COIL. NEGATIVE I I I I I I I ________ OPTIONAL I 42A BATTERY VOLTAGE (FUSE PROTECTED) I I CONTROLLER BOARD 3 ONE ISOLATED ALARM I CONTACT 70C GENERATOR IN COOLOOWN I I I I A KIT CONNECTIONS I TERMINAL ID. DESCRIPTION I I (OPTIONAL LOCAL EMENEI,LNL.T sIuv: 5N (24 i I I __________ OUT OVERSPEED B 70R GENERATOR RUNNING I I I I I EMERGENCY-STOP RELAY (K4\ GROUND I NA A I I I 328 COMMON FAULT LINE 2 (ACTIVATED BY: E-STOP, I I I I CIRCULATING ly PUMP BLOCK AUG. OS, LOP, NET. FAULTS) I I INDICATOR PANEL I 3 REMOTE START GROUND 9 CRANK MODE (OPENACYCLE GROUNDCONUOUS) L - - - - - - CONTROLLER METER BOX - - - - - - - ASSEMBLY I 4 REMOTE START (ACTIVE LOW) L 270, -'i (TYPICAL I HEATER _( CONNECTION) I NA CRANK MODE GROUND C PRIME POWER OPERATION 12 OVERCRAT4I< INDICATOR I NC 26 AUXILIARY INDICATOR I STANDARD HDP, LOP, LOPP. OS, L. DC, LA, AUX. AD, NIA FAULTS) I - - - - - - - - CONTROL BOARD TB2 32 COMMON FAULT/PREALARM LINE T (ACTIVATED BY: HET. ' CONTROLLER ______________________________________________________________ p PLACE JUMPERS ACROSS T82-TP 3P & TB2-4 TO TB2-3. TO POWER- 2P TO T82-2P. TB2-3P TO TB2-4P 36 HIGH ENGINE TEMPERATURE INDICATOR I 38 LOW OIL PRESSURE INDICATOR I I DRY CONTACT KIT 2 39 35 26 56 40 41 48 I (f1 DOWN CONTROLLER PLACE I (51 GENERATOR MASTER SWITCH IN 39 OVERSPEED INDICATOR I IIII INPUT 55 AIR DAMPER INDICATOR I _________________________________________ I 51 "OFF/RESET. TO START GENERATOR, 60 SYSTEM READY INDICATOR ____________________________________________ 4 (51.. MOVE MASTER SWITCH TO AUTO" TO BATTERY VOLTAGE (RUN ONLY) I 3 " POSITION. TN GROUND I SO NOT 114 AUTO INDICATOR I I 41 PRE -ALARM LOW OIL PRESSURE INDICATOR I OPTION ADDITIONS OUT Ki OUT K2 OUT K3 O K4 OUT KS OUT K6 OUT K7 OUT KB OUT K9 UT K] I RECOMMENDED UNLESS OTHERWISE NOTED ON ThI ___________________ INSTALLATION NOTE: 33 LOW WATER TEMPERATURE I FOR FIELD INSTALLATION A MAXIMUM OF TWO WIRI 40 RE ALARM HIGH ENGINE TEMPERATURE INDICATOR I- PRE-ALARM FUNCTION ________ I TERMINALS PER TERMINAL STRIP SCREW IS 38 LINE POWER TRANSFER SWITCH OPTION AOOTEONS WIRING DIAGRAM. DO NOT EXTEND ABOVE THE A 59 GENERATOR POWER 27 HIGH BATTERY VOLTAGE (ACTIVE LOW) NFPA [ NO NC C I NO NC C I NO AC C I NO NC C I NO NC C NO NC C NO NC C I NO NC C I NO NC C NO NC C TERMINAL STRIP BARRIER. 48 EMERGENCY-STOP INDICATOR ST BATTERY CHARGER FAULT (ACTIVE LOW) H 62 LOW BATTERY VOLTS (ACTIVE LOW) OPTION ADDITIONS I OVERSPEED OVERCRANK NIGH ENGINE LOW OIL LOW WATER AUXILIARY AIR PRE-ALARM PRE-ALARM EMERGENCY 53 LOW F U EL (ACTIVE LOW) I HLERCQ TEMPERATURE PRESSURE TEMPERATURE FAULT DAMPER HIGH ENGINE LOW OIL I P PRIME POWER OPERATION 2P PRIME POWER OPERATION 3P PRIME POWER OPERATION - OPTION ADDITIONS L. - - - - - - TEN ISOLATED ALARM CONTACTS KIT CONNECTIONS TEMPERATURE PRESSUREOPTIONAL — - (TYPICAL CONNECTIONS) INTERCONNEdTION PRIME POWER OPERATION DEC 3+ ACCESSORIES I h/ 404Nl20 I.- MUST HAVE JUMPER IF THERE IS NO EMERGENCY STOP KIT CONNECTIONS. 20160OKW Io—sa.—ooI'4- 32B912 I 4 NOTE: INSTALLATION NOTE: LEAD N CONNECTION: CONNECT LEAD N TO ENGINE BLOCK GROUND. FOR FIELD INSTALLATION A MAXIMUM OF TWO WIRE LEAD P CONNECTION: TERMINALS PER TERMINAL STRIP SCREW IS PREFERRED- CONNECT LEAD P TO TERMINAL WITH P WIRES RECOMMENDED UNLESS OTHERWISE NOTED ON THE ON CRANK RELAY. WIRING DIAGRAM. DO NOT EXTEND ABOVE THE ALTERNATE - CONNECT LEAD P TO BATTERY POSITIVE (+) TERMINAL TERMINAL STRIP BARRIER. ON STARTER SOLENOID. USE WIRE HARNESS PROVIDED, CUT AND TERMINATE AS REQUIRED. vi OPTIONAL DECISION MONITOR CONNECTIONS 10-IWO M ID-I) 1WO 161 011 1000 00231 'S WIRING HARNESS TO CONTROLLER BOARD, CUSTOMER INTERCONNECTION KIT, OR INNER PANEL TERMINAL BLOCK. IAUXILLARY CONTACTS MOUNTED I ON TRANSFER SWITCH 10 CONTACTOR ASSEMBLY. I II I DO NOT APPLY ANY VOLTAGE I 1 TO THESE CONTACTS.NC NOTE: TRANSFER SWITCH TERMINAL DESIGNATIONS MAY RY VARY FROM THOSE SHOWN HERE. VERIFY THE CORRECT c I DESIGNATIONS USING THE APPROPRIATE LISFER SWITCH WIRA4G DIAGRAM - - - REMOTE ANNUNCIATOR I DRY CONTACT BOX MOUNTED AT DEN 42 2 39 12 36 38 26 60 80 41 48 61 62 63 35 40 I 6 I 8 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I 6 I INPUT C'J t rs t 1 W £ 0 0 t fl t — .