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KOHLER Power Systems
4R9X 4R12X Model: 100REOZJF KOHLERPOWER SYSTEMS 2084600 V Diesel 09001 � SiSTEMS NATIONALLY REGISTERED Tier 3 EPA-Certlfied for Stationary Emergency Applications Ratings Range Standby: kW kVA Prime: kW kVA Generator Set Ratings Alternator Voltage 120/208 127/220 120/240. 120/240 139f240 220/380 277/480 347/600 120/208 127/220 120/240 120)240 139/240 220/380 277/480 347/600 130°C Rise Standby Rating Ph Hz kW/kVA Amps 3 60 100/125 347 3 60 100/125 328 3 60 100/125 301 1 3 3 3 3 3 3 3 1 3 3 3 3 1 60 60 60 80 60 60 B0 80 80 60 60 80 60 60 77/71 100/125 100/125 100/125 100/125 102/128 102/128 102/128 91/91 102/128 102/128 102/128 102/128 321 301 190 150 120 354 335 307 379 307 194 153 123 417 105°C Rise Prime Rating kW/IkVA Amps 90/113 312 90/113 295 90/113 271 71/71 90/113 90/113 90/113 90/113 92/115 92/115 92/115 84/84 92/116 921115 92/115 92/115 90/90 296 271 171 135 108 319 302 277 350 277 175 138 111 Standard Features • Kohler Co. provides one -source responsibility for the generating system and accessories. • The generator set and its components are 60 Hz prototype -tested, factory-bulit, and production -tested. 77-102 • The 60 Hz generator set offers a uL 2200 listing. 77-128 • The generator set accepts rated load in one step. 71-92 • The 60 Hz generator set meets NFPA 110, Level 1, 71-115 when equipped :math the necessary accessories and Installed per NFPA standards. • A standard one-year limited warranty covers all systems and components. Two-, live-, and ten-year extended warranties are also available. • Alternator features: o The unique Fast -Response"' X excitation system delivers excellent voltage response and short-circuit capability using a rare-earth, permanent magnet (PM) -excited alternator. o The brushless, rotating -field alternator has broadrange reconnectability. • Other features: o Kohler designed controllers for guaranteed system integration and remote communication. See Controllers on page 3. o The low coolant level shutdown prevents overheating (standard on radiator models only). o Integral vbration isolation eliminates the need for under -unit vibration spring isolators. o Multiple circuit breaker configurations. 4T12X 120/240 100/100 375 RATINGS: A0Woe-phase unitive Meat 0.8panda:ior. All argle.quseuilearemutlat1.0 power factor. yi:7hestandbyraerlpisapplioebulovaryirtgtotalsforthedurationofapower oftape.7hereis no overload cepeb'itytor this rating Pane POISerfa8Tg0:Atvarying losathe nurberageneratasetoperuighoursisuturged.A10%overload atackyisavallebletormehoutMea°. Reangisma int000rdenceoath ISO-8 5-1 and ISO-3048-1. For rmietlrunning lime aManiinuota nsengs,oareadtthelactory. ObtaintecnioeiIntimation bulletin (119.101) far retails gidermes, complete range defarmre, end site oonaaon dereme. The generator 0e1 manufacturer reserves genial igtd to change the design or specifications without nasoe and Without er y olligetlonor Way whatsoever. 0636/ (OOREOZJF) 4/12a Alternator Specifications • NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting. • Sustained short-circuit current of up to 30D% of the rated currentfor up to 10 seconds. • Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field. • Self -ventilated and ddpproof construction. • Vacuum -impregnated windings with fungus -resistant epoxy varnish for dependability and tong life. • Superior voltage waveform from a two-thirds pitch stator and skewed rotor. spselllrxtlon$ Alternator Manufacturer Kohler Type 4-Pole, Rotating -Field Exciter type Brushiess, Rare -Earth, Permanent -Magnet Leads: quantity, type 4RX 12, Reconnectable 4TX 4, 120/240 Voltage regulator Solid State, Volts/Hz Insulation: NEMA MG1 . Material Class H Temperature rise 130°C, Standby Bearing: quantity, type 1, Sealed Coupling Flexible Disc Amortisseur windings Full Voltage regulation, no-load to full -load Cadrotler Dependent One-step Toad acceptance 100% of Rating Unbalanced load capability 100% of Rated Standby Current Engine Specifications Alternator Peak motor starting kVA: 480 V 4R9X (12 lead) 480 V 4R12X (12 lead) 240 V 4T12X (4 lead) Application Data Engine Electrical Engine Specifications Manufacturer Engine model Engine type Cylinder arrengemerd Displacement, L (cu. In.) Bore and stroke, mm (in.) Compression ratio Piston speed, m/min. (ft./min.) Main bearings: quantity, type Rated rpm Max. power at rated rpm, kWm (BHP) Cylinder head material Crankshaft material Valve material: Intake Exhaust Governor. type, make/model Frequency regulation, no-load to full -load Frequency regulation, steady state Frequency Alr cleaner type, all models Exhaust John Deere 4045HF2851 4-Cycle, Turbocharged, Charge Air -Cooled 4 'One 4.5 (276) 108 x 127 (4.19 x 5.00) 19:1 457 (1500) 5, Replaceable insert 1800 118 (158) Cast Iron , Forged Steel Chromium -Silicon Steel Stainless Steel JDEC Electronic L16 Dense HP3 Isochronous s025% Fixed Dry Exhaust System Exhaust manifold type Exhaust flow at rated kW, rmtpnin. (chi) Exhaust temperature Ed rated kW, dry exhaust, °C (°F) Maximum allowable back pressure, kPa (in. Hg) Exhaust outlet size at engine hookup, mrn (in.) Dry 22.8 (805) 580 (1076) 7.5 (22) 08 (3.86) G5S57 .(1 (35% dip for voltages below) 385 448 275 Engine Eiectdcat Systam'(12/24 Volt") Battery charging alternator. Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (o,): 12 Volt/24 Volt Quantity, CCA rating each One, 640/rwo, 570 Battery voltage (DC) 12 *12-volt engine electrical system is standard and 24-volt is available. • Fuel 12 Volt/24 Volt Negative 12/24 65/45 12/24 Fuel System Fuel supply line, min. ID, mm (in.) Fuel retum line, thin. ID, mm (In.) Max. lift, fuel pump: type, m (ft.) Max. fuel flow, Lph (gph) Fuel per. pump Fuel filter Primary Secondary Water Separator Recommended fuel Lubrication 11.0 (0.44) 6.0 (025) Englne-Driven, 1.8 (6.0) 74.6 (19.7) Manual 30.Microns 2 Microns @ 98% Efficiency Yes #2 Diesel Lubricating System Type Oil pan capacity, L (qt) OO pen capacity with finer; L (qt.) 011 filter:. quantity, type Oil cooler 0ZJFI 4n2a Full Pressure 14.7 (15.5) 15.6 (16.5) 1, Cartridge Water -Cooled Application Data Cooling Radiator System Ambient temperature, °C (°F)50 (122) Engine Jacket water capacity, L (gal) 8.5 (2.25) Radiator system capedly, including engine, L (gal.) 20.1 (5.3) Engine jacket water flow, Lpm (gpm) 182 (48) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 62 (3544) Heat rejected to air charge cooler at rated kW, dry exhaust, kW (Bttr/n ln.) 20 (1127) Water pump type Centrifugal Fan diameter, including blades, mm lln.) MD (23.8) Fan, kWm (HP) 8.6 (8.8) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H20) 0.125 (0.5) ' Enclosure with enclosed silencer reduces ambient temperature capability by 5°C (9°F). Operation Requirements Air Requirements Radiator -cooled cooling air, ni3/min. (sctm)<. Combustion air, m3/min. (ctm) Heat rejected to ambient air: Engine, kW (Btu/min.) Alemator, kW (W/min.) 1 Air density = 1.20 kgfm3 (0.0751bride) 142 (5000) 8.2 (288) 25.0 (1420) 11.6 (660) Fuel Consumption Diesel, Lph (gph) at % load 100% 75% 50% 25% Standby Rating 31.0 (8.2) 25.0 (8.6) 17.8 (4.7) 9.5 (2.5) Diesel, Lph (gph) at % load Prime Rating 100% 75% 50% 25% 27.6 (7.3) 22.7 (6.0) 14.4 (3.8) 7.6 (2.0) Controllers Deolslon-Maker° 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility. • Digital display and menu control provide: easy local data access • Measurements are selectable in metric or English units • Remote communication thru a PC via network or . serialconfiguration • Controller supports Modbuse protocol • Integrated hybrid voltage regulator with 20.5% repletion • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-100 for additional controller features and accessories. e Dedsion-Makers 550 Controller Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities. • Digital display and keypad provide easy local data access • Measuremecs are selectable in metric or English units • Remote communication thru a PC via network or modem configuration • Controller supports Modbuse protocol • Integrated voltage regulator with a0.25% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-48 for additional controller features and accessories. IVIRTmgarr emus [5• I I u 4 Decision -Maker` 6000 Paralleling Controller Provides advanced control, system madding, and system diagnostics with remote monitoring capabilities for paralleling multiple generator sets. • Paralleling capability with iirst-on logic, synchronizer, kW and kVAR load sharing, and protective relays • Digital display and keypad provide easy local data access • Measurements are selectable in metric or English units • Remote communication thou a PC via network or modem configuration • Controller supports Modbus• protocol • Integrated voltage regulator with e0.25% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-107 for additional controller features and accessories. KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1648 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 Standard Features • Alternator Protection • Battery Rack and Cables • Customer Connection (standard wlh Decision -Maker• 6000 controller only) • Local Emergency Stop Switch • Oil Drain Extension • Operation and Installation Literature Available Options Approvals and Listings ❑ California OSHPD Approval ❑ CSA Approval ❑ IBC Seismic Certification ❑ UL 2200 Listing Enclosed Unit ❑ Sound Enclosure (with enclosed critical silencer) ❑ Weather Enclosure (with enclosed c ritical silencer') Open Unit ❑ Exhaust Silencer, Critical (kit PA-354809) ❑ Flexible Exhaust Connector, Stainless Steel Fuel System ❑ Flexible Fuel Lines ❑ Fuel Pressure Gauge ❑ Subbase Fuel Tanks Controller ❑ Common Failure Relay ❑ Communication Products and PC Software ❑ Customer Connection (Decision -Makers 550 controller only) •❑ Decision -Makers Paralleling System (DPS) (Decision -Maker• 6000 controller only) ❑ Dry Contact (isolated alarm) (Decision-Makerm 550 and 6000 controllers only) ❑ Input/Output Module (Decision -Makers 3000 controller only) ❑ Remote Emergency Stop ❑ Remote Serial Annunciator Panel ❑ Run Relay Cooling System ❑ Block Heater, 1500 W, 90-120 V, 1 Ph (recommended for ambient temperatures below WC (3269) ❑ Radiator Duct Flange Electrical System ❑ AkematorStrip Heater ❑ Battery ❑ Battery Charger, Equalize/Float Type ❑ Battery Hester ❑ Line Circuit Breaker (NEMA type 1 enclosure) ❑ line Circuit Breaker with Shunt Trip (NEMA type 1 enclosure) Paralleling System ❑ Manual Speed Adjust O0000ao Miscellaneous Air Cleaner, Heavy Duty Air Cleaner Restriction Indicator Certified Test Report Crankcase Emissions Canister Engine Fluids Added Rated Power Factor Testing Rodent Guards Literature ❑ General Maintenance ❑ NFPA 110 ❑- Overhaul O .Production Warranty ❑ 2-Year Basic ❑ 5-Year Basic ❑ 5-Year Comprehensive Other Options ❑ ❑ ❑ Dimensions and Weights Overall Size, L x W x H, mm (in.): Wide Skid: See Enclosure ADV Drawing Narrow Skid: 2334 x 864 x 1216 (91.89 x 34.02 x 47.90) Weight (radiator model), wet, kg (Ib.): 1234 (2720) NOTE TNa drmr'igis provided for reference only end should not be used for penning 'intonation. Contact your local nfstributorfor mare deed intimation. DISTRIBUTED BY: ©2011, 2012 by Kohler Co- All hark reserved. G5357 (1OOREOZJF) 4/12e 4R12X 4R13X Model: 1 25REOZJG KONLER.POWER SYSTEMS Diesel 09001 Tier 3 EPA -Certified for (AnnysrEms Stationary Emergency NATIGNAUY REGISTERED Applications Ratings Range Standby: kW kVA Prime: kW kVA Generator Set Ratings Alternator Voltage 120)08 127/220 120240 120/240 139/240 220/380 277/480 347030 120/208 127/220 120/240 120/240 139/240 220/380 277/480 130°C Rise Standby Rising Ph Hz kW/kVA Amps 3 60 124/155 430 3 80 125/156 410 3 1 3 3 3 3 3 3 3 1 3 3 3 80 so 60 60 60 so 60 60 60 80 60 s0 80 105°C Rise Prime Rating kW/kVA Amps 114/143 396 114/143 374 124/165 373 114/143 91/91 379 84/84 125/156 376 114/143 112/140 213 104/136 125/156 188 114/143 125/158 150 114/143 128/160 444 116/145 128/180 420 116/145 128/160 365 116/145 107/107 446 99/99 128/160 385 118/145 124/155 235 116/145 128/160 192 116/145 343 350 343 198 171 137 402 381 349 413 349 220 174 347/ 00 3 60 127/158 153 114/142 137 Standard Features • Kohler Co. provides one -source responsibility for the generating system and accessories. • The generator set and its components are eo Hz prototype -tested, factory -bunt, and production -tested. 91-128 • The 60 Hz generator set offers a UL 2200 listing. 91-160 • The generator set accepts rated load in one step. 84-118 • The 60 Hz generator set meets NFPA 110, Level 1, 84-145 when equipped with the necessary accessodes and installed per NFPA standards. • A standard one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Alternator features: o The unique Fast -Response" X excitalion system delivers excellent voltage response and short-chcutt capability using a rare-earth, permanent magnet (PM) -excited alternator. o The brushless, rotating -field alternator has broadrange reconneciability. • Other features: o Kohler designed controllers for guaranteed system integration and remote communication. See Controllers on page 3. o The low coolant level shutdown prevents overheating (standard on radiator models only). o Integral vibration isolation eliminates the need for under -unit vibration spring isolators. o Multiple circuit breaker configurations. 4T13X 120/240 1 60 125/125 521 114/114 475 • RATINGS: AiIUrespites.urRlBearated ante powerfaetor. AB sinpepfeaoudeala rated 011.0power factor. fir : The stainer, rent is appecelleto varying loadsforthe 4semote power Dute9a. Thereisrroovedcadcepaholyforthisre refine. Prime PowerRelivir Alverymglore thenur iberDfBinge:teatoPeralighome'surton fed. A10%embed cepaciyisere abletarmohair hlwreM. Ratings are in ecmrtleneawith B0-9528-1 endI804 48-1. Fainted MT r th*widmtiruarsratinpa.consR thohrtoy. Obtain Whew' irtornononeuteul(101-101) for Mines auk/dines, complete ratings deletions, and site condition dereles. The generate set maraAactam reserves the vt 1 to change are design a' Seeditcodons walnut notice and "Mat any abIi9etim or Mk wrlateoevn. G5461 (125REOZJ(i) 4/12b Alternator Specifications Specifications Alternator Manufacturer Kohler Type 4-Pole, Rotating -Fiend Exciter type Brushless, Rare -Earth. Permanent -Magnet Leads: quantity, type 4RX 12, Reconneclable 4TX 4,120/240 Voltage regulator Solid State, Volts/Hz Insulation: NEMA MG1 Material Class H Temperature rise 130°C, Standby Bearing: quantity, type 1, Sealed Coupling Flexible Disc Amordsseur windings Fud Voltage regulation, no-load to full -load Controller Dependent One-step load acceptance 100% of Rating Unbalanced load capability 100% of Rated Standby Current Engine • NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starling. • Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds. • Sustained wort -circuit current enabling downsbeam circuit breakers to trip wlhout 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. Specifications • Attemator Peak motor starting kVA: 480 V 4R12X (12 lead) 480 V -4R13X (12 lead) 240 V 4T13X (4 lead) Application Data Engine Electrical Engine Specifications Manufacturer Engine model Engine type Cylinder arrangement Displacement, L (cu. In.) Bore and stroke, mm (in.) Compression ratio Piston speed, m/mtn. (tt./min.) Main bearings: quantity, type Rated rpm Max. power at rated rpm, kWm (BHP) Cylinder head material Crankshaft material Valve material: Intake Exhaust Governor: type, make/model Frequency regulation, no-load to full -load Frequency regulation, steady state Frequency Air cleaner type, all models Exhaust John Deere 4045HF285 4Cycte, 'Turbocharged, Charge Air -Cooled 4 Inllne 4.5 (276) 106 x 127 (4.19 x 5.00) 19:1 457 (1500) 5, Replaceable Insert 1800 147 (197) Cast Iron Forged Steel ChrondumSlicon Steal Stainless Steel JDEC Electronic L18 Denso HP3 Isochronous s025% Fixed Dry Exhaust System Exhaust manifold type Exhaust flow et rated kW, m3/min. (cfm) Exhaust temperature at rated kW, dry tedlauat, °C. Maximum allowable back pressure, kPa (in. Hg) Exhaust outlet size el engine hookup, mm (in.) Dry 27.0 (953) 580 (1076) 7.5 (22) 98 (3.86) (35% dlp for voltages below) 448 540 440 Engine Electrical System (12124 Volt') Battery charging alternator: Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Quantity, CCA rating each Battery voltage (DC) *12-volt engine electrical system kt standard Fuel 12 VoW24 Volt • Negative 12/24 65/45 12/24 12 VoW24 Volt One, 800/Two, 670 12 and 24volt is available. Fuel System Fuel supply line, min. ID, nun (in.) Fuel retum line, min. ID, nun (m.) Max. 8R, fuel pump: type, m (ft.) Max. fuel flow, Lph (gph) Fuel prime pump Fuel filter Primary Secondary Water Separator Recommended fuel Lubrication 11.0 (0.44) 6.0 (025) Mechanical, 1.8 (6.0) 90.0 (23.8) Manual 30 Microns 2 Microns @ 98% Efficiency Yes #2 Diesel Lubricating System Type OII pan capacity, L (qt.) 011.pan.cepecity.with filter, L (qt.) • Oil filter: quantity, type Oil cooler a5a61 t125REozr4 40211 Full Pressure 27.0 (28:5) 27.9-(29.5) 1, Cartridge Water -Cooled Application Data Cooling Radiator System Ambient temperature, °C (°F) * 50 (122) Engine jacket water capacity, L (gal.) 8.5 (2.25) Radiator system capacity, including engine, L (gal.) 192 (5.1) Engirat jacket water flow, Lpm (gpm) 180 (48) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 72 (4098) Heat rejected to air charge cooler et rated kW, dry exhaust, kW (Btu/min.) 265 (1508) Water pump type Centrifugal Fan diameter, including blades, nun (in.) 660 (26) Fan, kWm (HP) 7.7 (10.3) Max. restriction of coding air, intake and discharge side of radiator; kPa (in. H20) 0.125 (0.5) ' Enclosure with endosed silencer reduces ambient temperature capability by6°C (9 F). Operation Requirements Air Requirements Radiator -cooled cooling air, m3/mln. (sctm)* Combustion air, m3/rn n. (cim) Heat rejected to ambient air. Engine, kW (Btu/min.) Alternator, kW (Btu/min.) Air density =1.20 kg/m3 (0.075 IbmAt3) 226.5 (8000) 965 (341) 30A (1730) 13.5 (770) Fuel Consumption Diesel, Lph (gph) at % Ioad 100% 75% 50% 25% Diesel, Lph (gph) at % Ioad Standby Rating 37.4. (9.9) 29.0 (7.6) 21.1 (5.6) 11.4 (3.0) Prim Rating 100% 75% 50% 25% 34.8 (9.2) 26.9 (7.1) 19.5 (5.1) 10.6 (2.8) Controllers Declelon.Make? 