- * 1<7 1<6 I 1<9 I 1<10 1<11 I 1<12 I 1<13 I 1<14 41 48 61 62 63 35 40 r OPTIONAL DECISION MONITOR CONNECTIC TERMINAL ID. DESCRIPTION 1 EMERGENCY-STOP RELAY (K41 GROUND 1A EMERGENCY-STOP RELAY K4S COIL NEGATIVE 42A BATTERY VOLTAGE (FUSE PROTECTED) 2 GROUND 70C GENERATOR IN COOLOOWN 70R GENERATOR RUNNING 9 32A COMMON FAULT LINE 2 (ACTIVATED BY: E-STOP, AUX, OS, LOP. HET FAULTS) 3 REMOTE START GROUND 4 REMOTE START (ACTIVE LOW) 9 CRANK MODE (OPEN-CYCLE GROUND-CONTINUOUS) STANDARD 9A CRANK MODE GROUND - CONTROLLER 12 OVERCRANI< INDICATOR 26 AUXILIARY INDICATOR 32 COMMON FAULT/PRE,ALARM LINE 1 (ACTIVATED BY: NET. HElP. LOP, LOPP. OS. LWT. CC. LF, AUX. AD, N&A FAULTS) 36 HIGH ENGINE TEMPERATURE INDICATOR 38 LOW OIL PRESSURE INDIC.ATI'IR 39 OVERSPEED INDICATOR 56 AIR DAMPER INDICATOR 60 SYSTEM READY INDICATOR 70 BATTERY VOLTAGE (RUN ONLY) 714 GROUND 80 NOT IN AUTO INDICATOR 35 LOW WATER TEMPERATURE I PRE-ALARM FUNC 40 " PRE-ALARM HIGH ENGINE TEMPERATURE INDICATOR OPTION ADDITIONS 41 PRE-ALARM LOW OIL PRESSURE INDICATOR 58 LINE POWER TRANSFER SWITCH 59 GENERATOR POWER OPTION ADDITIONS A 48 EMERGENCY-STOP INDICATOR 51 BATTERY CHARGER FAULT (ACTIVE LOW) I NFPA 52 LOW BATTERY VOLTS (ACTIVE LOW) OPTION ADDITIONS 63 LOW FUEL (ACTIVE LOW) 1P PRIME POWER OPERATION 2P 3P PRIME POWER OPERATION PRIME POWER OPERATION OPTION ADDITIONS 4P PRIME POWER OPERATION CUSTOMER SUPPUED WIRES #N & 142B WIRE REQUIRE 100 Fl. - 18-20 GA. 500 FT. - 14 GA. 1000 FT. - 10 GA. SIGNAL WIRES 18-20 GA. TO 1000 FT. NOTE: IF ADDmONAL LOAD IS ADDED RESIZE N & 428 AS REQUIRED ANNUNCIATOR FUSE BLOCK 10 AMP on DEC 3+ 3+ ACCESSORIES 20-2000 KW " 14 RELAY DRY CONTACT/DECISION MONITOR KIT - 1 3 1 2 ii• DCC 3+ CONTROLLER' CXI )j 1jJ11iIJ11]ij 7,17 1717 Id11iiJi Ii I Iiij, TRIP tI1.IItla4'* I- 1 H pw.Iowu_{ PRK powat !a iI:;: 00 twa PT at000O1 ------------------------------- 000000 000000 1800000 METER/CONTROLLER BOX -1--- 20 ' RELAY DRY CONTACT KIT D IJIDIDIDIIJKIDID ME I XIEXIEZIEZICZIIXIEZIEZIUIUJ IlU II ri Elm OECTRONIC GDAEERO1 SPEEGTRflROLi C SAFEGUARD I I TERMINAL RLXK I L J ------------- 2000/201000R I - AOLTACE REGULATOR IIB1 ; 1IIIIIIIIII I LJUNC.TTONBOX J I s um [ft XIV twWNT XIMOI RI - TUE. NT = TOW WATER 10 ii 1 01 00 if1 00L01 TI'rl'rl I TEl II 0I*IVI0IhI '*44*'* : a CXC TIER IF - COXIOW FONT NT - NT - ERRS TORSMTE 010 -wow— - INSTALLATION NOTE: FOR FIELD INSTALLATION A MAXIMUM OF TWO WIRE TERMINALS PER TERMINAL STRIP SCREW IS RECOMMENDED UNLESS OTHERWISE NOTED ON THE WIRING DIAGRAM. DO NOT EXTEND ABOVE THE A TERMINAL STRIP BARRIER. L DEC 3+ 300-1800KW TWENTY RELAY DRY CONTACT KIT 2 Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Silencers and Exhaust Systems 09001 jr KOHLER — Ji'!fF NAflOIALLY C:j Legend Use the information below for identifying the exhaust system components shown in the illustrations on the following pages. Side Inlet End Outlet (SlEO) FSIE0 End Inlet End Outlet (EIEO) EIEO Flex Exhaust Jflli1tJ I Flex Exhaust (wye) Kohler Co. offers silencers rated for hospital, critical, residential, and industrial applications and stainless steel flexible exhaust connectors for unhoused generator sets. The accessories described in this spec sheet apply to open units unless otherwise stated. These silencers withstand exhaust flow pressure and temperature without creating excessive engine backpressure. Silencer Noise Ambient Silencing Type Reduction dB(A) Noise Level Requirement Hospital 32-42 Low Very High Critical 25-35 Low High Residential 18-25 Low-Medium Medium Industrial 12-18 Medium-High Low-Medium Silencer and Exhaust System Selection Select the silencer based on the required degree of exhaust noise reduction using the four silencer ratings in the table above. In addition, select the silencer inlet/ outlet type using the legend descriptions. Note: Some generator set models may not offer all exhaust system combinations. Use the illustrations on the following pages to select the available silencer type and exhaust system configuration best suited for your application. Refer to your authorized distributor/dealer for silencer and component kit numbers and for silencer dimensions. Backpressure Considerations Consult the generator set spec sheet to determine the maximum allowable exhaust backpressure. Add the backpressure produced by the silencer and exhaust piping together to determine the total exhaust system backpressure. Contact an authorized distributor/dealer to calculate backpressure in the exhaust piping. Do not exceed the maximum allowable backpressure. G6-39 2/09x Page 1 Table of Contents Model Page Gas 25RZGB —i-- 3ORZG 3ORZGB 3 35RZG ii 45RZG —p--- 5ORZGB 6ORZG 3 BORZG 100RZG —3--- 125RZG 3 150RZGB 400RZW 3 600RZW ii 800RZW 3 Model Page Diesel 2OROZJB 2OREOZJB 4 2OREOZJC 4 3OREOZJB 30REOZJC 4OREOZJB 4 40REOZJC ii 5OREOZJB 4 50REOZJC ii 60REOZJB ±____ 60REOZJC i___ 8OREOZJB 4 8OREOZJC 8OREOZJD 4 100REOZJB 5 IOOREOZJC 4 100REOZJD 4 125REOZJB 5 125REOZJD 5 135REOZJC 5 150REOZJB 5 150REOZJC 5 150REOZJD 5 180REOZJB 5 18OREOZJC 5 18OREOZJD 5 200REOZJB 5 200REOZJC 5 200REOZJD 5 230REOZDB 6 230REOZDD 6 230REOZJB 5 230REOZJD 5 250REOZD8 6 250REOZDD 6 250REOZJC 5 25OREOZJD 5 275REOZDB 6 275REOZDD 6 275REOZJD 5 275REOZV 7 300REOZDB 300REOZDD 300REOZV 35OREOZDC 3SOREOZDD 3SOREOZVC 400REOZDC 400REOZDD 6 Model Page Diesel, continued 400REOZVC 7 4SOREOZDB 4SOREOZDD 450REOZVB 7 500REOZVB 550REOZV i___ 600REOZM 11 600REOZMB 11 600REOZV 7_ 650REOZDB 8 650REOZDC 9 700REOZDD 750REOZDB 8 75OREOZDC 7SOREOZM 11 75OREOZMB 11 BOOREOZDB 8 BOOREOZDD 9 BOOREOZM 11 800REOZMB 11 900REOZDB 8 900REOZDC 900REOZDD 900REOZM 11 900REOZMB 11 1000REOZDB 8 1000REOZDC 9 1000REOZDD 9 1000REOZM 11 100OREOZMB 11 1250REOZDC 10 1250REOZM 11 1250REOZMB 11 150OREOZDB 8 1500REOZDC 10 1600REOZM 11 1600REOZMB 11 1750REOZDC 10 1750REOZMB 11 1820REOZM 11 2000REOZDB 8 2000REOZDC 10 2000REOZM 11 2000REOZMB 11 2250REOZDC 10 250OREOZDB 10 2800REOZDB 10 3000REOZD 10 3250REOZD 10 G6-39 2/09x Page 2 Diesel 230-300REOZDB 230-275REOZDB em Exhaust System Kits City. in Kit Size, In/Out 1 r 1 Flex Exhaust, 6" or 6" * I - 2 Weld Flange, 6" or 8' t 2 - 3 Hospital Silencer EIEO 1 8" 4 Hospital Silencer SIEO 1 8" 3 Critical Silencer EIEO 1 6" 4 Critical Silencer SIEO 1 6" 3 Residential Silencer EIEO 1 6" 4 Residential Silencer SIEO 1 6" 3 Industrial Silencer EIEO 1 6' 4 Industrial Silencer SIEO 1 6" 300REOZDB Item Exhaust System Kits Qty. in Kit Size, In/Out 1 Flex Exhaust, 8" * 1 - 2 Weld Flange, 8" -t 2 - 3 Hospital Silencer EIEO 1 8" 4 Hospital Silencer SIEO 1 8" 3 Critical Silencer EIEO 1 8" 4 Critical Silencer SIEO 1 8" 3 Residential Silencer EIEO 1 8" 4 Residential Silencer SIEO 1 8" 3 Industrial Silencer EIEO 1 8" 4 Industrial Silencer SIEO 1 8" * Kit includes exhaust clamp. One kit includes (2) exhaust flanges, (2) gaskets, and the mounting hardware. See Weld Flange Kits for additional data. 2 EIEO__ / 2( \3 HH 1i SIEO 4 230-45OREOZDD, 350/400REOZDC, and 450REOZDB F7 2 2KH SIEO Item Exhaust System Kits Oty. in Kit Size, In/Out 1 Flex Exhaust, 8" * 1 - 2 Weld Flange, 8" t 2 - 3 Hospital Silencer SIEO 1 8" 3 1 Critical Silencer SIEO 1 8" * Kit includes exhaust clamp and kits for 400REOZDC/45OREOZDB include an insulation blanket. T One kit includes (2) exhaust flanges, (2) gaskets, and the mounting hardware. See Weld Flange Kits for additional data. 66-39 2/09x Page 6 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Weld Flange Kits Use the weld flange kit to connect the exhaust silencer to customer-supplied exhaust pipe. One weld flange kit includes two exhaust flanges, two gaskets, and the mounting hardware. A Angle Bolt circle diameter C Outside diameter D Quantity of bolts, bolt hole diameter G&, 70___ Weld Flange Dimensions (3asKet and mounting hardware Silencer Customer-supplied exhaust pipe ANSI Class 150_ Flange _Dimensions Nominal Pipe Size, in. A deg. B mm (in.) C mm (in.) D Qty., mm (in.) 5 45 215.90 (8.50) 254.0 (10.0) 8,22.23 (0.88) 6 45 241.30 (9.50) 279.4 (11.0) 8,22.23 (0.88) 8 45 298.45 (11.75) 342.9 (13.5) 8,22.23 (0.88) 10 30 361.95 (14.25) 406.4 (16.0) 12,25.40 (1.00) 12 30 431.80 (17.00) 482.6 (19.0) 12,25.40 (1.00) 14 30 476.25 (18.75) 533.4 (21.0) 12,28.58 (1.13) 16 225 539.75 (21.25) 596.9 (23.5) 16,28.58 (1.13) 18 225 577.85 (22.75) 635.0 (25.0) 16,31.75 (1.25) 20 18 1 635.00 (25.00) 698.5 (27.5) 20,31.75 (1.25) Gasket Weld flange I Weld flange Customer-supplied exhaust pipe Weld flange Gasket and mounting hardware Flex exhaust Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler® generator set distributor for availability. DISTRIBUTED BY: Bay City Electric Works 12208 Industry Road Lakeside, CA 92040 619-938-8200 © 2001, 2002. 2003, 2004, 2005, 2006: 2007, 2008, 2009 by Kohler Co All rights reserved. G6-39 2/09x Page 12 - =-' .o iillj E 550 Controller with Menu-Driven Integral Voltage Regulator Digital DVR® 2000E Voltage Regulator Fast-Response'II PMG/RMS Voltage Regulator (RMS Voltage Regulator Circuit Board Shown) Industrial Generator Set Accessories 20 2800 kW Industrial Generator KOHLERPOWER SYSTEMS Set Voltage Regulators 09001 KOHLP VL g - .!.a L.LLj Fast-Response" Ill Voltage Regulator Voltage Regulators The following information provides general features, specifications, and functions of available voltage regulators. This information generally applies to a single generator set and multiple generator sets with paralleling applications. Refer to the respective generator set specification sheet and see your authorized distributor for information regarding specific voltage regulator applications and availability. Integral Voltage Regulator with Kohler® DecisionMaker®550 Controller and Menu-Driven Selections (20-2800 kW Generator Set Models) The voltage regulator is integral to the controller and uses microprocessor logic providing ±0.25% no-load to full-load regulation using root-mean-square (RMS) voltage sensing. The voltage regulator features three-phase sensing and is available for 12- or 24-volt engine electrical systems. Digital DVR® 2000E Voltage Regulator (350-2000 kW Generator Set Models) The digital voltage regulator has ±0.25% no-load to full-load regulation using RMS voltage sensing. The voltage regulator features three-phase sensing and is available for 12- or 24-volt engine electrical systems. Fast Response' II PMG with Average