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum •performance and.compatibility. • Digital display and MGM owurolprovide easy local data access • Measurements are selectable in metric or English units • Remote communication thru a PC via network or serial configuration • Controller supports Modbuse protocol • Integrated hybrid voltage regulator with s0.5% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G8-100 for additional controller features and accessories. Item MirI Decision -Maker. 550 Controller Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities. • Digital display and keypad provide easy local data access • Measurements are selectable in metric or English unila • Remote commurdcation thni a PC via network or modem configuration • Controller supports Modbuse protocol • Integrated voltage regulator wl h :025% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-46 for additional controller features and accessories. O • *any irp- TRW l I � � u Decision -Maker' 6000 Paralleling Controller Provides advanced control, system monitoring, end system diagnostics with repute monitoring capabilities for paralleling multiple generator sets. • Paralleling capability with Tirst-on logic, synchronizer, kW and kVAR load sharing, and protective relays • Digital display and keypad provide easy local data access • Measurements are selectable in metric or English units • Remote communication thru a PC via netwcrk or modem configuration • Controller supports Modbuso protocol • Integrated voltage regulator with s0.25% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-107 for additional controller features and accessories. GG-381 (125RE0ZJt1) 4/12b KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 820-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohier Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 819159 • Phone (85) 6264-8422, Fax (655) 6264-6455 Standard Features • Alternator Protection • Battery Rack and Cables • Customer Connection (standard with Dedeion-Makero 6000 controller only) • Local Emergency Stop Switch • 011 Drain Extension • Operation and Installation Literature Available Options Approvals and Listings ❑ California OSHPD Approval ❑ CSA Approval ❑ IBC Satanic CertMcedon ❑ UL 220D Listing Enclosed Unit ❑ Sound Enclosure (with enclosed critical silencer) ❑ Weather Enclosure (with enclosed criticai.silencer) Open Unit Q Exhaust Silencer, Critical (kit: PA-354809) ❑ Flexible Exhaust Connector, Stainless Steel Fuel System ❑ Flexible Fuel Lines ❑ Fuel Pressure Gauge ❑ Subbase Fuel Tanks Controller Q Common Failure Relay ❑ Communication Products and PC Software Q Customer Connection (Decision-Mekera 550 controller only) ❑ Decision -Maker• Paralleling System (DPS) (Decision -Makers 6000 controller only) ❑ Dry Contact (lsolated alarm) (Decision-Makere 550 and 6000 controller: only) ❑ Input/Output Module (Decision-Make0 3000 controller only) ❑ Remote Emergency Stop ❑ Remote Serial Annunciator Panel ❑ Run Relay Cooling System ❑ Black Heater,1500 W, 90-12011,1 Ph (recommended for ambient temperatures below0•C I32°Fj) Q Radiator Duct Flange Electrical System ❑ Alternator Strip Heater ❑ fiery ❑ Battery Charger, Equalize/Float Type ❑ Battery Heater Q Line Circuit Breaker (NEMA type 1 enclosure) ❑ Line Circuk Breaker with Shunt Trip (NEMA type 1 enclosure) Paralleling,System ❑ Manual Speed Adjust 0000000 Miscellaneous Air Cleaner, Heavy Duty Ak Cleaner Restriction indicator ator Certified Test Report Crankcase Emissions Canister Engine Fluids Added Rated Power Factor Testing Rodent Guards Literature ❑ General Maintenance (� NFPA 110 ❑ Overhaul ❑ Production Warranty ❑ 2-Year Basic ❑ 5-Year Basic • 5-Year Comprehensive Other Options Dimensions and Weights Overall Size, L x W x H; fnm Weight (radiator model), wet, kg (lb.): 2700 x 1120 x 1527 (106.3 (80.1) NOTE:7Metiming tomolded for refere soilye dsho,dnotbeusedfarOwning nsteaegon. contact yoirlocal disbimtormore tleeRed hfemotlm. DISTRIBUTED BY: 02011,2012byKohler Co. AO t t1s'reoerved. G5361 (125RE0ZJI3) A/12b Model: 15OREOZJF KtOHLER..POWER SYSTEMS �-�V Diesel 09001 Tier 3 EPA -Certified for (f)imps,Isilms Stationary Emergency NATIONALLY REGISTERED Applications Ratings Range Standby: kW kVA Prime: kW WA 106-154 106-193 99-140 99-175 r---0 "I o o• Generator Set Ratings Alternator Voltage 120/208 127/220 120/240 4R13X 120/240 139/240 220/380 277/480 130°C Standby Ph Hz kW/kVA 3 3 3 1 3 3 3 60 60 60 60 60 60 60 137/171 143/179 137/171 107/107 150/188 124/155 150/188 Rise 105°C Rise Rating Prime Rating Amps kW/kVA Amps 475 469 412 446 451 235 226 128/160 132/165 128/160 99/99 136/170 116/145 136/170 444 433 385 413 409 220 204 4812X 4513X 120/208 127/220 120/240 120/240 139/240 220/380 277/480 347/600 120/208 127/220 120/240 120/240 139/240 220/380 277/480 347/600 4T13X 120/240 3 3 3 1 3 3 3 3 3 3 3 1 3 3 3 3 1 60 60 60 60 60 60 60 80 60 60 60 80 60 154/193 154/193 154/193 106/106 154/193 140/175 154/193 154/193 154/193 154/193 154/193 113/113 154/193 534 505 463 442 463 266 232 185 534 505 463 471 463 60 154/193 292 60 154/193 - 232 80 154/193 185 60 144/144 600 140/175 486 140/175 459 140/175 421 105/105 438 140/175 421 131/164 249 140/175 210 140/175 168 140/175 140/175 140/175 113/113 140/175 140/175 140/175 140/175 133/133 488 459 421 471 421 266 210 168 554 Standard Features • Kohler Co. provides one -source responsibility for the generating system and accessories. • The generator set and its components are 80 Hz prototype -tested, factory -built, and production -tested. • The 60 Hz generator set offers a UL 2200 listing. • The generator set accepts rated load in one step. • The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards. • A standard one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Alternator features: o The unique Fast -Response' X excitation system delivers excellent voltage response and short-circuit capability using a rare-earth, permanent magnet (PM) -exalted aftemator. o The brushiess, rotating -field alternator has broadrange reconnectability. • Other features: o Kohler designed controllers for guaranteed system integration and remote communication. See Controllers on page 3. o The Low coolant level shutdown prevents overheating (standard on radiator models only). o Integral vibration isolation eliminates the need for under -unit vibration spring isolators. o Multiple circuit breaker configurations. RATINGS: Mtldee-Mesethrills we rated et 0.8 power fir: All RMpe-P a alto ere need el 1.0 powerthaw. SavedbyRothor The aI y diem hs applicable to varring bade tor the dundion aponer Wage, There 11 nooverload capability tennis rating. Prtrne PoeerRetrrDs Atvarying load, the ru rnherolgeneratesetopanetlng hams Isun9nMled A 10%overoad asperity isevegabbtarone hour In Lemke. Ratings stein accordance wtih 100.8520-1 end 18030461. For limited running erne end continuous ra11n aasathe factory Ohlalntechnkol Informal/co bulletin (ne40l) to tangs guiding& coir4lete ridge definitions, and site oondtlan anew Tha generator eel namulazsuer meows the right to change the design or apedaceeme without notice end without an' oHlpa1orl or tlehRy whatsoever. 06-371 (18IREOZJF) 4/12e Alternator Specifications Specifications Alternator Manufacturer Kohler Type 4-Pole, Rotating -Field Exciter type Brushless, Rare -Earth, Permanent -Magnet Leads: quantity, type 4RX, 4SX 12, Reconnectable 4TX 4,120/240 Voltage regulator Solid State, Volts/Hz Insulation: NEMA MG1 Material Class H Temperature rise 130°C, Standby Bearing: quantity, type 1, Sealed Coupling Flexible Disc Amortisseur windings Full Voltage regulation, no-load to full -load Controller Dependent One-step load acceptance 100% of Rating Unbalanced Toad capability 100% of Rated Standby Current Engine • NEMA MG1, 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 vamish for dependability and long life. Specifications Alternator Peak motor starling kVA: 480 V 4R13X (12 lead) 480 V 4S12X (12 lead) 480 V 4S13X (12 lead) 240 V 4T13X (4 lead) Application Data Engine Electrical Engine Specifications Manufacturer Engine model Engine type Cylinder arrangement Displacement, L (cu. In.) Bore and stroke, mm (in.) Compression ratio Piston speed, m/min. (ft/min.) Main bearings: quantity, type Rated rpm Max. power at rated rpm, kWm (BHP) Cylinder head materiel Crankshaft material Valve material: Intake Exhaust Governor: type, make/model Frequency regulation, no-load to full -load Frequency regulation, steady state Frequency Air cleaner type, all models Exhaust John Deere 6088HF285 4-Cyde,Turbocharged, Charge Air -Cooled 6 Inline 6.8 (415) 106 x 127 (4.19 x 5.00) 17.0:1 457 (1500) 7, Replaceable Insert 1800 177 (237) Cast Iron Forged Steel Chromium -Silicon Steel Stainless Steel JDEC Electronic L16 Denso HP3 Isoohronous x0.25% Fixed Dry Exhaust System Exhaust manifold type Exhaust flow at rated kW, mg/min. (cfm) Exhaust temperature at rated kW, dry exhaust °C-(°F_ .. Maximum allowable back pressure, kPa (in. Hg) Exhaust outlet size at engine hookup, mm (in.) Dry 33.9 (1197) 510 (950) 7.5 (22) 98 (3.86) (35% dip for voltages below) 540 480 570 440 Engine Electrical System (12/24 VW) Battery charging alternator: Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Quantity, CCA rating each Battery voltage (DC) *12-volt or 24-volt engine electrical systems Fuel 12 Volt/24 Volt Negative 12/24 65/45 12/24 12 Volt/24 Volt One, 640/Two, 570 12 are available. Fuel System Fuel supply line, min. ID, mm (In.) Fuel retum line, min. ID, mm On.) Max. eft, fuel pump: type, m (IL) Max. fuel flow, Lph (gph) Max. return line restriction, kPa (in. Hg) Fuel prime pump Fuel filter Primary Secondary Water Separator Recommended fuel Lubrication 11.0 (0.44) 6.0 (0.25) Electronic, 1.8 (6.0) 96.9 (25.6) 20 (5.9) Manual 30 Microns 2 Microns @ 98% Efficiency Yes #!2 Diesel Lubricating System Type Oil pan capedty,L(qt.).. 011 pan capacity with filter, L (qt.) Oil filter: quantity, type Oil coder 05-371 (15OREOZJF) 4/12a Full Pressure 27.0 (28.5) 27.9 (29.5) 1, Cartridge Water -Cooled Application Data Cooling Radiator System Ambient temperature, °C (°F) * Engine jacket water capacity, L (gat.) Radiator system capacity, including engine, L (gal.) Engine jacket water flow, Lpm (gpm) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) Heat rejected to air charge cooler at rated kW, dry exhaust, kW (Stu/min.) Water pump type Fan diameter, including blades, mm (in.) Fan, kWm (HP) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H20) * Enclosure with endosed silencer reduces temperature capability by 5°C (9°F). Operation Requirements 50 (122) 11.3 (3.0) 25.7 (6.8) 174 (48) 76.3 (4340) 31.8 (1810) Centrifugal WO (26) 7.7 (10.3) 0.125 (0.5) ambient Air Requirements Radiator -cooled cooling air, m3/min. (scfm)$ Combustion air, m3/min. (cfm) Heat rejected to ambient air: Engine, kW (Btuimin.) Altemator, kW (0tuhnin.) $ Air density =120 kg/m3 (0.075 Ibn tt3) 226.5 (8000) 13.6 (480) 35.9 (2040) 12.3 (700) Fuel Consumption Diesel, Lph (gph) at % load 100% 75% 50% 25% Standby Rating 44.3 (11.7) 35.1 (9.3) 26.3 (6.9) 162 (4.3) Diesel, Lph (gph) at % load Prime Rating 100% 75% 50% 25% 40.6 32.3 24.0 14.4 (10.7) (8.5) (6.3) (3.8) Controllers Decision -Maker° 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility. • Digital display and menu control provide easy local data access • Measurements are selectable in metric or English units • Remote convnunication thru a PC via network or serial configuration • Controller supports Modbuse protocol • Integrated hybrid voltageregulator with :0.5% regulation • Built-in alternator thermal overload protection • NFPA110'Level l capability Refer to G6-100 for additional controller features and accessories. C� Decision -Maker 550 Controller Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities. • Digital display and keypad provide easy local data access • Measurements are selectable In metric or English units • Remote communication thru a PC via network or modem configuration • Controller supports Modbuse protocol • Integrated voltage regulator with ±0.25% regulation • Built-in altemator thermal overload protection • NFPA 110 Level 1 capability Refer to G6-46 for additional controller features and accessories. Decision-Maker°6000 Paralleling Controller Provides advanced control, system monitoring, and system diagnostics with remote ranitoring capabilities for paralleling multiple generator sets. • Paralleling capability with first -on logic, synchronizer, kW and kVAR load sharing, and protective relays • Digital display and keypad provide easy local data access • Measurements are selectable In metric or English units • Remote communication thru a PC via network or modem configuration • Controller supports Modbuse protocol • Integrated voltage regulator with :0.25% regulation • Built-in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G8-107 for additional controller features and accessories. 05-371 (150REOZJF) 4/12a KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 ' KohlerPoweroom Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264.6422, Fax (65) 6264-6455 Standard Features • Altemator Protection • Battery Rack and, Cables • - Customer Connection (standard with Decision -Maker* 6000 controller only) • Local Emergency Stop Switch • Oil Drain Extension • Operation and Installation Literature Available Options Approvals and Listings- ❑ California OSHPD Approval ❑ CSA Approval ❑ IBC Seismic Certification ❑ UL2200 Listing Enclosed Unl ❑ Sound Enclosure (with enclosed critical silencer) ❑ Weather Enclosure (with enclosed critical silencer) Open Unit ❑ Exhaust Silencer, Critical (kit PA-354809) ❑ Flexible Exhaust Connector, Stainless Steel Fuel System ❑ Flexible Fuel Lines ❑ Fuel Pressure Gauge ❑ Subbase Fuel Tanks Controller ❑ Common Failure Relay ❑ Communication Products and PC Software ❑ Customer Connection (Dectalon-Makef® 550 controller only) ❑ Decision -Maker* Paralleling System (DPS) (Decision -Maker* 6000 controller only) ❑ Dry Contact (Isolated alarm) (Decision -Maker* 550 and 6000 controllers only) ❑ Input/Output Module (Decision -Maker* 3000 controller only) ❑ Remote Emergency Stop Switch ❑ Remote Serial Annunciator Panel ❑ Run Relay Cooling System O Block Heater, 1800 W, 90-120 V, 1 Ph O Block Heater, 2000 W,190-240 V, 1 Ph (recommended for ambient temperatures below 0°C (32°Fj) ❑ Radiator Duct Flange Electrical System ❑ Altemator Strip Heater ❑ Battery ❑ Battery Charger, Equalize/Float Type ❑ Battery Heater ❑ Line Circuit Breaker (NEMA type 1 enclosure) ❑ Line Circuit Breaker with Shunt Trip (NEMA type 1 enclosure) Paralleling System ❑ Manual Speed Adjust Miscellaneous ❑ Air Cleaner, Heavy Duty a Air Cleaner Restriction Indicator ❑ Certified Test Report ❑ Crankcase Emissions: Canister ❑ Engine Fluids Added ❑ Rated Power Factor Testing ❑ Rodent Guards Literature ❑ General Maintenance ❑ NFPA 110 ❑ Overhaul ❑ Production Warranty ❑ 2-Year Basic ❑ 5-Year Basic ❑ 5-Year Comprehensive Other Options Dimensions and Weights Overall Size, L x W x H, mm (In.): Weight (radiato model), wet, kg (lb.): 2950x1120x1527 (116.1 x 44.1 x 60.1) 1295-1402 (2855-3090) NOTE Thls drawing b prodded for reference only and shook' not be used for pbnNng Installation. Cordes your local dee1butor to more detailed Information. DISTRIBUTED BY: 02011, 2012 by Kohler kb. All rights reserved. 