Voltage Sensing Voltage Regulator (20-300 kW Generator Set Models) The solid-state voltage regulator has ±2% no-load to full-load regulation using average voltage sensing. The voltage regulator features single- or three-phase sensing options and is available for 12- or 24-volt engine electrical systems. Available with optional ±1% no-load to full-load regulation using average single-phase voltage sensing. Fast Response II PMG with RMS Sensing Voltage Regulator (20-300 kW Generator Set Models) The solid-state voltage regulator has ±0.5% no-load to full-load regulation using RMS voltage sensing. The voltage regulator features single- or three-phase sensing options and is available for 12- or 24-volt engine electrical systems. Not available on all models. Fast Response Ill with Average Voltage Sensing Voltage Regulator (20-300 kW Generator Set Models) The solid-state voltage regulator has ±0.25% no-load to full-load regulation using average voltage sensing. The voltage regulator features single-phase sensing and is available for 12- or 24-volt engine electrical systems. Available with the wound-field alternator only. OVA0- is a registered trademark of Marathon Electric Mfg Corp. G6-58 12j05b Specifications and Features Voltage Regulator Type Integral with 550 Fast Fast Response" II Fast Specification/Feature Controller Digital DVR® 2000E Response" II w/RMS Sensing Response" Ill Generator Set Availability 20-2800 kW Models 350-2000 kW Models 20-300 kW Selected 20-300 kW 20-400 kW Models Models Models Type Microprocessor based Analog/Discrete Status and Shutdown LEDs and Digital [ LEDs - DC Power LED Power + Shutdown Indicators Display LEDs Operating Temperature -40°C to 70°C (-40°F to 158°F) Storage Temperature -40°C to 851C (-40°F to 158°F) Humidity 5-95% MIL-STD-750, Method NA Non-Condensing 711-1 C Compliant Non-Condensing Circuit Protection Solid-State, Redundant Software and Fuses 5 Amp Fuse 15 Amp Fuse 10 Amp Fuse Sensing, Nominal 100-240 Volts (L-N), 95-600 Volts (L-L), 190-277 Volts, (L-L) 100-160 Volts (L-N), 190-277 Volts, (L- L) 50-60 Hz 25-420 Hz 50-60 Hz 50-60 Hz 50-60 Hz Sensing Mode RMS, Single- or 3-Phase Average, Single- or RMS, Single- or Average, 1-Phase Three-Phase 3-Phase Input Requirements 8-36 VDC 180-240 VAC, 200-360 Hz (PMG) 8-32 VDC 9-18 or 18-36 VDC 8-36 VDC Continuous Output 100 mA at 12 VDC 3 Amps at 75 VDC 100 mA at 2 VDC 4 Amps at 75 VDC Maximum Output 100 mA at 12 VDC 7.5 Amps at 150 VDC 100 mA at 2 VDC 7.5 Amps at 150 (1 minute) VDC (1 minute) Transition Frequency 50-70 Hz 40-70 Hz 50-70 Hz Exciter Field Resistance NA 18-25 Ohms NA 12.5 Ohms Mm. No-Load to Full-Load Voltage Regulation ±0.25% ±0.25% ±2% * Linear Loads ±0.5% Linear Loads ±0.25% Less than 0.5% for <1.0% 40°C <1.0% 40°C <0.5% 40°C (104°F) Ambient (104° F) Change <0.5% 40°C Change Change (-40°C to Thermal Drift (-40°C to 70°C range) Temperature Change (-40°C to 70°C (-40°C to 70°C range) 70°C range) [-40°F to 158°F] (15°Cto70°Crange) range) [-40'F to 158°F] [-40°F to 158°F] [59°F to 158°F] [-40°F to 158°FI Response Time Less Than 5.iS Less Than 7S ________________ Voltage Adjustment ± 10% 150-300 (low volt connection) -10% (of system voltage) 300-600 (high volt connection) Voltage Adjustment Controller Keypad Pushbutton Switches Potentiometer Remote Voltage Digital Input Standard/ Remote-Mounted Digital or Analog Input Remote-MountedRemote-Mounted Remote-Mounted Adjustment Analog0-5 VDC Input Optional, 46 m (150 ft.) Potentiometer Potentiometer or Potentiometer Optional Max. Optional Analog Input Optional Paralleling Capability Reactive Droop Optional Reactive Droop Optional Reactive Droop Kit Required Standard Kit Required VAR/PF Control Input Standard Optional - I Optional VAR/PF Control Kit Required Standard * A ±1% (linear loads) voltage regulator with single-phase voltage sensing is available on selected models. DVR& is a registered trademark of Marathon Electric Mfg. Corp. NA Data not available at time of print. Integral Voltage Regulator with 550 Controller Calibration Digital Display Range Setting Default Selection Voltage Adjustment Volt Adj. ±10% of System Voltage System Voltage Amplifier Gain Regulator Gain Ad). 1-10000 100% Underfrequency Unload or Frequency Setpoint Frequency Setpoint 30 to 70 Hz 1 Hz Below System Frequency (ECM) 2 Hz Below System Frequency (non-ECM) Underfrequency Unload Slope Slope 0-10% of Rated Voltage (volts per cycle) 15 Volts per Cycle at 480 Volts (3.1%) Reactive Droop Voltage Droop 0-10% of System Voltage 4% of System Voltage Control WAR Adj. 0 to Rated WAR Generating 0 WARVAR 0 to 35% of Rated WAR Absorbing PF Adjust Control PF Ad). 