36471 (16OREOZJF) 4/12e Calderon, Yadissa From: Charles Yost <cyost@basulto.com> Sent: Tuesday, October 09, 2012 9:49 AM To: Bryan, Andre M; Gili-McGraw Architects (gili-mcgraw@att.net) Cc: Calderon, Yadissa Subject: RE: Fire Station Generator Replacement - Letter from Mr. Snow Re #IFB315279 Andre, The letter is acceptable. Thanks Charly Yost Basulto and Associates Consulting Engineers From: Bryan, Andre M [mailto:ABryan@miamigov.com] Sent: Tuesday, October 09, 2012 9:25 AM To: Gili-McGraw Architects (gili-mcgraw@att.net); Charles Yost Cc: Calderon, Yadissa Subject: Fire Station Generator Replacement - Letter from. Mr. Snow Re #IFB315279 Importance: High Gary/Charly, 1 believe the attached letter from the distributor satisfies our concerns and request. Please let me know if you concur. Thank you, Andre Bryan, P.E., LEEDeAP Electrical Engineer CITY OF MIAMI I Capital Improvements Program Office: (305) 416-1211 I Email: abrvanOmiamigov.com () Please consider the environment before printing this email. From: Calderon, Yadissa Sent: Tuesday, October 09, 2012 9:04 AM To: Bryan, Andre M Subject: FW: signed letter from Mr. Snow Re #IFB315279 Importance: High Good morning Andre, Please see attached and advise. Yadissa From: mcox fmailto:mcox@afcs-co.coml Sent: Tuesday, October09, 2012 7:07 AM To: Calderon, Yadissa Cc: Terry Daugherty; Doug Vecchio Subject: FW: signed letter from Mr. Snow Re #IFB315279 Hi Yadissa, Let me know if you have any questions. Mike Michael Cox President All Florida Contracting Services 3818 NW 126th Avenue, Coral Springs, FL 33065 954.775.7767 Fax 954.753.3122 CGC1517560 — EC0002256 — PCC1256894 From: John Pottsfmailto:John.PottsCaltawinc.coml Sent: Monday, October 08, 2012 6:00 PM To: 'mcox'; Terry Daugherty (terry(aafcs-co.com); Doug Vecchio <douaivecchio@aol.com> (douoivecchio(aaol.com) Subject: RE: signed letter from Mr. Snow Re #IFB315279 See attached. .+`` John Potts 1 Outside Sales Representative TAW Power Systems - Pompano 1500 NW 15th Avenue I Pompano Beach, FL 33069 �r tel: 954-977-0202 x1704 I fax: 954-977-9249 I cell: 954-234-4226 / John.PottsCo tawinc.com 1 htto://www.tawinc.com Excellence in Creating Innovative Solutions for the Supply, Control and Use of Energy From: mcox f maiito:mcox@afcs-co.coml Sent: Friday, October 05, 2012 4:59 PM To: John Potts Subject: FW: signed letter from Mr. Snow Re #IFB315279 Importance: High 2 Michael Cox President All Florida Contracting Services 3818 NW 126th Avenue, Coral Springs, FL 33065 954.775.7767 Fax 954.753.3122 CGC1517560 EC0002256 - PCC1256894 From: Calderon, Yadissa f mailto:ycalderonCla miamigov.coml Sent: Friday, October 05, 2012 3:45 PM To: Michael Cox Cc: 'terry@afcs-co.com'; Doug Vecchio; Bryan, Andre M Subject: signed letter from Mr. Snow Re #IFB315279 Importance: High Mr. Cox, The consultant marked the options with red arrows that are applicable to the project and in the best interest of the City. Can you revise your letter to indicate that you will comply with providing the items the consultant marked (please see attached)? Please provide a response no later than Tuesday, October 9, 2012 at 1:00 PM. Thank you in advance. Respectfully, Yadissa A. Calderon Senior Procurement Specialist Interim Procurement Card & Surplus Administrator City. of Miami' Purchasing Department 444 SW 2 Ave, 6th FL Miami, FL 33130 • 'R: 305 416-1909 A: 305 400-5369 ®: ycalderon@miamigov.com Website: http://www.miamigov.com/procurement/ 3 CONFIDENTIAL COMMUNICATION The information contained in this transmission may contain privileged and confidential information. It is intended only for the use of the person(s) named above. If you are not the intended recipient, you are hereby notified that any review, dissemination, distribution. or duplication of this communication is strictly prohibited. If you are not the intended recipient, please immediately contact the sender by reply e-mail and destroy all copies of the original message. Thank you. *Please Note: Due to Florida's very broad public records law, most written communications to or from City of Miami employees regarding City business am public records, available to the public'and media upon request. Therefore, this e-mail communication may be subject to public disclosure. From: Terry Daugherty jmailto:terryAafcs-co.coml Sent: Wednesday, October 03, 2012 9:49 AM To: Calderon, Yadissa Cc: Doug Vecchio; Michael Cox Subject: signed letter from Mr. Snow Re #IFB315279 Yadissa I hope this will complete the requirements. Please, respond. If any questions or comments please contact me. Thank You, Terry Daugherty Project Manager AFCS, LLC 954-328-2151 fax 954-753-3122 3818 NW 126th Avenue Coral Springs, Fl. 33065 terry@afcs-co.com This email has been scanned by the TAW® Email Security System and is guaranteed to be virus free. TAW®is a registered trademark of Tampa Armature Works, Inc. and Subsidiaries. CONFIDENTIALITY NOTICE: This email, and any files transmitted with it, may contain confidential, proprietary or privileged information that is intended only for the person or entity to which it is addressed. If you are not the intended recipient, you are hereby notified that any unauthorized dissemination, distribution, copying, or retransmission of this document or its attachments, if any, is strictly prohibited. If you have received this email in error, please notify the sender immediately and delete this material from all known records. This email has been scanned by the TAW® Email Security System and is guaranteed to be virus free. TAW® is a registered trademark of Tampa Armature Works, Inc. and Subsidiaries. 4 KOHLER. GENERATORS TAW Power Systems KOHLER POWER SYSTEMS DISTRIBUTOR FOR ALABAMA, S. GEORGIA, FLORIDA, LOUISIANA AND MISSISSIPPI 1500 NW 15a' Ave. Pompano Beach, FL 33069 TEL: (954) 977-0202 FAX: (954) 977-9249 SERVING FLORIDA SINCE 1921 October 8, 2012 To: Basulto & Associates, City of Miami Purchasing Phone: (305) 698-3988 Fax: (305) 698-3989 Project Name: City of Miami Fire Station Generator Replacement Ref: Generator Shop Drawing Submittal (Revision 1) In order to achieve the required overall length of 84" maximum, the generator base rail on our 100REOZJF will be shortened by 8" on the alternator end of the unit. This area oldie base rail is only utilized on enclosed units and is not required in this application. This modification will be done with factory authorization and will not affect performance or warranty of the generator. Furthermore, please refer to the "pre -submittal" package dated 9/24/2012. The generators will be configured in compliance with the options highlighted in this document. Please feel free to contact us if you require any additionalinformation. Regards, an no Project Manager TAW Power Systems Page 1 of KOHLER POWER SYSTEMS TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 Submittal Package Job Name: Quote: Proposal: PRELIMINARY SUBMITTAL PACKAGE FOR MIAMI FIRE STATIONS # 6, 8, 9 31555C-MIAMI FIRE STATION #8 0025851030 We are pleased to offer the following submittal for your consideration:. Thank you, Olga Mestey; Tampa Armature Works TAW. 9/11 TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 Job Name: 31555C-MIAMI FIRE STATION #8 Offer: K300517703 Version 1.0. Page 1 GENERATOR SET Model: 100REOZJF This generator set equipped with a 4R9X alternator operating at 120/208 volts is rated for 100 kW/125 kVA. Output amperage: 347 Configuration Qty Description 1 100REOZJF Generator Set 1 Radiator Duct Flange, Unhoused 1 100REOZJF, 12V, 60HZ 1 Nameplate Rating, Standby 130 Degree 1 Decal, UL2200 Listing (Diesel) 1 Voltage,60Hz,120/208V,3Ph,4W,0.8PF 1 Alternator & Mtg. 4R9X 1 Cooling, Unit Mounted Radiator 1 Skid/Tank, 100gal, Day Tank with Return & Supply Pumps 1 Air Intake, Standard Duty 1 Controller, DEC3000 400A, 3Ph 1 Control. & Harness, Dec3000 1 Flexible Fuel Lines 1 Inner Tank Leak Alarm 1 Block Heater, 1500W, 120V 1 Coolant in Genset 5 gals. 1 Silencer,Critical,4"NPT,SIEO 1 Flexible Exhaust Conn,4"NPT 1 Battery Charger,Float w/Alarms,12V-10A 1 Warranty, 1 Year Standby 1 Warranty, 5 Year Comprehensive 1 RSA II, Annunciator Only 1 Power Factor Test,0.8,3Ph Only 1 LCB, 400A, DGP, EL, 100% 1 Mtg, LCB, D-Frame, 400A. 4S 1 Shunt Trip, 12VDC, HD/JD/DG Frame 1 Neutral, 600A 4S 1 Covers, 4S J-Box D-Frame LCB 1 Accessory Inner Panel 1 Shunt Trip Wiring, DEC3000 KOHLER OWER SYSTEMS TAW,. TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 Job Name: 31555C-MIAMI FIRE STATION #8 Offer. K300517703 Version 1.0 Page 2 MISCELLANEOUS Part Number Qty Description GM81510-KP 5 Lit Kit, General Maint, 100REOZJF KOHLER.POWER SYSTEMS KOHLER POWER SYSTEMS Spec Sheets 100REOZJF KOHLER POWER SYSTEMS Diesel 09001 c.atm. NATIONALLY REGISTERED Generator Set Ratings Standard Features • Kohler Co. provides one -source responsibility for the generating system and accessories. • The generator set and its components are prototype - tested, factory -built, and production -tested. • The 60 Hz generatorset offers a UL 2200 listing. • The generator set accepts rated Toad in one step. • The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards. • A one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Altemator Features: o The unique Fast -Response X excitation system delivers excellent voltage response and short circuit capability using a rare-earth, permanent magnet (PM) -excited altemator. o . The brushless, rotating -field alternator has broad range reconnectability. • Other Features: o Controllers are available for all applications. See controller features inside. o The low coolant level shutdown prevents overheating (standard on radiator models only). o Integral vibration isolation eliminates the need for under -unit vibration spring isolators. o Multiple circuit breaker configurations. Standby130C Ratings Alternator Voltage Ph Hz . kW/kVA Amps 4R9X 120/208 3 60 100/125 347 RATINGS: All three-phase units are rated at 0.8 power factor. AP single-phase units are rated at 1.0 power factor. Standby Ratings: The standby rating is applicable to varying bads for the duration of a power outage. There Is no ovedoad capability for this rating. Prime Power Ratings: At varying load, the number ofgenerator set operating hours Is unlimited. A 10% overload capacity Is available for one hour In twelve. Ratings ere in accordance with 1SO-8528-1 and ISO3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical Information bulletin (TIB-701) for ratings guidelines, complete ratings definitions, and site condition derates. The generator set manufacturer reserves the right to change the design 01 specifications without notice and without any obligation or (lability whatsoever. Model: 10"OREOZJF, continued Alternator Specifications Specifications Alternator Alternator manufacturer Type Exciter type Leads, quantity Voltage regulator Insulation Insulation: Material Insulation: Temperature Rise Bearing: quantity, type Coupling Amortisseur windings Voltage regulation, no-load to full -load RMS One -Step Load Acceptance Unbalanced load capability Kohler 4-Pole, Rotating -Field Brushless, Rare -Earth Permanent -Magnet 12, Reconnectable Solid State, Volts/Hz NEMA MG1 Class H 130°C, Standby 1, Sealed Flexible disc Full Controller Dependent 100% of rating 100% of Rated Standby Current • Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds. • Sustained short-circuit current enabling down stream circuit breakers to trip without collapsing the altemator field. • Self -ventilated and dripproof construction. • Vacuum -impregnated windings with fungus -resistant epoxy varnish for dependability and Tong life. • Superior voltage waveform from a two-thirds pitch stator and skewed rotor. Engine Engine Specifications Engine Manufacturer Engine Model Engine: type Cylinder arrangement Displacement, L (cu. in.) Bore and stroke, mm"(in.) Compression ratio Piston speed, m/min. (ft./min.) Main bearings: quantity, type Rated rpm Max. power at rated rpm, kWm (BHP) Cylinder head material Crankshaftmaterial Valve "(exhaust) material Intake Valve (exhaust) material Exhaust Governor: type, make/model Frequency regulation, no-load to -full load Frequency regulation, steady state Frequency Air cleaner type, all models John Deere 4045HF285I 4-Cycle, Turbocharged, Charge Air -Cooled 4 Inline 4.5 (276) 106 x 127 (4.19 x 5.00) 19:1 457 (1500) 5, Replaceable Insert 1800 118 (158) Cast Iron Forged Steel Chromium -Silicon Steel Stainless Steel JDEC Electronic L16 Denso HP3 Isochronous ±0.25% Fixed Dry Model: 100REOZJF, continued Exhaust Exhaust System Exhaust Manifold Type Exhaust flow at rated kW, m3/min. (cfm) Exhaust temperature at rated kW, dry exhaust, °C (°F) Maximum allowable back pressure, kPa (in. Hg) Exh. outlet size at eng..hookup, mm (in.) Engine Electrical Dry 22.8 (805) 580 (1076) 7.5 (2.2) 98 (3.86) Engine Electrical System Battery charging alternator Battery charging alternator: Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Qty., CCA rating each Battery voltage (DC) Fuel 12 Volt/24 Volt Negative 12/24 65/45 12/24 One, 640/Two, 570 12 Fuel System Fuel type Fuel supply line, min. ID, mm (in.) Fuel return line, min. ID, mm (in.) Max. lift, fuel pump: type, m (ft.) Max. fuel flow, Lph (gph) Fuel prime pump Fuel Filter Secondary Fuel Filter Primary Fuel Filter Water Separator Recommended fuel Lubrication Diesel 11.0 (0.44) 6.0 (0.25) Engine -Driven, 1.8 (6.0) 74.6 (19.7) Manual 2 Microns@ 98% Efficiency 30 Microns Yes #2 Diesel Lubrication System Type Oil pan capacity, L (qt.) Oil pan capacity with filter, L (qt.) Oil filter: quantity, type 0il.cooler Full Pressure 14.7 (15.5) 15.6 (16.5) 1, Cartridge. Water -Cooled Model: 100REOZJF, continued Cooling Radiator System. Ambient temperature, °C (°F) 50 (122) Engine jacket water capacity, L (gal.) 8.5 (2.25) Radiator system capacity, including engine, L (gal.) 20.1 (5.3). Engine Jacket water flow, Lpm (gpm) 182 (48) Heat rejected to cooling water at rated kW, dry 62 (3544) exhaust, kW (Btu/min.) Heat rejected to air charge cooler at rated kW, dry 20 (1127) exhaust, kW (Btu/min.) Water pump type Centrifugal Fan diameter, including blades, mm (in.) 600 (23.6) Fan, kWm (HP) 6.6 (8.8) Max. restriction of cooling air, intake and discharge 0.125 (0.5) side of radiator, kPA (in. H20) * Enclosure with internal silencer reduces ambient temperature capability by 5°C (9°F). Operation Requirements Air Requirements Radiator -cooled cooling air, m'/min. (scfm) * 142 (5000) Combustion air, m3/min. (cfm) 8.2 (288) Heat rejected to ambient air: Engine, kW (Btu/min.) 25.0 (1420) Heat rejected to ambient air: Alternator, kW (Btu/ 11.6 (660) min.) *Air density = 1.20 kg/m'.(0.075 Ibm/ft3) Fuel Consumption Diesel, Lph (gph), at % load Rating Standby Fuel Consumption at 100% load Standby Fuel Consumption at 75% load Standby Fuel Consumption at 50% load Standby Fuel Consumption at 25% load' Prime Fuel Consumption at 100% load Prime Fuel Consumption at 75% load Prime Fuel Consumption at 50% Toad Prime Fuel Consumption at 25% load 31.0 Lph (8.2 gph) 25.0. Lph (6.6 gph) 17.8 Lph (4.7 gph) 9.5 Lph (2.5 gph) 27.6 Lph (7.3 gph) 22.7 Lph (6.0 gph) 14.4 Lph (3.8 gph) 7.6 Lph (2.0 gph) Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Generator Set Controller 09001 . NATIONALLY REGISTERED KOHLER Di C ISIONI-t.t,,:KE It. Declslon-Maker® 3000 Kohler® Decision -Maker® 3000 Controller General Description and Function The Decision -Maker® 3000 generator set controller provides advanced control, system monitoring, and system diagnostics for optimum performance. The Decision -Maker® 3000 controller meets NFPA 110, Level 1 when equipped with the necessary accessories and Installed per NFPA standards. The Decision -Maker® 3000 controller uses patented software logic to manage sophisticated functions, such as voltage regulation and alternator thermal overload protection, normally requiring additional hardware. Additional features Include: • A digital display and pushbutton/rotary selector dial provide easy local access to data. • Measurements selectable in metric or English units. • The controller can communicate directly with a personal computer via a network or serial configuration using SiteTech' or Monitor Ill software. • The controller supports Modbuse protocol. Use with serial' bus or Ethernet networks. • Scrolling display shows critical data at a glance. • Digital display of power metering (kW and kVA), • Integrated hybrid voltage regulator providing ±0.5% regulation. • Built -In alternator thermal overload protection. Modbus® is a registered trademark of Schneider Electric. 06-100 1/12b Page 1 Emergency Stop Switch Digital Display Alarm Horn (located — Inside the controller) Master Control Buttons Off-Reset/Auto/Run with Ughts a Volts -V a80.0 Ll n e�. .-- FRUIT OFF/RESET AUTO RUN ALARM SILENCE/ LAMP TEST , sa User Interface Controls and Components • Emergency stop switch • Backlit LCD digital display with two lines of 12 characters (see User interface Displays for menus) • Alarm hom Indicates generator set shutdown and warning faults • Environmentally sealed membrane keypad with three master control buttons with lights o Off/Reset (red) o Auto (green o Run (yellow • Pushbutton/rotary selector dial for menu navigation o Rotate dial to access main menus o Push dial and rotate to access sub menus o Press dial for 3 seconds to retum to top of main menu • Annunciator fault light o System shutdown (red) o System warning (yellow) • Alarm silence/lamp test button o Alarm silence o Lamp test • USB and RS-485 connections o Allows software upgrades o Provides access for diagnostics o PC communication using SiteTech' or Monitor III software • Dedicated user Inputs o Remote emergency stop switch o Remote 2-wire start for transfer switch o Auxiliary shutdown • Integrated hybrid voltage regulator • Auto-resettable circuit protection mounted on circuit board. • One relay output standard. Optional five relay output available. • One analog and three digital inputs standard. Optional two inputs available. NFPA 110 Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generatorfunctions and faults shown below. • Engine functions: o Overcrank o Low coolant temperature warning b High coolant temperature warning o High coolant temperature shutdown o Low oil pressure shutdown o Low oil pressure warning o High engine speed o Low fuel (level or pressure) * o Low coolant level o EPS supplying load o High battery voltage o Low battery voltage • General functions: o Master switch not In auto- o Battery charger fault* o Lamp test o Contacts for local and remote common alarm o Audible alarm silence button o Remote emergency stop * • Functions require optional Input sensors or kits Pushbutton/Rotary Selector Dial Annunciator Fault Ught Red -Shutdown, Yellow -Warning Alarm Silence/Lamp Test Button wlth Ught USB Communication Connection User Interface Displays The listing below has • denoting main menus and 0 denoting sub -menus. • Overview o Software version o Active shutdowns and warnings (If any are present) o Engine run time, total hours o Average voltage line -to -line o Frequency. o Average current o Coolant temperature o Fuel level or pressure * o 011 pressure o Battery voltage • Engine Metering o Engine speed o 011 pressure o Coolant temperature o Battery voltage • Generator Metering o Total power, VA o Total power, W o Rated power, % o Voltage, L-L and L-N for all phases o Current, L1, L2, L3 o Frequency • GenSet Information o Generator set model number o Generator set serial number o Controller serial number • GenSet Run Time o Engine run time, total hours o Engine loaded, hours o Number of engine starts o Total energy, kWh • GenSet System o System voltage o System frequency, 50 or 80 Hz o System phase, single or three (wye or delta) o Power rating, kW o Amp rating o Power type, standby or prime o Measurement units, metric or English (user selectable) o Alarm silence, always or auto only (NFPA 110) • GenSet Calibration o Voltage, L-L and L-N for all phases o Current, L1, L2, L3 o Reset calibration • Voltage Regulation o Adjust voltage, :10% • Digital Inputs o Input settings and status • Digital Outputs o Output settings and status • Analog Inputs o Input settings and status • Event Log o Event history (stores up to 1000 system events) • Selector Switch (requires Initial activation by SiteTech') • Function requires optional input sensors or kits 66.1001/12b Page2 Controller Features • AC Output Voltage Regulator Adjustment. The voltage , adjustment provides a maximum of 210% of the system voltage. • Alarm Silence. The controller can be set up to silence the alarm hom only when in the AUTO mode for NFPA-110 application or Always for user convenience, • Alternator Protection, The controller provides generator set overload and short circuit protection matched to each alternator for the particular voltage/phase configuration. • Automatic Restart. The controller automatic restart feature initiates the start routine and recrank after a failed start attempt, • Common Failure Relay. This relay Is Integrated on the controller circuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at 120 VAC. - • Communication. Controller communication Is available. • Cyclic Cranking. The controller has programmable cyclic cranking: • ECM Diagnostics. The controller displays engine ECM fault code descriptions to help In engine troubleshooting. • Engine Start Aid. The starting aid feature provides control for an optional engine starting aid. • Event Logging. The controller keeps a record (up to 1000 entries) for warning and shutdown faults. This fault information becomes a stored record of system events and can be reset. • Historical Data Logging. Total number of generator set successful starts is recorded and displayed. • Integrated Hybrid Voltage Regulator. The voltage regulator provides 20.5% no-load to full -load regulation with three-phase sensing. • Lamp Test. Press the alarm silence/lamp test button to verify functionality of the indicator lights. • • LCD Display. Adjustable contrast for improving visibility. • Measurement Units. The controller provides selection of English or metric displays. . • Power Metering. Controller digital display provides kW and kVA • Programming Access (USa). Provides software upgrades and diagnostics. • Remote Reset. The remote reset function resets faults and allows restarting of the generator set without going to the master control switch off/reset position. • RSA II Remote Monitoring Panel. The controller Is compatible with the Kohlere Remote Serial Annunciator (RSA II). • Run Time Hourmeter. The generator set run time Is displayed. • Time Delay Engine Cooldown (TDEC). The TDEC provides a time delay before the generator set shuts down. • Time Delay Engine Start (TOES). The TDES provides a time delay before the generator set starts. • Voltage Selection Menu. This menu provides the capability of quickly switching controller voltage calibrations. Requires initial activation using SlteTech' software. NOTE: Generator set output leads require voltage reconnection. Controller Functions The following chart shows which functions cause a warning or shutdown. All functions are available as relay outputs. Warning causes the fault Tight to show yellow and sounds the alarm hom signaling an impending problem. Shutdown causes the fault light to show red, sounds the alarm horn, and stops the generator set. Warning Function Shutdown Function Critically high fuel level* o ECM communication loss • ECM diagnostics • • Engine over speed el - Engine start aid active Engine under speed •• Fuel tank leak * o 0 High battery voltage • High coolant temperature • •t High fuel level* o Low battery voltage • Low coolant level • Low coolant temperature • Low cranking voltage • Low engine oil level* o o Low fuel level (diesel models) * o 0 Low fuel pressure (gas models) * o Low oil pressure • •f No coolant temperature signal • No oil pressure signal • Overcrank •t Speed sensor fault - • rolneratTundioris t . Alarm horn silenced Analog inputs o o Battery charger fault* • Chicago code active * Common fault (Includes t) • Common warning • Digital inputs o o Emergency stop •t Engine cooldown (delay) active Engine start delay active Engine started Engine stopped EPS supplying Toad Generator running Input/output communication loss • Internal failure • Master switch not in auto • NFPA 110 alarm active Remote start System ready (Generator„Functions 4 '. r a ' AC sensing loss • • Alternator protection • Ground fault input * • kW overload • Locked rotor • Overfrequency • Overvohage (each phase) • Underfrequency • Undervoltage (each phase) • • Standard functions o Available user functions * Functions require optional Input sensors or kits t items Included with common fault shutdown G6-100 1/12b rage 3 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1848 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 819159 Phone (65) 6264-6422, Fax (65) 6264-6455 Controller Specifications Decision -Makers 3000—Software Version 3.0.25 or higher • Power source with circuit protection: 12- or 24-volt DC • Power drain: 200 milliamps • 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; o CE Directive o NFPA 99 o NFPA 110, Level 1 o UL 508 o ASTM B/17 (salt spray test) • Panel dimensions—W x H, 229 x.160 mm (9.0 x 6.3 in.) Decision-Makere 3000 Available Options Float/Equalize Battery Charger available with 6 or 10 amp DC volt output. The 10 amp models are available with and without NFPA alarm to signal a battery charger fault. 0 Prime Power Switch prevents battery drain during generator set non -operation periods and when the generator set battery cannot be maintained by an AC battery charger. ❑ Remote Emergency Stop Switch available as a wall mounted panel to remotely shut down the generator set. ❑ Remote" Monitoring Panel. The Kohler® Remote Serial Annunciator (RSA II) enables the operator to monitor the status of the generator set from a remote location, which may be required for NFPA 99 and NFPA 110 installations. ❑ Run Relay provides a relay indicating that the generator set Is running. ❑ Shunt Trip Wiring provides relay outputs to trip a shunt trip circuit breaker and to signal the common fault shutdowns. Contacts rated at 10 amps at 28 VDC or 120VAC. ❑ Two Input/Five Output Module provides a generator set mounted panel with two Inputs and five relay outputs. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohlerm generator set distributor for availability. Communication and PC Software Available Options Refer to 05-76 Monitor 111 Software and the communication literature for additional communication and PC software information including Modbuss communication. ❑ Monitor III Software for Monitoring and Control (Windows• -based user Interface) ❑ Converter, Modbuse/Ethemet. Supports a power system using controllers accessed via the Ethernet. Converter is supplied with an IP address by the site administrator. Refer to GB-79 for converter details. ❑ Converter, RS-232/RS-485. Supports a power system using controllers accessed via a serial (RS-232) connection. Modbue° ls a registered trademark of Schneider Electric.. Window° is a mattered trademark of Microsoft Corporation. DISTRIBUTED BY: ® 2009, 2010, 2012 by Kohler Co., All rights reserved. ee-1001/12b Page4 PowerPact® D-Frame Circuit Breakers and Switches General Information Section 1—General Information Introduction PowerPact® D-frame electronic trip molded case circuit breakers are designed to protect electrical systems from damage caused by overloads and short circuits. All circuit breakers are designed to open and dose a circuit by nonautomatic means and to open the circuit automatically on a predetermined overcurrent. The D-frame circuit breakers use an electronic trip system to signal the circuit breaker to open automatically. Table 1: D-Frame Circuit Breakers and Switches Circuit Breaker Switches Motor Circuit Protectors Rated Current (A) Application 150-600 A 400 A. 600 A 400-600 A For information on other PowerPact molded case circuit breakers manufactured by Square D®, see the Class 611, 612 and 613 catalogs. Features and Benefits D-frame electronic trip circuit breakers: • Provide overload and short-circuit protection • Are true RMS sensing devices • Provide means to manually, disconnect power to the circuit . • Provide enhanced coordination by theiradjustability • Provide high interrupting ratings and withstand ratings • Use many of the same accessories as other PowerPact circuit breakers • Have a wide range of NEMA and IEC operating mechanisms @ 2007-2009 Schneider Electric All Rights Reserved SLILIARE D by INirielder Etectr c 08/2009 7 PowerPact® D-Frame Circuit Breakers and Switches General Information Table 2: Catalog Numbering D L L 3 6 250 T Brand blank Square D N Schneider Electric Terminations Voltage 6 600 Vac 7 500 Vdc (Future) L Lugs Una/Load Side M Lugs ON Side, Bus OFF Side P Lugs OFF Side, Bus ON Side F Bus Bar Both Sides S Rear Connected N Plug -In D Drawout Interruption Rating (kA) Poles 3 3P 4 4P1 5 4P+Oversized Neutrals Amperage 150 250 400 600 000 60-150 A 100-250 A 160-400 A 240-600 A Switch LT(IP Unit E20 STR23SP (LS) E53 STR53UP-F (LSI) E54 STR53UP-FT (LSIG) E58 STR53UP-FI (LSI) E59 STR53UP-FTI (LSIG) F40 150, 250, or 400 A Frame Only (No trip unit) F60 600 A Frame Only (No trip unit) M36 400 A Motor Circuit Protector (MCP) M42 600 A Motor Circuit Protector (MCP) S40 400 A Molded Case Switch S60 600 A Molded Case Switch Accessory Suffix Code (See Table 3 and Section 6) -Line® Phasing (Future Offering) Interrupting Rating UUCSA/N OM IEC 60947-2 IcuAcs 240 Vac 480 Vac 600 Vac 220/240 Vac 380/440/415 Vac 500/525 Vac 250 Vdc. 500 Vdc G 65 kA 35 kA 18 kA 65/65 kA 35/35 kA 18/18 kA 20 kA 20 kA J 100 kA 65 kA 25 kA 100/100 kA 65/65 kA 25/25 kA 20 kA 20 kA L 125 kA 100 kA 25 kA 125/125 kA 100/100 kA 50/50 kA 20 kA 20 kA 1 4P circuit breaker available In plug-in, draw -out and rear -connected only. Availability of 4P bus -connected and lug configurations to be announced. Table 3: Accessory Suffix Codes (Building Sequence as Listed) (1) Aux Ilary Switch Suffix AA AB AE AF Contacts 1A/1B Standard 2A/2B Standard 1 A/1 B Low Level 2A/2B Low Level Kit No. S29450 2x S29450 829482 2x S29482 (2) Alarm/Overcursnnt Trip Switch Suffix BC Switch Kit No. Alarm Switch (SD) S29450 BH Alarm Switch (SD) Low -Level 329452 BD BJ SDE Standard 829450 SDE Low -Level S29452 BE SD end SDE 2 S29450 Standard BK SD and SDE 2 529452 Low -Level (3) Shunt Trip Voltage (4) Undervoltage Release UVR Suffix Kit No. Suffix Kit No. SK S29384 24 Vac. UK S29404 SL S29385 48 Vac UL S29405 SA S29386 120 Vac UA S29406 SD S29387 208-277 Vac UD S29407 SH S29388 380-480 Vac UH S29408 SJ S29389 525-600 Vac UJ S29409 SN S29382 12 Vdc UN S29402 SO S29390 24 Vdc UO S29410 SU S29391 30 Vdc UU S29411 SP S29392 48 Vdc UP S29412 SV S29383 60 Vdc UV S29403 SR S29393 125 Vdc UR S29413 SS S29394 250 Vdc US S29414 (5) Motor Operator Suffix ML MA MD MF MH MO MP MR MS Voltage 48/60 Vac 120 Vac 277 Vac 380/415 Vac 440/460 Vac 24/30 Vdc 48/60 Vdc 110/130 Vdc 250 Vdc Kit No. S32839 S32840 S32841 S32845 S32847 S32843 832844 S32845 S32846 (6) IEC Style Rotary Handle Suffix RD12 RE12 RT12 RD22 RE22 Handle Type (color) Direct Mount (black) Extended Door Mount (black) Telescoping (black) Direct Mount (red) Extended Door Mount (red) MCC Conversion Accessory KIt No. 32597 32598 32603 32599 32800 32606 08/2009 SQUARE I] 8dmeider Electric ® 2007-2009 Schneider Electric All Rights Reserved PowerPact® D-Frame Circuit Breakers and Switches General Information Features PowerPact electronic trip circuit breakers have a molded case made of a glass -reinforced insulating material (thermal set composite resin) that provides high dielectric strength. These circuit breakers: • Are available in either dual -rated UUIEC or IEC-only constructions • Dual -rated UL/IEC circuit breakers are also GSA and ANCE certified • Are manufactured in unit -mount, plug-in and drawout constructions • Share common tripping of all poles • Can be mounted and operated in any position • Are available in motor circuit protector and automatic molded case switch constructions • Can be reverse connected, without restrictive LINE and LOAD markings • Meet the requirements of NECe Sections 240-6 by providing a means to seal the rating plug and trip unit adjustments • Have field -interchangeable trip units Circuit Breaker Ratings Interrupting Rating The interrupting rating is the highest current at rated voltage which the circuit breaker is designed to safely interrupt under standard test conditions. Circuit breakers must be selected with interrupting ratings equal to or greater than the available short-circuit current at the point where the circuit breaker is applied to the system (unless it is a branch device in a series -rated combination). Interrupting ratings are shown on the front of the circuit breaker. Table 4: • UL/IEC Circuit Breaker Interrupting Ratings (See Table 18 and Table 22 for additional ratings.) Circuit Breaker•240 UL/CSA Rating (60 Hz) IEC 60947-2 Rating (50/60 Hz) Vac 380/415 Vac 240 Vac 480 Vac 600 Vac Icu Ics Icu Ics I, DG 65kA 35kA 18kA 85kA 85kA 45kA 45kA DJ 100 kA 65 kA 25 kA 100 kA 100 kA 70 kA 70 kA DL - 150 kA 100 kA 25 kA 150 kA 150 kA - ' 150 kA 150 kA Ampere Rating (Continuous Current Rating) The ampere rating (or continuous current rating) (Ir) is the maximum current that a circuit breaker can carry. The sensor size (In) is the maximum ampere rating for a specific circuit breaker and is based on the size of the sensor inside the