0.7 to 1.0 Leading, 0.6 To 1.0 Lagging 0.8 Lagging VAR/PF Gain Adjustment VAR/PF Gain Adj. 1-10000 100% G6-58 12/05b Integral Voltage Regulator with 550 Controller A digital display and keypad provide access to data. A two- line vacuum fluorescent display provides complete and concise information. The Decision-Maker 550 controller provides an interface between the generator set and switchgear for paralleling applications incorporating multiple generator set and/or utility feeds. The controller can communicate with a personal computer directly or on a network. See spec sheets G6-76, Monitor Ill Software, and G6-50, Decision-Maker-550 Controller Communications, for more information. Using optional menu-driven, Windows®based PC software, an operator can monitor engine and alternator parameters and also provide control capability. The controller supports Modbus® RTU (Remote Terminal Unit), an industry standard open communication protocol. The Decision-Maker° 550 controller provides ISO 8528-5, Class G3, compliance for transient response on some 20-300 kW generator set models. See the respective generator set spec sheet for specific applications. Voltage Regulator Menu 11 Displays AVG L-L V Volt Adjustment Li -L2 Volts L2-L3 Volts (3-phase) L3-L1 Volts (3-phase) Under Freq. Unload Enabled N/V Frequency Setpoint (cut-in point) Slope Volts-Per-Cycle Reactive Droop Enabled N/V Voltage Droop at 0.8 PF Rated Load VAR Control Enabled N/V (active only when the digital input is active) Total WAR (running) WAR Adjustment Generating/Absorbing Y/N PF Control Enabled N/V (droop at rated load, 0.8 PF) Average PF (running) PF Adjustment Lagging/Leading Y/N Regulator Gain Adjustment Utility Gain Adjustment Reset Regulator Defaults DVR5 is a registered trademark of Marathon Electric Mfg. Corp. Modbusr is a registered trademark of Schneider Electric. Wirtdows5 is a registered trademark of Microsoft Corporation. Digital DVR® 2000E Voltage Regulator The sealed electronic, solid-state microprocessor-based digital voltage regulator controls the generator set output by regulating the current flow into the exciter field. The digital voltage regulator is equipped with single- and/or three-phase sensing. Single-phase sensing is achieved by connecting terminal E2 and E3 to the same generator set terminal. Provisions are included in the regulator to allow the paralleling of two or more generator sets using either reactive droop or reactive differential (cross current) compensation with the addition of an external 5-amp 5VA current transformer (paralleling capability with optional DVR® 2000EC model only). The underfrequency function allows the generator set to operate with a constant volts-per-hertz characteristic. The over-excitation function monitors the voltage regulator output voltage and causes the voltage regulator to shut down when the output voltage exceeds the preset trip level of 80 volts for 15 seconds. The overvoltage function monitors the voltage regulator sensed voltage and causes the voltage regulator to shut down when the sensed voltage exceeds the preset trip levels of 120% for 0.75 seconds. The voltage regulator is equipped with a sensor that monitors the ambient temperature and will turn itself off when the temperature exceeds 70°C (158°F). The loss of the sensing function causes the voltage regulator to shut down if an open circuit occurs in one or more of the sensing leads. The field current limit function monitors voltage regulator output current and limits current should a heavy load or short circuit occur across the field output terminals. The manual mode of field current controls aid in setup and troubleshooting. The alarm output contacts provide remote indication of fault condition. Status and Mode Adjustments Status and Shutdown Indicators Field Amp Limit Loss of Sensing Manual Mode Over Excitation Over Temperature Over Voltage Under Frequency VAR/PF Active Adjustments Coarse Voltage Adjustment Droop Fine Voltage Adjustment Gain Manual Mode Adjustment Manual Mode On/Off Phase Sensing, 1-3 Stability Range Under Frequency VAR/PF Adjustment VAR/PF Select G658 12/05b KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 Kohl erPowerSystems. com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Fast Responsell PMG Voltage Regulator Fast Responselll Voltage Regulator The voltage regulator monitors output voltage magnitude and frequency to supply current to the stationary LED board. The stability potentiometer adjusts the voltage regulator to reduce light flicker. The volt/Hz adjustment potentiometer determines the engine speed (Hz) at which the generator output voltage begins to drop. Adjustment Potentiometers Stability 50 Hz Volt/Hz Adjustment 60 Hz Volt/Hz Adjustment Jumpers 50 or 60 Hz Selection Jumper for Volts/Hz Standard Average Voltage Sensing Model 12- or 24-Volt Engine Electrical System, ±2% Single-Phase Voltage Sensing Average Voltage Sensing Models Available 12- or 24-Volt Engine Electrical System, ±2% Three-Phase Voltage Sensing 12- or 24-Volt Engine Electrical System, ±1% Single-Phase Voltage Sensing (some models) Fast Response"' l RMS Voltage Regulator The voltage regulator monitors output voltage magnitude and frequency to supply current to the stationary LED board. The gain potentiometer adjusts the voltage regulator to reduce light flicker. The volt/Hz adjustment potentiometer determines the engine speed (Hz) at which the generator output voltage begins to drop. Adjustment Potentiometers Gain .50 Hz Volt/Hz Adjustment 60 Hz Volt/Hz Adjustment Jumpers 50 or 60 Hz Selection Jumper for Volts/Hz VAR/PF Input (or Analog Voltage Adjust Input) Standard Models (RMS Voltage Sensing Model) 12- or 24-Volt Engine Electrical System, Single-Phase Voltage Sensing Three-Phase RMS Models Available 12- or 24-Volt Engine Electrical System, Three-Phase Voltage Sensing DVR is a registered trademark of Marathon Electric Mfg. Corp 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 Kohierm generator distributor for availability. The voltage regulator monitors output voltage magnitude and frequency to supply current to the stationary exciter field. The stability potentiometer adjusts the voltage regulator to reduce light flicker. The volt/Hz adjustment potentiometer determines the engine speed (Hz) at which the generator output voltage begins to drop. Adjustment Potentiometers Stability Volt/Hz Adjustment Jumpers VAR/PF Input Standard Model (Average Voltage Sensing Model) 12- or 24-Volt Engine Electrical System, Single-Phase Voltage Sensing Accessories Refer to the respective generator set spec sheet and your authorized distributor for specific accessories. 550 Controller with Menu-Driven Integral Voltage Regulator U Utility Paralleling, Protective Relay Functions Digital DVR® 2000E Voltage Regulator U Reactive Droop Compensator Kit [J Voltage Regulator Relocation Kit [J VAR/PF Control (with DVR® 2000EC only) Fast Response' 11 PMG Voltage Regulator U Reactive Droop Compensator Kit U Voltage Adjustment Potentiometer Kit U Voltage Regulator Relocation Kit Fast Response "ll RMS Voltage Regulator tJ Reactive Droop Compensator Kit U Voltage Adjustment Potentiometer Kit U Voltage Regulator Relocation Kit U VAR/PF Controller Kit Fast Response- III Voltage Regulator U Reactive Droop Compensator Kit DISTRIBUTED BY: Bay City Electric Works 12208 industry Road Lakeside, CA 92040 619-938-8200 (hI 2002, 2004. 2005 by Kohler Co.. All rights reseed. 06-58 12105b Fuel Tank Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Weather Housings 09001 Applicable to the following: 200REOZPB 230-300REOZDB 230-45OREOZDD 350/400REOZD 350/400REOZDC 45OREOZDB Kohler® weather housings protect stationary generator sets from rain, snow, and sleet. Rust-inhibiting primer protects the inside and outside surfaces of these rugged 14- to 18-gauge steel construction weather housings. The weather housing outside surface has a top coat of Kohier® cream beige and black enamel. Field-installed kits ship with an electro-coat gray primer. Easy-to-remove side panels allow convenient access for generator set service. Lockable latch panels prevent tampering. The skid end cap kit protects the generator set from weather and deters entry by animals. Louvers at the generator and radiator ends supply ample cooling air flow, eliminating the need to remove the side panels for additional air circulation. Weather housing accessories include a silencer mounting kit for mounting the silencer on top of the weather housing. G6-10 11/07) Page 1 Dimensions: mm [in.] U, Ui C - - I667[6562j230-300MODELS •.-.-- 1355153.361230-300 MODELS . 114845.10] - - S .--.----- --- cc CU 'I - = 1107 43.6] I DOOR REMOVAL - - 790 ]31.10]TYP 4X 017.50 V4.688] CLEARANCE 52 2961 - OPENING WITH —I I I DOOR REMOVED MID HOLES 180017087] 580 [22.83] 3500137.801 27610.85] 0 0- I 1I1fflfflfflll41fflfl1 I j1i1 jL L- DOOR REMOVAL - 1 1067142011 OPENU400FH -J DOOR EMOV 3911.52] ______ 1173 18] CLEARANCE OPENING 4011.51 —i 117046.061 125049.211 230-300REOZDD Weather Housing with Optional Silencer and Mounting AD V 70 02-C 06-40 11/07j Page 5 KOHLER CO. Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Weather Housing Weights Model Generator Set (Wet) with Housing, kg (lb.) Steel Weather Housing Only, kg (lb.) 200REOZPB 2449 (5390) 449 (990) 230REOZDB 3363 (7414) 508 (1120) 230REOZDD 3238 (7140) 517 (1140) 250REOZDB 3411 (7520) 508 (1120) 250REOZDD with 4UA10W/4UA10 3284 (7240) 517 (1140) 25OREOZDD with 4UA13W/4UA13 3420 (7540) 517 (1140) 275REOZDB 3411 (7520) 508 (1120) 275REOZDD 3284 (7240) 517 (1140) 300REOZDB 3540 (7804) 508 (1120) 300REOZDD 3420 (7540) 517 (1140) 350REOZD 3978 (8770) 517 (1140) 35OREOZDC 4060 (8950) 794 (1750) 350REOZDD 4060 (8950) 794 (1750) 400REOZD 3978 (8770) 517 (1140) 400REOZDC 4060 (8950) 794 (1750) 400REOZDD with 40°C radiator 4060 (8950) 794 (1750) 400REOZDD with 50°C radiator 4442 (9790) 812 (1790) 45OREOZDB 4060 (8950) 794 (1750) 45OREOZDD with 40°C radiator 4060 (8950) 794 (1750) 450REOZDD with 50°C radiator 4442 (9790) 812 (1790) 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' generator set distributor for availability. Bay City Electric Works 12208 Industry Road Lakeside, CA 92040 619-938-8200 ( 1998. 