circuit breaker (sensors are an integral part of the D-frame circuit breaker and cannot be removed or replaced). This value is printed in a window above the trip unit. . NOTE: The maximum ampere rating a circuit breaker family can carry is called the frame size. Sensor size is less than or equal to frame size. The ampere rating of an electronic trip circuit breaker is determined by the mathematical equation: Ampere Rating = Sensor Size (1o) x Long -Time (Ir) The rating plug varies the circuit breaker ampere rating as a function of its sensor size. Rating plugs have nine dial settings; the multiplier values corresponding with each setting are printed on the rating plug. The maximum setting range is 0.4-1.0 x In. ® 2007-2009 Schneider Electric All Rights Reserved SUUARE D h sco ietder Et•etrIc 08/2009 PowerPact® D-Frame Circuit Breakers and Switches General Information Circult Breaker Marldng Switch Marking 14 Codes and Standards D-frame electronic trip circuit breakers and switches are manufactured and tested in accordance with the following standards: Table 9: Standards Circuit Breakers Switches UL 4891 IEC Standard 60947-2 CSA 22.2 No 6-022 Federal Specification W-C-375B/GEN NEMA AB1 NF, VDE, BS, CEI, AS UL 489 IEC Standard 60947-3 CSA 222 No 5-02 Federal Specification W-C-375B/GEN NEMA AB 1 NF, VDE, BS, CEI, AS 1 Circuit breakers, switches and their accessories, except where noted, are Listed under UL files E63335, E103740 and E103955 2 Circuit breakers, switches and their accessories, except where noted, are Certified under CSA files LR69561 and LR88980 Circuit breakers should be applied according to guidelines detailed in the National Electrical Code® (NEC®) and other local wiring codes. Specifications of Marine Classification Organizations PowerPact D-frame circuit breaker is UL Listed per UL489 Supplement SA. Certifications for marine application by the American Bureau of Shipping, Bureau Vertas, Lloyd's Register of Shipping, Registro Italian() Navale, Germanischer Lloyd's and Det Norske Veritas are pending. Pollution Degree PowerPact circuit breakers are certified for operation in pollution degree III environments as defined by IEC standard 60947-1 (industrial environments). Environmental Protection PowerPact circuit breakers take into account concems for environmental protection. Most components are recyclable and parts are marked as specified in applicable standards. Suitability for Isolation (Positive Contact Indication) All PowerPact circuit breakers and switches are suitable for isolation as defined in the IEC 60947-2 Standard: • The isolation position corresponds to the off (0) position' • The operating handle cannot indicate the off position unless the contact are open • Padlocks may not be installed unless the contacts are open Installation of a rotary handle or a motor mechanism does not alter the functionality of the position indication system. The isolation function is certified by tests guaranteeing: • The mechanical reliability of the position indication system • The absence of leakage currents • Overvoltage withstand capacity between upstream and downstream connections 08/2009 SOUAAE D bysduielder Elec5ric © 2007-2009 Schneider Electric All Rights Reserved PowerPact® D-Frame Circuit Breakers and Switches Electronic Trip Units Section 2—Electronic Trip Units Trip Units for PowerPact® D-Frame Circuit Breakers PowerPact D-frame circuit breakers are equipped with current sensors and an STR electronic trip unit. Current sensors are available in two different sizes: • 400 A frame-150, 250 and 400 A versions • 600 A. frame-600 A version STR trip units provide protection for Toads, from 60 to 600 A: • STR23SP and STR53UP for standard protection can be mounted on all circuit breakers • Trip unit STR53UP offers a greater number of optional indication and measurement functions, protection settings and ground -fault protection • STR23SP-OSN for oversized neutral protection (factory -installed only) • STR53UP for generator supplied network protection and long cable runs • STR23SP and STR53UP trip units are available on 4P circuit breakers with sealable, three -position neutral protection setting: — 4P 3D (no neutral protection) — 4P 3D + N/2 (neutral protection at 0.5, x Ir) where Ir is trip unit current setting — 4P 4D (neutral protection at Ir) where Ir Is trip unit current setting. © 2007-2009 Schneider Electric All Rights Reserved GG1UARE iD by lidifeldOr Electric 17 08/2009 PowerPact® D-Frame Circuit Breakers and Switches Electronic Trip Units Table 12: Trip Units STR23SP. STR53UP Overload Protection (Long -Time) Tripping Threshold In 20-70'C Adjustable (48 Settings) 0.4-1 x In Adjustable (32 Settings)(A) 0.4-1 x In Tripping Time (s) (Min -Max) — Fixed Adjustable At 1.5 x Ir 120-180 17-25 34-60 89-100 138-200 277-400 At 6 x Ir 5-7.5 0.8-1 1.6-2 3.2-4 6.4-8 12.8-16 At 7.2 x Ir 3.2-5.0 0.5-0.7 1.1-1.4 2.2-2.8 4.4-5.5 8.8-11 Short -Circuit Protection (Short Time) Tripping IMIISD Adjustable (7 Settings) 2-9 x Ir Adjustable (7 Settings) 1.5-7 x Ir Accuracy t 15% Time DelayMax. (ma) Overcurrent Time Before Tripping Fixed s 40 Adjustable (4 Settings + Constant Izt Function) 515 5 60 5140 s 230 Total Breaking Time s 60 s 60 s 140 s 230 s 350 Short -Circuit Protection (Instantaneous) Tripping Threshold (A) I Fixed 2 9 x In 'Adjustable (7 Settings) 1.5-7 x Ir Adjustable Neutral Protection (Three Position Switch) (STR23SP OSN1 only) Switch Position 1 Position 2 Position 3 Settings Protection Level 4P 3D No Neutral Protection 4P 3D + N/2 0.5x1r 4P4D 1.0x1r Electronic Trip Unit (Field Replaceable) Trip Unite Trip Function Suffix Cat. No. Long -Time, Short -Time and Fixed Instantaneous Protection STR23SP LS E20 36940 Long -Time, Short -Time, Instantaneous Protection and Options STR53UP-F LSI E53 36942 STR53UP-FT LSIG E54 36943 STR53UP-FI LSI E58 36944 STR53UP-F fl LSIG E59 36945 Communication Wiring — — 32441 Replacement Battery — — 32434 1 Oversized Neutral 2 F - Fault Indicator, T = Residual -Type Ground -Fault Protection; 1= Ammeter 18 08/2009 SQUARE 13 by Sdthekder Eleatrlc © 2007-2009 Schneider Electric All Rights Reserved Definitions = Current In - Nominal Current = Sensor Rating to = Course Adjustment x In Ir= Long -Time (LT) Pickup x to Short -Time (ST) Im = Pickup x Ir PowerPact® D-Frame Circuit Breakers and Switches Electronic Trip Units Electronic Trip Unit STR23SP and SR23SP-OSN (Oversized Neutral) Protection • Long-time (LT) overload protection, adjustable threshold, based on the actual RMS current — Adjustable threshold (2) using six lo base settings (0.5-1) and fine adjustment Ir with eight - settings (0.8-1) — Non-adjustable tripping time (2) • Short -time (ST) short-circuit protection: — Adjustable threshold Im (3) — Fixed time delay (4) • Instantaneous (I) short-circuit protection, fixed threshold (5) • Neutral protection available on standard 4P circuit breakers; protection level controlled using three - position switch: — 4P 3D: no protection of neutral — .3D + N/2: neutral protection at 0.5 Ir — 4P 4D: neutral protection at Ir • Neutral protection for STR23SP-OSN (oversized neutral) available on four -pole circuit breakers equipped with oversized neutral protection; protection level controlled using three -position switch: — 4P 3D: no protection of neutral — 3D + N/2: neutral protection at 0.75 x Ir — 4P 4D: neutral protection at 1.5 x Ir Indications Load indication (LED) in front (6): • Lights solid at 90% of Ir threshold • Flashes at > 105% or greater of Ir threshold Test Test connector in front (7) allows connection to the test kit, to check circuit breaker operation after fitting the trip unit or other accessories. Setting Example Question: what is the overload protection threshold of a 400 A D-frame circuit breaker equipped with trip unit STR23SP where lo - 0.5 and Ir - 0.8? ® 2007-2009 Schneider Electric All Rights Reserved SGiu,4RE D sit 9Cheetder E i•ctrk 08/2009 19 PowerPact® D-Frame Circuit Breakers and Switches Electronic Trip Units Definitions = Current In = Nominal Current = Sensor Rating to = Course Adjustment x In Ir = Long -Time (LT) Pickup x to Short -Time (ST) Im = Pickup x Ir Isd = Instantaneous Pickup Ig = Ground -Fault Pickup 20 Answer: In x lo x 1r = 400 x 0.5 x 0.8 = 160 A The same trip unit with the same settings, mounted on a 600 A frame circuit breaker, will have the following tripping threshold: In x to x Ir = 600 x 0.5 x 0.8 = 240 A. Electronic Trip Unit STR53UP Protection • Long-time (LT) overload protection, adjustable threshold, based on actual rms current, as defined by IEC 60947-2, appendix F: — Adjustable threshold (1) using six to base settings (0.5-1) and fine adjustment Ir with eight settings ranging (0.8-1) — Adjustable tripping time (2) • Short -time (ST) short-circuit protection: — Adjustable threshold Isd (3) — Adjustable time delay (4), with or without constant I2t function • Instantaneous (Ii) short-circuit protection, adjustable threshold (5) • Neutral protection available on standard 4P circuit breakers; protection level controlled using three - position switch: — 4P 3D: no protection of neutral — 3D + N/2: neutral protection at 0.5 Ir — 4P 4D: neutral protection at Ir Overload Indications (%lr) • LED (9) lights solid when current exceeds 0.9 Ir • LED (9) flashes when current exceeds long-time threshold Ir Fault Indications LEDs indicate the type of fault that caused tripping: • Overload (LT protection) or abnormal component temperature (> Ir) • Short-circuit (ST or instantaneous protection) (> Isd) • Ground -fault (if ground -fault protection option is present) > Ig • Microprocessor malfunction —both (> Ir and > Isd) LEDs go on, plus the > Ig LED, if the ground fault protection option is present The LEDs are battery powered with spare batteries supplied in the adapter box. When a fault occurs, the LED indicating type of fault shuts off after approximately 10 minutes to conserve battery power. 08/2009 ❑� SQUARED © 2007-2009 Schneider Electric All Rights Reserved by Schneider Electr I Industrial Generator Set Accessories KOHLERPOWER SYSTEMS Line Circuit Breakers 20-2250 kW 09001 NATIONALLY REGISTERED Single Circuit Breaker Kit with Neutral Bus Bar 20-300 kW Model Shown Dual: Circuit Breaker Kit w th Neutral Bus Bar 20-300 kW Model Shown 0 • • MR IRA IR • Multiple Circuit Breaker Kits with Neutral Bus Bar 350-2250 kW Model Shown (also appliesto some 300 kW -models) 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 provided with Toad -side lugs and neutral bus bar. • Kohler Co. offers a wide selection of molded -case line circuit breaker kits including single, dual, and multiple configurations for each generator set. • Four types of line circuit breakers are available: (see page 2 for definitions and pages 3 and .4 for application details) o Magnetic trip o Thermal magnetic trip o Electronic trip. o Electronic with Ground Fault Circuit Interruption (GFCI) trip • In addition, line circuit breakers are offered with 80% and 100% ratings. • Single line circuit breaker kits allow circuit protection of the entire electrical system load. • Dual line circuit breaker kits allow circuit protection , of selected priority loads from the remaining electrical system load. • Multiple line circuit breaker kits with field connection barrier allow circuit protection for special applications (350-2250 kW). • Line circuit breakers comply with the following codes and standards unless otherwise stated. o UL 489 Molded Case Circuit Breakers o UL 1077 Supplementary Protectors o UL 2200 Stationary Engine Generator Assemblies GB-811 1W11e Pape 1 ❑ 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. ❑ Auxiliary Contacts These switches send a signal indicating whether the main circuit breaker contacts are in the open or closed position. ❑ Breaker Separators (350-2250 kW) Provides adequate clearance between breaker circuits. O Bus Bars Bus bar kits offer a convenient way to connect load leads to the generator set when a circuit breaker is not present. 20-300 kW. Bus bar kits are available on altemators with leads for connection to the generator set when circuit breakers are not ordered. 350-2250 kW. A bus bar kit is provided on the right side of the unit when no circuit breaker is ordered. Bus bars are also available in combination with breakers or other bus bars on the opposite side of the junction box. On medium voltage (3.3 kV and above) units, a bus bar kit is standard. ❑ Field Connection Barrier , Provides installer wiring isolation from factory connections. ❑ Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. 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 C 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. Line Circuit Breaker Types 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. Ground fault trip units are an integral part of the circuit breaker and are not available as field -installable kits. The ground fault Line Circuit Breaker Options ❑ 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. 0 Neutral Lugs Various neutral lug sizes are available to accommodate multiple cable sizes for connection to the bus bar only. ❑ 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. ❑ 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, ❑ Shunt Trip Wiring Connects the shunt trip to the generator set controller. ❑ 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. G6-88 10/11e Page2 20-300 kW Line Circuit Breaker Specifications 80% Rating Circuit Breaker Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Slze 20-80 4Pl4PX/ 4O/40X 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 15-150 Thermal magnetic HD 175-250 Thermal magnetic JD 80-200 4Rw4S/ 4SX/ 4TX/4V 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 15-150 ' Thermal magnetic HD 175-250 Thermal magnetic . JD 300-400 Thermal magnetic LA 800 Electronic DG Electronic GFCI 700-800 Thermal magnetic MG 800 Electronic PG 800 Electronic GFCI 200-300 4UA 15-150 Thermal magnetic HD 175-250 Thermal magnetic JD 300-400 Thermal magnetic LA Electronic DG Electronic GFCI 700-800 Thermal magnetic MG 1000-1200 Thermal magnetic PG 800-1200 Electronic PG 800-1200 Electronic GFCI PG 100% Rating Circuit Breaker Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Size 20-80 4P/4PX/ 4Q/4QX 150-400 Electronic DG Electronic GFCI 80-200 4RX/4S/ 4SX/ 4TX/4V 150-400 Electronic . DG Electronic GFCI 600-800 Electronic PG Electronic GFCI 200-300 4UA 150-400 Electronic DG Electronic GFCI 600-1200 Electronic PG Electronic GFCI Circuit Breaker Lugs Per Phase (Al/Cu) Frame Slze Ampere Range Wire Range E (480 V max.) 30-100 Up to two wire terminals fitting 10-32 or 1/4-20 stud HD 15-150 One #14to3/0 JD 175 One 1 /0 to 4/0 200-250 One 3/0 to 350 kcmil LA 300-400One #1 to 600 kcmil or (2) #1 to 250 kcmil DG 150-400 One #2 to 500 kcmil Al only One #2 to 600 kcmil Cu only 600 Two 2/0 to 500 kcmil Al only Two 2/0 to 350 kcmil Cu only MG 700-800 Three 3/0 to 500 kcmil PG 600.800 Three 3/0 to 500 kcmil 1000-1200 Four 3/0 to 500 kcmil Interrupting Ratings Circuit Breaker Frame Slze 240 Volt, kA 480 Volt, kA 800 Volt, kA HD 25 18 14 JD 25 18 14 LA 42 30 22 DG 65 35 18 MG 65 35 18 PG 65 35 18 069e tare Page$ 350-2250 kW Line Circuit Breaker Specifications 80% Rating Circuit Breaker 100% Rating Circuit Breaker Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Size 15 20 25 30 35 40 45 50 . HD 80 70 Thermal Magnetic 80 90 100 110 125 150 175 200 JD 225 250 30 9-325 Mag. Trip 50 84-546 Mag. Trip HJ 100 180-1040 Mag. Trip 150 ' 348-1690 Mag. Trip 250 684-2500 Mag. Trip JJ 300 350 Thermal Magnetic LA 350-2250 kW 400 ' 500-1000 Mag. Trip (also4 750-1600 Mag. Trip available on 5W/ 7M 1000-2000 Mag. Trip some 300 kW) 400 1125-2250 Mag. Trip LA 1250-2500 Mag. Trip 1500-3000 Mag. Trip 1750-3500 Mag. Trip 2000-4000 Mag. Trip 600 Electronic LSI DG Electronic LSIG 700 Thermal Magnetic MG 600 1000 Thermal Magnetic 1200 800 1000 Electronic LSI PG 1200 800 1000 Electronic LSIG 1200 • 1200 Thermal Magnetic 1200 Electronic LSI PJ 1200 Electronic LSIG 1600 2000 Thermal Magnetic 2500 1600 2000 Electronic LSI RJ 2500 1600 2000 Electronic LSIG 2500 Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Size 15 20 25 30 35 40 45 50 HD 60 70 Thermal Magnetic 80 90 100 110 125 150 175 200 JD' 225 350-2250 250 150 kW (also 4W 250 Electronic LSI DG available on 7M 400 some 150 300 kW) 250 Electronic LSIG DG 400 600 800 Electronlc LSI 1000 1200 PG 600 6tX) Electronic LSIG 1000 1200 1200 Electronic LSI PJ 1200 Electronic LSIG 1600 2000 Electronic LSI 2500 RJ 1600 2000 Electronic LSIG 2500 3000 Electronic LSI NW 3000 Electronic LSIG Interrupting Ratings. Circuit Breaker Frame Size 240 Volt, kA 480 Volt, kA 600 Volt, kA HD ? 