1999, 2000. 2002 2003, 2005: 2007 by Koher Co. All rights reserved. G6-40 11!07j Page 12 11 8 I 7 I 6 I 5 4 I 3 I 2 1 - 5.10.01 IC COAC (TOnAl) 5*a I I_A-.01 (1.4) OIC6 C Th IF2 (01 I (70101) 51_I 8 P 0.75-01 (I-I) IC 01 (CNIC (P0*101 (Tale) AIM C 1.17-01 (A-La) 150/401*5 P0CC 1550 5075 C TIME. (CE-I) o IM CCOD. (1-44) IleW 901W 0 IM 150CC (TIle) ME 1667 (6562) 230-300 MODELS B IF B 1355 [53.36] 230-300 MODELS— - —1148 (45.19] 276 0.851 a L kOI4. _______ 00 ___ _ B 831 [327] 1067 [42.01] B OPENING WITHDOOR REMOVAL - MO DOOR R 1107 1EM0V1L— 39 (1.52] 1173 6.18] CLEARANCE CLEARANCE DOOR OPENING 48 [1.5l]— 1170 (46 06] 1250 [49 21] NOTE; DIMENSIONS IN ( ARE IN ENGLISH EQUIVALENTS. A __________________________________________________ METRIC CAD FILE A - I kONLIER CO L 7z- 230-300 MODELS DIMENSION PRINT DOC SERIES 60 DIESEL AIs WEATHER ENCLOSURE e-s-o.L 1C 1-- O010*51 WITH ROOF MOUNTED SILENCER I ADV-7002 I 0 8 I 7 6 5 4 3 1 2 I 1 MODEL I GENSET WEIGHT (WET) H H 1I h 0 y .o. 4X 017.50 [0688) (31.10] NTG HOLES OPENING WITH —752 [29.61] DOOR RED I (800 (70.87] I 580 [22.83)—. cflfl tVO7 Pill WEATHER I ENCLOSURE ONLY I GENSET WEIGHT (WET) I AND WEATHER ENCLOSURE 230 (4UA9/W) ALT 2721 Kg [6000 LBS) 517 Kg [1140 LBS] 3238 Kg [7)40 LBS) I 250/275 (4UA1O/W) ALT 2767 Kg [8(00 LBS] 517 Kg [(140 LBS) I 3284 Kg [7240 LBS) 258/300 (4UA3F/W) ALT I 2903 Kg [6400 LBS) 517 Kg [1140 LBS] 3420 Kg (7540 LaS) Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Subbase Fuel Tanks 09001 Applicable to the following: (.1') I4I.ER oan- 3501400R EOZDC 350-45OREOZDD 45OREOZDB Secondary Containment (SC) Tank The above-ground rectangular secondary containment tank mounts directly to the generator set, below the generator set skid (subbase). The secondary containment generator set base tank meets UL 142 requirements. The containment tank's double-wall construction protects against fuel leaks or ruptures. The inner (primary) tank is sealed inside the outer (secondary) tank. The outer tank contains the fuel if the inner tank leaks or ruptures. The generator set is designed to comply with the installation standards of NFPA 30 and NFPA 37. The subbase fuel tank is compatible with a weather housing. Standard Features Heavy-gauge construction Integral stub-up area Removable end channel for easy access to stub-up area Emergency pressure-relief vent outer tank * Lockable fill cap and riser, 2 in. NPT Low fuel level switch for controller alarm Mechanical fuel gauge Normal vent with riser and mushroom cap Emergency pressure-relief vent inner tank * Fuel supply and fuel return openings Basin drain Overflow opening Tank fuel fill for day tank * Standard on 350/400REOZDC, 350-45OREOZDD, and 45OREOZDB. G6-17 8/08k Fuel Tank Features and Options r / 00 0 V. I'L L - - - — — — -- IL — — — — ,/ // / 6 5 4 3 Inner tank leak alarm kit 4. 1/2 in. NPT for leak detection switch Fuel tank fittings and components 5. Day tank kit Removable end channel (standard) 6. Emergency pressure relief vent opening on the inner tank (standard) Figure 1 Double-Wall Subbase Fuel Tanks (Secondary Containment) Accessories EJ Inner tank leak alarm kit. U Electrical control harness, 6 m (20 ft.). t Lj Electronic-control day tank kit includes a 7.6 Lpm (2 gpm) transfer pump, 120 VAC, 1/3 HP motor, and controls. Requires an electrical control harness. t Li Relay control day tank kit includes a 7.6 Lpm (2 gpm) transfer pump, 120 VAC, 1/3 HP motor, and controls. Requires an electrical control harness. U Electrical control harness, 12 m (40 ft.). t U Emergency pressure-relief vent outer tank. t U Emergency pressure-relief vent inner tank. t t Available on 230-300REOZDB models only. 06-17 8/08k H 5 IS o ao 10 9 8 7 6 ODOO C View A-A Aov-6932-/ADv-701oA.A 0(0(a(0(a 0(0000 10 9 8 7 6 View A-A ADV-641 OA-D KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 For the nearest sates and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 1. 2 in. NPT for overflow to main tank, 7.6 L (2 gpm) pump maximum, (1 in. NPT reducer bushing) 2. 2 in. NPT for fuel inlet from supply pump (1 in. NPT reducer bushing) 3. 2 in. NPT for additional accessory (sensor/pump control float switch) 4. 2 in. NPT for removable engine supply diptube (3/8 in. female NPT with check valve) 5. 2 in. NPT for removable fuel return diptube (3/8 in. female NPT) 6. Emergency pressure relief vent inner tank per NFPA 30 3 in. NPT 719-1020 L (190-270 gal.) 4 in. NPT 1400-2271 L (370-600 gal.) Sin. NPT 2953-5678 L (780-1500 gal.) 6 in. NPT 6738-10183 L (1780-2690 gal.) 7. 2 in. NPT normal vent with 127 mm (5 in.) riser and mushroom cap 8. 2 in. NPT raised manual fill cap with 51 mm (2 in.) riser 9. 2 in. NPT mechanical fuel level gauge 10. 2 in. NPT for low fuel level switch (set to activate at less than 50% full) Figure 2 Fuel Tank Fittings Top View 1 2 3 4 5 1. 1/2 in. NPT for overflow, 7.6 L (2 gpm) pump maximum 2. 2 in. NPT mechanical fuel level gauge 3. 3/8 in. NPT (female)diptube with check valve, customer fuel return connection 4. 3/8 NPT in. diptube with check valve, (female) customer fuel supply connection 5. 2 in. NPT with low level switch 6. Emergency vent per NFPA 30 3 in. NPT 772 L (204 gal.) 4 in. NPT 1544/2317 L (408/612 gal.) 7. 1 1/4 in. NPT normal vent with 127 mm (5 in.) riser and mushroom cap 8. 2 in. NPT raised lockable manual fill cap with 51 mm (2 in.) riser 9. 2 in. NPT for sensor/pump control float 10. 3/8 in. NPT for day tank pump fill Figure 3 Fuel Tank Fittings Top View 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 set distributor for availability. Bay City Electric Works 12208 Industry Road Lakeside, CA 92040 619-938-8200 © 1996: 1997, 1998, 2000, 2002: 2005, 2007. 2008 by Kohler Co. All rights reserved. G6.17 8/081, TYPE 1 RADIATOR END 05" 1/2" NPT BASIN DRAIN 17.50 X 26.0 _r127 (5.00) (4 OBROUND MOUNTING HOLES) Elm TANK FITTING: "A" NPT EMERGENCY VENT FITTING PER NFPA 30 WITH VENT CAPS (OTT 2), (SEE CHART). 2" NPT FUEL FILL FITTING WITH LOCKABLE CAP AND 2" RISER. 2" NAT FUEL LEVEL GAUGE FITTING WITH DIRECT READING MECHANICAL GAUGE. ID. 2" NAT NORMAL VENT FITTING (BUSHED DOWN TO 1-1/4" NAT) WITH MUSHROOM VENT CAP AND 5' RISER. o E. 2" NAT FITTING FOR REMOVABLE ENGINE SUPPLY DIP TUBE (3/8" NAT FEMALE WITH CHECK VALVE). F. 2" NAT FITTING FOR REMOVABLE FUEL RETURN DIP TUBE (3/8" NAT FEMALE). H. 2" NAT FOR LOW LEVEL SWITCH (SET AT 50% FULL SILICONE PACKED). 2" NAT ADDITIONAL FITTING FOR OPTIONAL ACCESSORY (INSTALL 2" NPT PIPE PLUG). 2" NAT FOR OVERFLOW TO MAIN TANK (BUSHED DOWN TO 1" NPT AND PLUGGED), L 2" NAT FOR FUEL INLET FROM SUPPLY PUMP (BUSHED DOWN TO 1" NPT AND PLUGGED). N. 1/2" NAT FOR FUEL IN BASIN SWITCH. -02 TE - ME 48 (1 76(3.00) 10 I 127 (5.01 4.0 [1.5 .- : VIEW X-X (ENLARGED FOR CLARITY) ju -U NE METRIC CAD FILE! NOTE: DIMENSIONS IN [ ] A ARE IN ENGLISH EQUIVALENTS. 560 230-300 MODELS TIER III SECONDARY CONTAINMENT ILE WALL SUBBASE FUEL TANK MODEL TYPE CAPACITY UTERS1 GAL WEIGHT KG JLBS "A" VENT "L" TANK LENGTH MM I IN "W" TANK WIDTH MM IN "H" TANK HEIGHT JMM I IN "01" .M I IN '02" MM I IN "03" MM IN "04" iL IN "05" L IN "06 (STUB-UP) MM IIN = S 43.21 43.21 230 1 1009 1 267 662 1459 - 3' 3500 13780 1250 49.21 457 18.00 89 3.50 635 125.00 1170 46.06 580 1 22.83 0 0 1097.5 43.21 1 2423 640 1045 2304 5" 3800 149.61 1250 49.21 914 36.00 102 4.00 635 25.00 1170 46.06 880 34.65 300 11.81 1097.5 1 3424 905 1348 2972 5" 5000 196.85 1250 49.21 914 36.00 121 4.75 635 25.00 1170 46.06 2080 81.89 1500 59.06 1097.5 2 3944 1042 1668 3677 5" 5200 204.72 1350 53.15 914 36.00 121 4.75 675 26.57 1270 50.00 2280 89.76 1700 66.93 1197.5 46.44 2 5665 1497 2069 4.561 6" 5200 204.72 1850 72.82 914 36.00 121 4.75 925 34.42 1770 69.69 2280 89.76 1700 66.93 1697.5 66.83 o 250 1 1009 267 662 1459 3" 3500 137.80 1250 49.21 4.57 18.00 89 3.50 635 25.00 1170 46.06 580 22.83 0 0 1097.5 43.21 1 2423 640 1045 2304 5" 3800 149.61 1250 49.21 914 36.00 102 4.00 635 25.00 1170 46.06 880 34.65 300 11.81 1097.5 43.21 1 3424 905 1348 2972 5" 1 5000 1196.851 1250 1 49.211 914 136.001 121 1 4.751 635 25.00 1170 1 46.06 2080 81.89 1500 59.06 11097.5 43.21 275 1 1 3424 905 1348 129721 5" 5000 1196.851 1250 49.211 914 136.00 121 1 4.751 635 25.00 1 1170 1 46.06 2080 1 81.891 1500 59.06 11097.5 1 43.21 2 4976 1315 1909 4208 5" 5200 204,72 1650 64,96 914 36.00 121 4.75 825 32.48 1570 61.81 2280 89.76 1700 66.93 1479.5 57.78 2 7024 1856 2,381 5249 6" 5400 212.60 2150 84.65 914 36.00 133 5.25 1075 42.32 2070 81.50 2480 97.64 1900 74.80 1997.5 78.64 1 1392 368 765 1687 4" 3500 137,80 1250 49.21 810 24,02 102 4.00 635 25.00 1170 46.06 580 22.83 0 0 1097.5 43.21 1 2423 640 1045 2304 5" 3800 149,61 1250 49,21 914 36.00 102 4,00 635 25.00 1170 46.06 880 34.65 300 11.81 1097.5 43.21 300 1 3424 905 1348 2972 5" 5000 196,85 1250 49,21 914 38.00 121 4,75 635 25.00 1170 46.06 2080 81.89 1500 59,06 1097.5 43.21 C 2 4876 1315 1909 4208 5 5200 20472 1650 696 914 300 121 4.75 825 328 1570 61.81 2280 876 1700 6693 14793 578 c 2 7024 1856 2381 5249 6"5400 212.60 2150 84.65 914 36.00 133 5.25 1075 42.32 2070 81.50 2480 97.84 1900 74.80 1997.5 78.64 B I 6 IMETRIC CAD FILEI A I 560 230-300 MODELS TIER III ________________ SECONDARY CONTAINMENT , I" I I ILE WALL SUBBASE FUEL TANK _ ADV-7098 I OI 1 2 1 1