25 18 14 HJ 100 65 25 JD 25 18 14 JJ 100 65 25 LA 42 30 22 DG 65 35 • 18 MG 65 35 18 PG 85 35 18 PJ 10D 65 25 RJ 100 65 25 NW 100 100 85 G6e6 16111e' Page 350-2250 kW Line Circuit Breaker Specifications Breaker Positions Mulitple Circuit Breaker Combinations 8 7 8 8 LEFT Pasoan JSDX MIT PONTION3 1 2 3 4 &Tt381ATQt NOTE: Breaker and load bus phasing on right positions Is A-B-C and on left positions is C-B-A. D-Frame GFCI Circuit Breaker Combinations Alternator Model lor5 Positions 2or6 Positions 3or7 Positions 4or8 Positions DG GFCI Neutral DG GFCI HD/JD Neutral DG GFCI LA Neutral DG GFCI DG Neutral DG GFCI DG GFCI Neutral Neutral 4M/ DG GFCI HD/JD HD/JD Neutral 5M/ 7M DG GFCI LA HD/JD Neutral DG GFCI LA LA Neutral DG GFCI DG HD/JD Neutral DG GFCI DG LA Neutral DG GFCI DG DG Neutral MG/PG DG Neutral NOTE: D-frames with LSIG trip require (2) spaces (one for breaker and one for LSIG neutral). Circuit Breaker Lugs Per Phase (Ai/Cu) Frame Size Ampere Range Wire Range HD (80% rating) 15-150 One #14 to 3/0 HD (100% rating) 15-150 One #14 to 2/0 Cu only JD (80% rating) 175 One 1/0to4/0 200-250 One 3/0 to 350 kcmil JD (100% rating) 175-250 One 1/0 to 300 kcmll Cu only LA 300-400 One #1 to 600 kcmil or (2) #1 to 250 kcmil DG 150-400 One #2 to 500 kcmil Al only One #2 to 600 kcmil Cu only 600 Two 2/0 to 500 kcmil Al only Two 2/0 to 350 Komi' Cu only MG 700-800 Three 3/0 to 500 kcmil PG•1000-1200 600-800 Three 3/0 to 500 kcmil Four 3/010 500 kcmil R 1600-2500 (8) lugs per phase rated for (1) 1/0-750 kcmil or (2) 1/0-300 kcmil NW 2500/3000 Alternator Model f or5 Positions 2or8 Positions 3or7 Positions 4or8 Positions HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD LA LA HD/JD LA LA LA HD/JD HD/JD LA LA HD/JD LA LA LA LA HD/JD HD/JD HD/JD LA LA HD/JD HD/JD LA' LA LA H/J LA LA LA LA DG DG HD/JD DG LA DG DG DG HD/JD ' HD/JD DG LA HD/JD DG LA LA DG DG HD/JD DG DG LA 4W DG DG DG 5M/ 7M DG HD/JD • HD/JD HD/JD DG LA HD/JD HD/JD DG LA LA HD/JD DG LA LA LA , DG DG HD/JD HD/JD DG DG LA HD/JD DG DG LA LA DG DO DG HD/JD DG DG DG LA DG DG DG DG MG/PG MG/PG HD/JD MG/PG LA MG/PG DG MG/PG MG/PG MG/PG HD/JD HD/JD MG/PG LA HD/JD MG/PG LA LA MG/PG DG HD/JD MG/PG DG LA MG/PG DG DG R NW LOAD BUS 0648 10/11e Page5 KOHLER CO., Kohler, Wlconsin 53044 USA Phone 920-457.4441, 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 20-300 kW Line Circuit Breaker Applications Single Circuit Breaker Installations 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. To Remaining Building Loads Single line circuit breaker configuration where circuit breaker can trip causing all power to building Toads including priority load to be disrupted. To Priority Load(s) Dual Circuit Breaker Combinations Alternator Model First C. B. Frame Size Second C. B. Frame 81ze Comments 4P/4PX/4Q/ 40X/4RX/4S/ 4SX/4TX/4V/ 4UA DG — 100% rating, standard or GFCI HD — JD — HD HD JD HD or JD 4RX/4S/4SX/ 4TX/4V/4UA LA — MG — PG — 100% rating, standard or GFCI LA HD, JD, or LA 4P/4PX/4Q/ 4QX/4RX/4S/ 4SX/4TX/4V DG HD, JD, LA, or DG 100% rating, no GFCI 4UA DG HD, JD, LA, or DG Primary or sec. available as 100% rating, std. or GFCI Availability Is sublect to change without notice. Kohler Co. reserves the right 10 change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler0 generator set distributor for availability. Dual. Circuit Breaker Installations A generator set with dual circuit breakers installed is used to separate critical Toads. Typically, one circuit breaker will feed a main transfer switch with noncritical Toads and the other circuit breaker will feed a second transfer switch that feeds critical loads. First Second ' Line C.B. Line C.B. To Remaining Building Loads Dual Ilne circuit breaker configuration where first circuit breaker can trip allowing second circuit breaker to continue supplying power to priority load(s). To Priority Load(s) Alternator Model First C. B. Frame Size Second C. B. Frame Size Comments 4RX/4S/ 4SX/4TX/4V MG HD, JD, LA, or DG 100% rating, no GFCI PG HD, JD, LA, or DG 100% rating, no GFCI 4UA MG HD, JD, LA, or DG DG available as GFCI PG HD, JD, LA, or DG PG and/or DG available as GFCI PG PG 100% rating, no GFCI DISTRIBUTED BY: 4J 2007, 2010,2011 by Kohler Co. All fights reserved. GO -se 1o/11e Pages Section 11—Trip Curves STR23SP 10 000 5 000 2 000 1 000 500 200 100 50 20 10 5 I(e) 2 .5 .2 1 .05 .02 .01 .005 .002 .001 .5 .7 1 PowerPact® D-Frame Circuit Breakers and Switches Trip Curves ■viii i i=o.iii.m■� ■■1111■■■■■1111■1111�■■■ 111111Yi If_0.4-1 xln_ �i�llllllllll�■II ■■11111 ■■■■iiii•IIIi■■■1111■1111�■■■ IIIII\\\■IIII111111aiu111i111111■■II ill 1=i I MOOD : :u--E. ■■lull11la►t iuuuii ■■■1911■■n1�■■■ 11111•11111100IIIII••I1111111111■■iI ■■111�1 ■I I■1111■■1,1.�■■■1111■1111�■■■ II111�.11i 111111111III!�!iil �.I.. 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T me by 2, Min Time by 4 ■11M■■■1111■■ 11l>•■■ ■•�■■ 11111=i111111H IOU iiii �••��n■��u.iiiiiiiia��u. ■■111 Im■■■1111■111m■■■ IiiH 11limUI11ii11IIIl•ii1 t 2 3 4 5 7 10 20 30 50 70100 200300 I/Ir © 2007-2009 Schneider Electric All Rights Reserved 08/2009 59 Industrial Generator Set Accessories KOHLER.POWER SYSTE VAS Remote Serial Annunciator II (RSA II) 09001 Remote Serial Annunciator II (RSA II) aalegirsysTEws for Kohlere Controllers NATIONALLY RRGISTRRRG • Monitors -the generator set equipped with one of the following controllers: KPC 1000 Decision-Makar® 3+ Decision -Maker® 3000 Declsion-Maker® 550 Decision -Maker® 6000 • Allows monitoring of the common alarm, remote testing of the automatic transfer switch, and monitoring of the normal/ emergency source with one of the following controllers: MPAC" 1000 MPAC' 1500 • Configuration via a personal computer (PC) software. • RSA II panel includes writable surfaces (four white boxes in illustration) for user -defined selections. • Uses Modbus® protocol, an industry standard. • Controller connections: RS-485 for serial bus network USB device port for PC 12-/24-volt DC power supply 120/208 VAC power supply (available accessory) • Meets the National Fire Protection Association Standard NFPA 110, Level 1. Dimensions • Dimensions-W x H x D, mm (in.). Also fits in a standard 203 mm x 203 mm (8 in. x 8 in.) Hoffman box. Surface Mounted: 203x203x56 (8.0 x 8.0 x 2.2) Flush Mounted: 203x203x58 (8.0x8.0x2.3) Flush mounting plate W1: 229 (9.0) Modbus® Is a registered trademark of Schneider EledlE. GENERATOR FAULTS, GENERAL FAULTS 1 RSA 11 Syste. ID: KOHLER. POWER SYSIEMS RSA II L GENERATOR FAULTS I L GENERAL FAULTS Nigh Engine icnll>c Lo:v Olt Plc,aann Enr_ruenc, s:U„ Lsrsrern STATUS r• Low Fuel r• EPS SuPPiyin9 Load • Lor, Coolant i.e.:ditto, Nom Not-In•Aulo w Lo-:, Coe,I:,nt Tcnli,CI:rttliu r^ Sytlern Ready • LU.•, Cr. ,1 Il y Vulni ge mime Grntnalol Rurni :i J • C3a::cfy Vol:AVV (Iti1Lo1 Communication 51:I1n: m 6:,t,e y CI,,,cr F.�Ilu,c r• Common 1=nul; RSA 11 System In: KOHLER. POWER SYSTEMS E TS Pawl E_cueC= N •—.,,—• E ISt a re Eyk RSA II with ATS Controls Surface Mounted G8-05 7/11C Flush Mounted Fault and Status Conditions Fault LEDs Fault Horn System Ready LED Generator Running LED Communication Status LED Overcrank Shutdown Red On Red Off Green High Engine Temperature Warning • Yellow On Red Green Green High Engine Temperature Shutdown Red On Red Off Green Low 011 Pressure Warning • Yellow On Red Green Green Low Oil Pressure Shutdown Red On Red Off Green overspeed Shutdown Red On Red Off Green Emergency Stop * Red On Red Off Green Low Coolant LeveVAux. Shutdown Red On Red Off Green Low Coolant Temperature • Yellow On Red Off Green Low Cranking Voltage Yellow On Red Off Green Low Fuel —Level or Pressure * Yellow On Red Green or Of Green Not -In -Auto Red On Red Green or Off Green Common Fault Red On Green Green or Off Green Battery Charger Fault (1) * Yellow On Red Green or Off Green Battery Charger Fault (2) * Yellow On Green Green or Off Green High Battery Voltage* Yellow Off Green Green or Off Green Low Battery Voltage * Yellow Off Green Green or Off Green User Input #1 (Warning) Yellow Off Green Green or Off Green User Input #1 (Shutdown) Red On Green Off Green User Input #2 (Warning) Yellow Off Green Green or Off Green User Input #2 (Shutdown) Red On Green Off Green User Input #3 (Warning) (1) t Yellow Off Green Green or Off Green User Input #3 (Shutdown) (1) t Red On Green Off Green EPS Supplying Load Yellow Off Green Green Green Communications Status (Fault mode) — Off Green or Red Green or Off Red ATS Fault (RSA 11 with ATS Controls only) Red On Red or Yellow Green or Off Green Green LEDs appear as steady on when activated. Yellow LEDs slow flash when activated except steady on with EPS supplying load and high battery voltage. Red LEDs slow flash when activated except fast flash with loss of communication and not -In -auto. Specifications • LED indicating lights for status, warning, and/or shutdown. See the above chart for details. • Power source with circuit protection: 12- or 24-volt DC • Power source with120/208 VAC, 50/60 Hz adapter (option) • Power draw: 200 mA • Humidity range: 0% to 95% noncondensing • Operating temperature range: -20°C to +70°C (-4°F to +158°F) • Storage temperature range: -40°C to +85°C (-40°F to +185°F) • Standards: o NFPA 110, level 1 o UL 508 recognized o CE directive o NFPA 99 o EN6I1-4-4 fast transient immunity • RS-485 Modbus® isolated port Q 9.6/19.2/38.4/57.6 kbps (default is 19.2 kbps) • USB device port • NEMA 2 enclosure (1) All generator set controllers except Decision -Makers 3+ controller. (2) Decision-Makere 3+ controller only. • May require optional kit or user -provided device to enable function and LED indication. t Digital input #3 Is factory -set for high battery voltage on the Decision -Maker® 3+ controller. Modbuse is a registered trademark of Schneider Electric. ATS Controls (RSA II with ATS controls only) • ATS position LED (normal or emergency) • Power source indicator LED (normal or emergency) • ATS fault LED • Key -operated spring -loaded test switch (Re-Transfer/Auto/Test) NFPA Requirements • NFPA 110 compliant • Engine functions: o High battery voltage warning * o High engine temperature shutdown o High engine temperature warning * o Low battery voltage warning * o Low coolant level/aux. shutdown o Low coolant temperature warning * o Low cranking voltage o Low fuel warning (level or pressure) * o Low oil pressure shutdown o Low oil pressure warning * o Overcrank shutdown o Overspeed shutdown • General functions: o Audible alarm silence o Battery charger fault* o Lamp test o Master switch not -in -auto 03-95 7/11c Fault and Status LEDs and Lamp Test Switch Alarm Horn. Horn sounds giving a minimum 90 dB at 0.1 m (0.3 ft.) audible alarm when a warning or shutdown fault condition exists except on high/low battery voltage or EPS supplying Toad. Alarm Silenced. Red LED lights when alarm horn Is deactivated by alarm silence switch (lamp test switch). Alarm Silence Switch. Switch quiets the alarm during servicing. The hom will reactivate upon additional faults. ATS Fault. Red LED lights when ATS fails to transfer. Aux. See Low Coolant Level/Aux. Battery Charger Failure. LED lights if battery charger malfunctions. Requires battery charger with alarm contact. (High/Low) Battery Voltage: LED flashes if battery or charging voltage drops below preset level. LED lights steady If battery voltage exceeds preset level. Common Fault. LED lights when a single or multiple common faults occur. Communication Status. Green LED lights indicating annunciator communications functional. Red LED indicates communication fault. Emergency Power System (EPS) Supplying Load. LED lights when the generator set is supplying output current (Decision -Maker® 550, 3000, and 6000 controllers) or when transfer switch is in the emergency position (Decision -Maker® 3+ controller). Emergency Stop. LED lights and engine stops when emergency stop is made. May require a local emergency stop switch on some Decision -Maker® 3+ controllers. Generator Running. LED lights when generator set Is in operation. (Generator Switch) Not In Auto. LED lights when generator set master switch is in RUN or OFF/RESET position. High Engine Temperature. Red LED lights if engine has shut down because of high engine coolant temperature. Yellow LED lights if engine coolant temperature approaches shutdown range. Requires waming sender on some models. Communications (Shown Local Single (Master) Connection A single RSA II connects directly to the controller's communication port with an RS-485 cable. Lamp Test Switch. Switch tests all the annunciator indicator LEDs and horn. Low Coolant Level. LED lights when engine coolant level is below acceptable range on radiator -mounted generator sets only. When used with a Decision -Maker® 3+ controller, the LED indicates low coolant level or an auxiliary fault shutdown. Requires user- supplied low coolant level switch on remote radiator models. Low Coolant Temperature. LED lights if optional engine block heater malfunctions and/or engine coolant temperature is too low. Requires preaiarm sender on some models. Low Cranking Voltage. LED Tights if battery voltage drops below preset level during engine cranking. Low Fuel (Level or Pressure). LED lights if fuel level in tank approaches empty with diesel models or fuel pressure is low on gas models. Requires customer -supplied switch. Low Oil Pressure. Red LED lights if generator set shuts down because of insufficient oil pressure. Yellow LED lights if engine oil pressure approaches shutdown range. Requires warning sender on some models, Overcrank. LED lights and cranking stops if engine does not start in either continuous cranking or cyclic cranking modes. Overspeed. LED lights if generator set shuts down because of overspeed condition. System Ready. Green LED lights when generator set master switch is in AUTO position and the system senses no faults. Red LED indicates system fault. User -Defined Digital Inputs #1, #2, and #3. Monitors two digital auxiliary inputs (warnings or shutdowns). Individual red LEDs flash when a fault occurs or the status changes. User -defined digital input #1 and #2 are selected via the RSA II master for Jona( or remote (generator set or ATS). The user -defined digital input can be assigned at the controller or via PC using SiteTech' setup software. with RSA II with ATS Controls) Local Multiple (Master/Slave) Connections A single RSA II master connects directly to the controller's communication port with an RS-485 cable. Additional RSA Its (slaves) can connect to the single master RSA II. Status of the RSA II (master) is annunciated on the RSA II (slave) panel Transfer Switch Remote annunciator (master) Use RS-485, • see Note* Communication Module (16-light only) r PC 1 (user -supplied) 1--- L-- Generator set controller Use RS-485, see Note* (Available on Decision-Makere 550, 3000, and 6000 controllers only) Transfer Switch Remote annunciator (master) Use RS-485, see Note* Communication Module (16-light only) Remote annunciator (slave) Use RS-485, see Note* Generator sat controller Remote annunciator ,(slave) Note*: Use RS-485 for a total of up to 1220 m (4000 ft.) maximum from the first device to the last device. GO-85 7/11c KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, 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 (85) 6264-8422, Fax (65) 8264-6455 Modbus®/Ethernet, Single Master or Multiple Master/Slave Connections (Shown with RSA II with ATS Controls) An RSA II mastercommunicates with a controller and RSA 11 slaves through an Ethernet network. A Modbus®/Ethernet converter Is required for each RSA II and controller. RS-485 cable connects the RSA 11 to the converter. Category 5e (Cat 5e) network cable connects the Modbus®/Ethernet converter to the Ethernet. Note: Combining RSA II remote annunciators with the RSA 1000 is permissible provided that the master remote annunciator is an RSA II remote annunciator. Note*: Use RS-485 fora total of up to 1220 m (4000 ft.) maximum from the first device to the last device. Remote Annunciator (Master) Modbus®/Ethemet Converter Use RS-485, see Note* Use RS-485, see Note* Remote Annunciator (Slave) Modbus®/Ethernet Converter Ethernet Generator set Controller Use RS-485, see Note* Modbus®/Ethemet Converter Communication Module (16-IIght only) Use RS-485, see Note* Modbus®/Ethemet Converter Use RS-485, see Note* Transfer Switch Remote Annunciator • (Slave) Accessories ❑ Power source adapter kit 120/208 VAC, 50/60 Hz. ❑ Modbuse/Ethernet converter GM41143-KP2 for serial to Ethernet communication. ❑ Communication module GM32644-KA1 or GM32644-KP1 is required wfth Decision -Maker® 3+ controllers. Modbus® Is a registered trademark of Schneider Electric. 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: m 2009, 2009, 2011 by Kohler Co. M rights reserved. 0e-95 7/11s Industrial Generator Set Accessories KOHLER POWER SYSTEMS Float/Equalize Battery Charger Standard Features • 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. O9001 il••I NATIONALLY REGISTERED Installed Battery NFPA 110 Alarm Outputs Output Number of Cells Voltage Amps Lead Acid Ni-Cd PAD-292863 Yes 12 10 6 9 , Battery Charger Kit PAD-292863 Input Voltage 120/240 VAC Input Frequency 120/240VAC, 50/60 Hz DC Voltage Regulation *1% Dimensions (L x W x D) 271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.) Weight 11.8 kg (26 Ib.) Float/Equalize Battery Charger, continued 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 Ievel.At the preset equalize level, the battery charger switches to the constant voltage Equalize Mode until the current required to maintain this voltage drops to 50% of the battery charger's high rate current.The battery charger then switches to the lower constant voltage Float Mode when the battery nears full charge. The battery charger continues to operate in this mode until AC input power disconnects or the current required to maintain the battery at the float voltage setting exceeds 6 amps. Temperature Compensation The battery charger compensates for battery temperature using a negative temperature coefficient. The battery charger provides temperature compensation of-2mv/°C per cell over the ambient temperature range of -40°C up to 60°C. The temperature compensation automatically adjusts the float and equalize voltage settings to prevent the battery from overcharging at high ambient temperatures and undercharging at low ambient temperatures. Figure 1 Figure 2 Float/Equalize Battery Charger, continued 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 (140°F). Battery charger float 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 Toad to full load and AC input line voltage variations of t10%. • 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. Float/Equalize Battery Charger, continued Ta87 a 11l 700 (i7tq w1lMtrlrr_T ''ice"' 118ISI 1am��vr \f (/�iir {I V '(! • 0 -. 7 28 (e(OW. St HOLES) IT7 AOo OIA.x 21s OIA, fl2.Txag ISLE P4ACES cuannot PM towel rod adman AC TpgMW406AC. 4213YdtT INPUT tit8WATP PUP a: TETCNWLBLOCK SWIM 1 I I 'SUM144hL60.:* IOW iLK:411,21VM.W. wE MINIMA a9n.wE. ,, �. I 1 33angl T bOWtt11, �l i1 it san.�• ACMMCCS01127101401ALS .=. N0llIRR14J. .Lv* no. my., aTmrNPe 2.ri0 NCFrtSu.0 ' WE �� WE »+».+uane ��► nab, AC TERMINAL KOCK I,4. )* olo VIEW B-B STONER CONNEC LV -N.O. CONTACTS. MOSE ON LOW BATTERY VOLTAGE HV-NA CONrACTB, CLOSE ON HIGH BATTERY VOLTAGE cM-N.O.00NTACTS, CLOSE ON LOSS OF AC INPUT OR LOSS OF OC OUTPUT VIEW A -A OPTIONAL AWRY BOARD _ Mv,.ei 0 A MAMI Industrial Generator Set Accessories KOHLER POWER SYSTEMS Silencers 09001 ttttta ��v��� NATIONALLY REGISTERED 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 Type Noise Reduction dB(A) Ambient Noise Level Silencing Requirement Critical 25-35 Low High 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 exhaust piping. Do not exceed the maximum allowable backpressure. Legend Use the information below for identifying the exhaust system components shown In the Illustrations on the following pages. Side et End Outlet (SIEO) End Inlet End Outlet (EIEO) Flex Exhaust Flex Exhaust (wye) EIEO Industrial Generator Set Accessories KOHLER POWER SYSTEMS Exhaust Systems 100REOZJF 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. Legend Use the intonation below for identifying the exhaust system components shown In the illustrations on the following pages. Side Inlet End Outlet (SIEO) End Inlet End Outlet (EIEO) Flex Exhaust Flex Exhaust (wye) 0 All exhaust systems require a flexible connection between the engine exhaust and the rest of the exhaust system. Seamless stainless steel connectors are availible for each generator set. Item Exhaust System Kits Engine Type Burn Qty. in Kit Size, In/ Out Note Flex Exhaust 4NPT 0 0 Kit includes the exhaust clamp. Industrial Generator Set Accessories KOHLER POWER SYSTEMS Voltage Regulators 09001 A ►4ATUQNAtt.Y REGISTERED Integral Voltage Regulator with Kohler® Decision - Maker® 3000 Controller (20-300 kW Generator Set Models) (06 0 0edalon-Makefe 3000 Controller with Integral Voltage Regulator The voltage regulator is integral to the controller and uses microprocessor logic providing 0.5% no-load to full -load regulation using root -mean -square (RMS) voltage sensing. The voltage regulator features three-phase sensing and is available for 12- or 24-volt engine electrical systems. 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 Decision -Maker® 3000 Controller Ad4ustment Digital Display Range Setting Default Selection Voltage Adjustment ' Vet Adj. :10% d System Voltage System Voltage SUtied aFrequency Frequocy &Speed d 42 to et Hz 2.5 Hz Below mFreqe Frequency Undefiequency Unload Slgie Slone 0-10% of Systwn Voltage IWlls pmt�yde) 5 Vo s per cycle Voltage Regulato rs, continued Specification Integral with DEC 3000 Controller Generator Set Availability 20-300 kW Models Type Microprocessor based Status and Shutdown Indicators LEDs and Digital Display Operating Temperature -40°C to 70°C (-40°F to 158°F) Storage Temperature -40°C to 85°C (-40°F to 185°F) Humidity 5-95% Non -Condensing Circuit Protection Solid -State, Redundant Softward and Fuses Sensing, Nominal 100-240 Volts (L-N), 50-60 Hz Sensing Mode RMS, Single- or 3-Phase Input Requirements 8-36 VDC Continuous Output 100 mA at 12 VDC Maximum Output 100mAat12VDC Transition Frequency 50-70 Hz Exciter Field Resistance NA No -Load to Full -Load Voltage Regulation t0.5% Thermal Drift Tess than 0.5% (-40 C to 70 C) [-40 Fto 158 F].Range Response Time Less Than 5pS Voltage Adjustment (of system voltage) ±10% Voltage Adjustment Controller Menu Knob Remote Voltage Adjustment NA Paralleling Capability NA VAR/PF Control Input NA DVR® is a registered trademark of Marathon Electric Mfg. Corp. NA - Data not available at time of print. Integral Voltage Regulators with Decision - Maker® 3000 Controller A digital display and pushbutton/rotary dial provide access to data. A two-line LCD display provides complete and concise information. • The 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 • See G6-100 Decision -Maker® 3000 for more information. Generator Set Calibration Menu • L1-L2 Volts L2 L3 Volts (3-phase) • L3-L1 Volts (3-phase) • L1-N Volts • L2-N Volts • L3-N Volts (3-phase) Voltage Regulation Menu • Adjust voltage, ±10% KOHLER POWER SYSTEMS Alternator Data TIB-102 POWER SYSTEMS TECHNICAL INFORMATION BULLETIN Alternator Model: Frequency: Speed: Leads: Alternator Data Sheet 4R9X 60 Hz 1800 RPM 12 (6 Lead, 600 Volt) Voltage Lad/L-L Phase Power Factor Connection kW* (kVA) Class B Class F Class H 80°C Continuous 90°C Lloyds 95°C ABS 105°C Continuous 130°C Standby 125°C • Continuous 150°C Standby 139/240 3 ' 0.8 Wye 84.0 88.5 90.5 95.0 103.0 101.5 109.5 277/480 (105.0) (110.5) (113.0) (118.5) (128.5) (126.5) (136.5) 127/220 3 0.8 yy a 83.0 87.5 89.5 - 93.5 101.5 100.0 108.0 254/440 y (103.5) (109.0) (111.5) (116.5) ' (.126.5) (125.0) (135.0) 120/208 3 0.8 Wye 82.0 86.0 88.0 92.0 100.5 98.5 106.5 240/416 (102.5) (107.5) (110.0) (115.0) (125.5) (123.0) (133.0) 110/190 3 0.8 Wye 74.5 78.0' 80.0 84.5 91.5 89.5 96,5 220/380 (93.0) (97.5) (100.0) (105.5) (114.0) (111.5) (120.5) 120/240 3 0.8 Delta 82.0 • 86.0 88.0 92.0 100.5 98.5 106.5 (102.5) (107.5) (110.0) (115.0) (125.5) (123.0) (133.0) 120/240 1 1.0 Dogleg 64.5 67.5 68.5 71.0 77.5 76.5 82.5 (64.5) (67.5) (68.5) (71.0) (77.5) (76.5) (82.5) 347/600 3 0.8 ytrya 83.5 88.0 90.0 94.5 102.5 101.0 109.0 (104.0) (110.0) (112.5) (118.0) (128.0) (126.0) (136.0) * All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Submittal Data: 139/240 Volts, 0.8PF,'1800'RPM, 60 Hz, 3 Phase, 130°C Rise Typical Cold Resistances Phase Resistance Rotor Resistance Typical Reactances Synchronous Direct Quadrature Transient Unsaturated Saturated Subtransient Direct Quadrature Negative Sequence Zero Sequence Symbol PerUnit Ohms Xd Xq X'du X'd X"d X'q x2 Xo 0.054 0.024 16.96 7.585 Typical Time Constants Armature Short Circuit Transient Short Circuit Transient Open Circuit Typical Field Current 2.969 1.328 Full Load 1.523 0.681 No Load Typical Short Circuit Ratio 0.292 0.131 Harmonic Distortion 0.257 0.115 RMS Total Harmonic Distortion Max. Single Harmonic 0.123 0.055 Deviation Factor (No Load, L-L) 0.114 0.051. Telephone Influence Factor 0.118 0.053 Insulation Class 0.011 0.005 per NEMA MG1-1.66 ` Phase Rotation TIB-102 4R9X 60 Hz 5/11 n Symbol Value T° 0.007 sec. T'd 0.065 sec. 0.748 sec. IfFL IfM 21.6 amps 5.6 amps 0.337 3.20% 5th <5% <50 H ABC 100 98 96 94 92 g tTi 90 e4 88 86 84 82 80 0 4R9X, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL ALTERNATOR EFFICIENCY*, 0.8PF • 40 35 30 . 25 I 20 a' 15 10 5 0 10 20 30 40 50 60 Output (KW) 70 80 90 100 4R9X, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 0 50 100 150 200 250 • 300 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. 110 350 400 450 500 2 4R9X 60 Hz 5/11n TIB-102 1000 100 Ts- E 1- 10 0.1 0.01 4R9X, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 1 1 1 1 1 1 1 1 1 .1 1 1 1 1 i 1 i 10 100 1000 Armature Current (A)* 10000 Altemator damage curve m•Line'to Line 1ph 3 phase symmetrical + Line to Neutral 1ph *Instantaneous current (t=O) Is asymmetric. Divide by 1.73 for symmetric. TIB-102 4R9X 60 Hz 5/11n 3 1000 100 10 m E 0.1 0.01 4R9X, 60 Hz, High Wye Connection SHORT CIRCUIT DECREMENT CURVE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 10 ♦ ••� ♦ 100 1000 Armature Current (A)* 10000 Alternator damage curve ftio on Line to Line 1ph 3 phase symmetrical •. Line to Neutral 1 ph instantaneous current (t=0) Is asymmetric. Divide by 1.73 for symmetric. 4 4R9X 60 Hz 5/11n TIB-102 KOHLER POWER SYSTEMS Emissions Data KOHLER. POWER SYSTEMS 60 HZ. DIESEL 100REOZJF INDUSTRIAL GENERATOR SET EMISSION DATA SHEET Model: Nameplate BPH @ 1800 RPM: Type: Aspiration: Compression Ratio ENGINE INFORMATION John Deere, 4045HF2851 158 4-Cycle, 4 Cylinder, Inline Turbocharged, Charge Air -Cooled 19:1 Bore: 106mm (4.19 in.) Stroke: 127mm (5.00 in.) Displacement 4.5 L (276 cu. in.) EPA Family: CJDXL04.5119 EPA Certificate: CJDXL04.5119-015 PERFORMANCE DATA: Engine bkW @ Stated Load Fuel Consupumtion (g/kWh) Exhaust Gas Flow (m3/s). Exhaust Temperature (°C) EXHAUST EMISSION DATA: HC (Total Unburned Hydrocarbons) NOx (Oxides of Nitrogen as NO2) CO (Carbon Monoxide) PM (Particular Matter) EPA CERTIFICATE DATA 0.2 3.4 1.3 0.17 1/4 Standby 49.78 272.10 1/2 3/4 Full Standby Standby Standby 66.38 88.50 118.00 254.70 237.40 222.40 1368.00 580.00 _ _ 0.270 3,250 2.760 0.249 0.100 3.190 2.250 0.169 0.060 3.800 1.150 0.101 0.050 5.350 0.980 0.089 Values are in g/kWh TEST METHODS AND CONDITIONS ISO 8528 D2 Data and specifications subject to change without notice For further information,'please contact Todd Loes at John Deere Power Systems, 319-292-6050 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 2012 MODEL YEAR CERTIFICATE OF CONFORMITY WITH THE CLEAN AIR ACT OF 1990 OFFICE OF TRANSPORTATION AND AIR QUALITY ANN ARBOR, MICHIGAN 48105 rtificate Issued To: Deere & Company (U.S. Manufacturer or Importer) rtificate Number: CJDXL04.5119-015 Effective Date: 10/07/2011 Expiration Date: 12/31/2012 Karl J. Si n, Director Compliance and In ative Strategies Division Issue Date: 10/07/2011 Revision Date: N/A odel Year: 2012 anufacturer Type: Original Engine Manufacturer igine Family: CJDXL04.5119 Mobile/Stationary Indicator: Stationary Emissions Power Category: 75<=kW<130 Fuel Type: Diesel After Treatment Devices: No After Treatment Devices Installed Non -after Treatment Devices: Engine Design Modification, Non-standard Non -After Treatment Device Installed, Smoke Puff Limiter, Electronic Control suant to Section 111 and Section 213 of the Clean Air Act (42 U.S.C. sections 7411 and 7547) and 40.,CFR Part 60, and subject to the terns and conditions prescribed in those provisions, this certificate formity is hereby issued with respect to the test engines which have been found to conform o;applicable rec�ttirements and which represent the following engines, by engine family, more fully described documentation required by 40 CFR Part 60 and produced in the stated model year. f s certificate of conformity covers only those new compression -ignition engines which conform in all material reslidcts to the design specifications that applied to those engines described in the umentation required by 40 CFR Part 60 and which are produced during the niod.l year stated :dtt this ceCtif Cate of the'said manufacturer, as defined in 40 CFR Part 60. o a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 1068 and authorized in a warrant or court order. Failure to comply with the requirements of such a rant or court order may lead to revocation or suspension of this certificate for reasons specified in 40 CFR Part 60. It isaaiso"a term of this certificate that this certificate may be revoked or suspended or dered void ab initio for other reasons specified in 40 CFR Part 60. s certificate does not cover engines sold, offered for sale, or introduced, or deli'ered for introduction, into commerce in tiie U.S. prior to the effective date of the certificate. SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865 East Copley Drive, Diamond Bar, CA 91765 Legal Owner or Operator: DEERE POWER SYSTEMS GROUP P.O. BOX 5100 WATERLOO, IA 50704-8000 ATIN: RICHARD A. BISHOP Application No. 462956 Page I Granted as of November 21, 2006 Expires December 31, 2011 ID 92796 Equipment Location: SAME AS ABOVE The equipment described below and as shown on the approved plans and specifications are subject to the special conditions or conditions listed. Equipment Description INTERNAL COMBUSTION ENGINE, JOHN DEERE, 4 CYLINDER, TURBOCHARGED/AFTERCOOLED, MODEL 4045HF285I, 158 BHP, DIESEL FUELED, DRIVING AN EMERGENCY ELECTRICAL GENERATOR Manufacturer Condition 1. THIS CERTIFIED EQUIPMENT PERMIT (CEP) IS NOT A PERMIT TO CONSTRUCT OR OPERATE. THE PERSON CONSTRUCTING, INSTALLING OR OPERATING THE EQUIPMENT AT EACH SPECIFIC SITE SHALL OBTAIN ALL NECESSARY PERMIT(S) TO CONSTRUCT AND PERMIT(S) TO OPERATE AND COMPLY WITH ANY OTHER DISTRICT RULES AND REGULATIONS INCLUDING THE REQUIREMENTS OF REGULATION XIII End User Conditions 1. OPERATION OF THIS EQUIPMENT SHALL BE CONDUCTED IN ACCORDANCE WITH ALL DATA AND SPECIFICATIONS SUBMITTED WITH THE APPLICATION UNDER WHICH THIS PERMIT IS ISSUED UNLESS OTHERWISE NOTED BELOW. 2. THIS EQUIPMENT SHALL BE PROPERLY MAINTAINED AND KEPT IN GOOD OPERATING CONDITIONS AT ALL TIMES. 3. A NON-RESETTABLE TOTALIZING TIMER SHALL BE INSTALLED AND MAINTAINED TO INDICATE THE ENGINE ELAPSED OPERATING TIME. 4. AN ENGINE OPERATING LOG SHALL BE KEPT AND MAINTAINED ON FILE TO RECORD WHEN THIS ENGINE IS STARTED MANUALLY. THE LOG SHALL LIST THE DATE OF OPERATION, THE TIMER READING IN HOURS AT THE BEGINNING AND END OF OPERATION, AND THE REASON FOR OPERATION FOR A MINIMUM OF THREE YEARS FROM. THE DATE OF ENTRY AND MADE AVAILABLE TO DISTRICT PERSONNEL UPON REQUEST. THE TOTAL HOURS OF OPERATION (INCLUDING HOURS FOR MANUAL AND AUTOMATIC OPERATION) ORIGINAL (copy) Application No. 462956 Page 2 SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865.East Copley Drive, Diamond Bar, CA 91765 SHALL BE RECORDED SOMETIME DURING THE FIRST 15 DAYS OF JANUARY OF EACH YEAR. THIS ENGINE SHALL NOT OPERATE MORE THAN 200 HOURS IN ANY ONE YEAR, WHICH INCLUDES NO MORE THAN 50 HOURS IN ANY ONE YEAR FOR MAINTENANCE AND TESTING PURPOSES. 6. THE OPERATOR SHALL NOT PURCHASE ANY DIESEL FUEL UNLESS THE FUEL IS LOW -SULFUR DIESEL FOR WHICH THE SULFUR CONTENT DOES NOT EXCEED 15 PPM BY WEIGHT. EFFECTIVE JANUARY 1, 2006, THE OPERATOR SHALL ONLY USE DIESEL FUEL WITH A SULFUR CONTENT THAT DOES NOT EXCEED 15 PPM BY WEIGHT; UNLESS THE OPERATOR DEMONSTRATES IN WRITING TO THE EXECUTIVE OFFICER THAT SPECIFIC ADDITIONAL TIME IS NECESSARY. 7. OPERATION BEYOND THE 50 HOURS PER YEAR ALLOTTED FOR ENGINE MAINTENANCE AND TESTING SHALL BE ALLOWED ONLY IN THE EVENT OF A LOSS OF GRID POWER OR UP TO 30 MINUTES PRIOR TO A ROTATING OUTAGE, PROVIDED THAT: (A) THE UTILITY DISTRIBUTION COMPANY HAS ORDERED ROTATING OUTAGES IN THE CONTROL AREA WHERE THE ENGINE IS LOCATED OR HAS INDICATED THAT IT EXPECTS TO ISSUE SUCH AN ORDER AT A CERTAIN TIME; AND (B) THE ENGINE 15 LOCATED IN A UTILITY SERVICE BLOCK THAT IS SUBJECT TO THE ROTATING OUTAGE. ENGINE OPERATION SHALL BE TERMINATED IMMEDIATELY AFTER THE UTILITY DISTRIBUTION COMPANY ADVISES THAT A ROTATING OUTAGE IS NO LONGER IMMINENT OR IN EFFECT. 8. THIS ENGINE SHALL BE A US EPA CERTIFIED, NON -ROAD COMPRESSION -IGNITION ENGINE, AS EVIDENCED BY THE MANUFACTURER'S ENGINE TAG. Please notify RAMAN PATEL at 909/396-2466 when SCAQMD information packets are needed or if you have any questions concerning the Certification/Registration Program. This Certified Equipment Permit is based on the plans, specifications, and data submitted as it pertains to the release of air contaminants and control measures to reduce air contaminants.. No approval or opinion concerning safety and other factors in design, construction or operation of the equipment is expressed or implied. This Certified Equipment Permit will become invalid if this application is cancelled. THIS PERMIT SHALL EXPIRE ONE YEAR FROM THE DATE OF ISSUANCE unless an extension Is granted by the Executive Officer. C. PATEL, P.E. Se or Air Quality Engineer ORIGINAL (copy) Subbase Fuel Tank Electrical stub -up area open to bottom Removable engine supply diptube Emergency Inner tank relief vent Normal vent Low fuel level switch Additional fitting for optional accessory oa v o o 0 a coo v 0 a a v goo 11 O O 0 CI0000 m/ po 0 0 o`j 00 0 0o a _/ o \ \ 0 0 0o Fuel leak detection switch retum diptube Removable fuel Fuel fill with lockable cap and Fuel level 203 mm (B In.) riser gauge Emergency outer tank relief vent L e TTTFT it it m J J ti Note: 20-60REOZJC models shown, other models are similar. Refer to the respective ADV drawings for details. Basin drain ADV-7430- Standard Subbase Fuel Tank Features • Extended operation. Usable tank capacity offers full Toad standby operation of up to 72 hours. • UL listed. Secondary containment generator set base tank meeting UL 142 requirements. • NFPA compliant. Designed to comply with the installation standards of NFPA 30 and NFPA 37. • Integral external lift Tugs. Enables crane with spreader -bar lifting of the complete package (empty tank, mounted generator set, and enclosure) to ensure safety. • Emergency pressure relief vents. Vents ensure adequate venting of the inner and outer tank under extreme pressure and/or emergency conditions. • Normal vent with cap. Vent is raised above lockable fuel fill. • Low fuel level switch. Annunciates a 50% low fuel level condition at generator set control. • Leak detection switch. Annunciates a contained primary tank fuel leak condition at generator set control. • Electrical stub -up. • State tank designed to comply with the installation standards of the Florida Dept. of Environmental Protection (FDEP) File No. E4-634. Tank to include factory installed return pump, supply pump, and level switches to be used as day tank fed from remote main tank. Tank Capacity - 100gal. Tank Footprint - 82" X 34" G6.99 ey12t Pegs 3 8 7 - 6 I 5 1 4 1 3 OPTIONAL BATTERY HEATER/CHARGER CONDUIT LOCATION I36MI]j9 123 .7Q 21J 2Y I23.431 [23..94174V "." f12.201 0 CONDUIT ENTRY AREA FOR GENERATOR'LOAD.LEADS (BOTTOM ENTRY) CIRCUIT BREAKER OPTION. REMOTE CONNECTION TO TRANSFER SWITCH AND.REMOTE ANNUNCIATOR 360 (14.21 R0X/4T9X 30 116.91.48120/4712X LLER LOCATIO •DX MOUNTING H022.20 OLES) AL6X NTING (NOL CMESI 8 7 a 0 0 wr 12 V BATTERY RACK LOCATION 75 [340j SUGGESTED LOCATION FOR — FUEL RETURN FLEXIBLE FUEL LINE, 3/8 N.P.T (MALE) r 375 114 8) 605 [23.81 730 I28.7) .1390 (54.71 123 [4.81 817 132.21 713] (IP 771(30.4 190,1 4190 818 (32.2) 48120/ 41120 CENTER OF BALANCE. 701 (27,61 699 (27.5] 2075 (81.71 6 24 V' BATTERY RACK LOCATION SUGGESTED LOCATION FOR FUEL RETURN FLEXIBLE FUEL LINE.. 3/8 N.P.T. (MALE) OPTIONAL BLOCK HEATER CONDUIT LOCATION 259 (10.21 INLET FOR OPEN OENMETS litOREOLIP WWI 4PIOX, 4119X, 4TOX 100RECEJP MODEL 4R9X, 4RW(, 4T7at RECONIIECTAEQF IMPROVE( MOTOR STARTV 0M RECOMECT, AEKE 800V 8 1 PHASE ALTERNATORS 40464285. JOHY MERE TER 01 5 4 INSTALLATION NOTE IF SUBBASE FUEL TANK AND/OR SOUND HOUSING IS USED. REFER TO SUBBASE FUEL TANK DRAWING TO DETERMINE MOUNTING LOCATIONS MODEL GENSET WEIGHT (WET) 80 4PIOX 973 KO [2145 LBSI 80 4R9X, 4T9X 100 4R9X 1058 KO [2328 MI 100 1R12X, 102x 1119 KO (2468 OS/ NOTES DIMENSIONS IN I I ARE ENGLISH EOUIVALENTS. IF AN ENCLOUSRE. IS'USED, THE FUEL LINE MUST BE.STUBBED UP FROM DIRECTLY UNDER THE UNIT OR BROUGHT IN FROM THE END OF THE' SKID. REFER TO ENCLOUSER A IF IBCCERTIFICATION IS REOUIRED SEE SEISMIC ADV FOR INSTALLATION INSTRUCTIONS REV DATE 01 mown 01u. at PART e1: 101 a11A101 AMA 9T 5-12.11 RE1 DRAWN (1137/-11 ERR 1n:1 na r.. 1rrro14B-e EieJSI0N miff 80100 1 Pr RRP $ 12 11 KOHLER CCi. Pato SMEAR. 40KE1. /P 520u 0 TII OTtlIa 10 _Em t ((Ppp 0 *11110 f ej�,,IOE[ .i 0[R' 01 ;1R:E1 YE a WOO NI 3 2 5 12 11 5.12-II •v e.111 ADW81181 KOHLER POWER SYSTEMS Warranty " Stationary Standby and Prime Power One -Year or Two Thousand (2000)-Hour Limited Warranty Your Kohler product has been manufactured and Inspected with care by experienced craftsmen. If you are the original consumer, Kohler Co. warrants, for the period indicated below, each product to be free from defects In materials and workmanship. Repair, replacement, or appropriate adjustment at Kohler Co.'s option will befumishad if the product, upon Kohler Co.'sinspection, Is found to be properly installed, maintained, and operated In accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, repair or service by unauthorized persons, or normal wear and tear. Kohler Product Warranty Coverage* Generator Set & Accessories 'One (1) year or 2000 hours (whichever occurs first) from date of initial startupt Prime Power Generator Set 20 kW or Larger One (1) year or 2000 hours (whichever occurs first) from date of initial startup# *Some restrictions may apply. Contact your Kohler distributor/dealer forfull details. tStartup must occur within 24 months of original shipment by Kohler Co. The following will not be covered by the warranty: 1. Normal engine wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage caused by accidents, improper installation or handling, faulty repairs not performed by an authorized service representative, or Improper storage. 3. Damage caused by operation with Improper fuel or at speeds, loads, conditions, modifications, or installation contrary to published specifications or recommendations. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficient quantity of lubricating oil. b. Failure to keep the air intake and cooling fin areas clean. c. Failure to service the air cleaner. d. Failure to provide sufficient coolant and/or cooling air. e. Failure to perform scheduled maintenance as prescribed in supplied manuals. f. Failure to regularly exercise the generator set under load (stationary applications only). 5. Original installation charges and startup costs. 6. Starting batteries and the following related expenses:, a. Labor charges related to battery service. b. Travel expense related to battery service. 7. Engine coolant heaters, heater controls, and circulating pumps after the first year. 8. Rental of equipment during performance of warranty repairs. 9. Parts purchased from sources other than Kohler Co. Replacement of afailed Kohler part with a non -Kohler part voids warranty on that part. 10. Radiators replaced rather than repaired. 11. Fuel injection pumps not repaired locally by an authorized servicing dealer. 12. Non -Kohler -authorized repair shop labor without prior approval from Kohler Co. Warranty Department. 13. Engine fluids such as fuel, oil, or coolant/antifreeze. 14. Shop supplies such as adhesives, cleaning solvents, and rags. 15. Expenses Incurred Investigating performance complaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, lamps, filters, spark plugs, loose or leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. ship date as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND Including, but not limltedto, incidental consequential labor costs, installation charges, telephone charges, ortransportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty nor Is anyone authorized to make any on our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE, Is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an Implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state. KOHLER. `POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1648 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com TP-6374 14I88cJ Extended Five -Year or Three Thousand (3000)-Hour Comprehensive Stationary Standby Limited Warranty This Kohler Standby Generator System has been manufactured and Inspected with care by experienced craftsmen. If you are the original purchaser. Kohler Co. warrants for five years or three thousand (3000) hours, whichever occurs first, that the system will be free from defects in material and workmanship if properly Installed, maintained, and operated in accordance with Kohler Co.'s Instruction manuals, A Kohler distributor, dealer, or authorized representative must perform startup. This warranty Is not effective unless a proper extended warranty registration form and warranty tee have been sent to Kohler Co. within one year of supervised startup. During the warranty period, repair or replacement at Kohler Co.'s option will befurnished free of charge for parts, provided an inspection to Kohler Co.'s satisfaction discloses a defect In material and workmanship, and provided that the part or parts are retumed to Kohler Co. or an authorized service station, if requested. This extended warranty expires five full years after date of startup orafter3000 hours of operation, whichever occurs first. This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while in your possession. The following will not be covered by this warranty: 1. Normal engine wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage caused by accidents, Improper installation or handling, faulty repairs not performed by an authorized service representative, or Improper storage. 3. Damage caused by operation with improper fuel or at speeds, Toads, conditions, modifications, or installation contraryto published specifications or recommendations. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficient lubricating oil. b. Failure to keep the air intake and cooling fin areas clean. c. Failure to service the air cleaner. d. Failure to provide sufficient coolant and/or cooling air. e. Failure to perform scheduled maintenance as prescribed in supplied manuals. f. Failure to exercise with load regularly. 5. Original installation charges and startup costs. 5. Starting batteries and the following related expenses: a. Labor charges related to battery service. b. Travel expense related to battery service. 7. Engine coolant heaters, heater controls, and circulating pumps after the first year. 8. Rental of equipment during performance of warranty repairs. - 9. Non -Kohler -authorized repair shop Tabor without prior approval from the Kohler Co. Warranty Department. 10. Parts purchased from sources other than Kohler. Replacement of afailed Kohler part with a non -Kohler part voids warranty on that part. 11. Radiators replaced rather than repaired. 12. Fuel injection pumps not repaired locally by an authorized servicing dealer. 13. Engq %aark ci urh aQ fuel, oil, or coolant/antifreeze. 14. Shop supplies such as adhesives, cleaning solvents, and rags. 15. Expenses Incurred investigating performance complaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, filters, spark plugs, loose/leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller end received at Kohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. shlp date as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative, or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND including, but not Iimitedto, incidental consequential labor costs, Installation charges, telephone charges, ortransportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty, nor is anyone authorized to make any in our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURCHASE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. KOHLER® POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet In the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com TP-6581 12I99c } KOHLER POWER SYSTEMS Certification Certificate US95/0189 The management system of Kohler Power Systems Americas N7650 County Road LS Sheboygan, WI 53083 United States has been resesmd and metaled as medic he requbemeras of ISO 9001:2008 For the hffonf gactivities Design, manufacture, and distributor support for electrical generators, alternators, automatic transfer switches, and switchgear. Fwtlier durationsweft the saps ofIbis oerofloaleand the appOcabeyof ISO90012008 may beotdd sdbyosrnufbaldremgantrd<m This certificate is valid from 17 November 2009 until 16 November 2012 and remalnsvafid subject to satisfactory surveillance audits. Recertifllcation'audit duea minimum of 30 days before the ettpiration date. Issue 8. Certified since February 1995 This is a multi -site certification. Additional site details are listed on subsequent pages. Authorized by gee Zachary Men* Accreditation Manager. Noah Amedea SOS US Tearing Cody. Mo.. System andSetvroes Cer11541 tr 201 Route 17 Noah, Rutherford. New Jersey, 07070 USA 1+1 201 5083000 5+12019254556 www•us.sas•com Thisanaticate remains the p open of SOS and shag be returned upon request Page 1012 IMk7/ pm*. otga dr,.ss/ 4wUWm msn,PIs4m..gsbtl Certificate U885/01139, continued Kohler Power Systems Americas ISO 9001 :2008 Issue a Dead soope FurtheraidScatiom regarding Me ewe of Ns meta and tte appkablity ISO 90012008 reoliwnente mei be °Wined twareding the orgenisaion Adelonalfacates 300 N. Dakota Woods Blvd., Saukville, WI 53080, United States 0 (9'.408 SGS Kohler Standby/Prime Generator Set Test Program Testing Is an integral part of quality assurance. In keeping with our uncompromising commitmentto quality, safety, and reliability, every Kohler Standby/Prime power generator set undergoes an extensive series of prototype and production testing. Prototype Testing Prototype testing includes the potentially destructive tests necessary to verify design, proper function of protective devices and safety features, and reliability expectations. Kohler's prototype testing includes the following: • Alternator temperature rise test per NEMA MG1-32.6. Standby and prime ratings of the alternator are established during this test. • Maximum power test to assure that the prime mover and alternator have sufficient capacity to operate within specifications. • Alternator overload test per NEMA MG1-32.8. • Steady-state load test to ensure voltage regulation meets or exceeds ANSI C84.1, NEMA MG1-32.17 requirements and to verify compliance with steady- state speed control specifications. • Transient test to verify speed controls meets or exceeds specifications. • Transient load tests per NEMA MG1-32.18, and ISO 8528 to verify specifications of transient voltage regulation, voltage dip, voltage overshoot, recovery voltage, and recovery time. • Motor starting tests per NEMA MG1-32.18.5 to evaluate capabilities of generator, exciter, and regulator system. • Three-phase symmetrical short-circuit test per NEMA MG1-32.13 to demonstrate short circuit performance, mechanical integrity, ability to sustain short-circuit current. . • Harmonic analysis, voltage waveform deviation per NEMA MG1-32.10 to confirm that the generator set is producing clean voltage within acceptable limits. • Generator set cooling and air flow tests to verify maximum operating ambient temperature. • Reliability tests to demonstrate product durability, followed by root cause analysis of discovered failures and defects. Corrective action is taken to improve the design, workmanship, or components. • Acoustical noise intensity and sound attenuation effects tests. Production Testing In production, Kohler Standby/Prime generator sets are built to the stringent standards established by the prototype program. Every Kohler Generator set is fully tested prior to leaving the factory. Production testing includes the following: • Stator and exciter winding high -potential test on all generators. Surge transient tests on stators for generators 180 kW or larger. Continuity and balance tests on all rotors. • One-step, full -load pickup tests to verify that the performance of each generator set, regulator, and governor meats published specifications. • Regulation and stability of voltage and frequency are tested and verified at no load, 1/41oad,1/2 load, 3/4 load, and full -rated Toad. • Voltage, amperage, frequency and power output ratings verified by full -load test. • The proper operation of controller logic circuitry, prealarm warnings, and shutdown functions is tested and verified. • Any defect or variation from specification discovered during testing is corrected and retested prior to approval for shipment to the customer. Torsional analysis data, to verify torsional effects are not detrimental and that the generator set will provide dependable service as specified, is available upon request. Kohler offers other testing at the customer's request at an additional charge. These optional tests Include power factor testing, customized load testing for specific application, witness testing, and a broad range of MIL-STD-705c testing. A certified test report is also available at an additional charge. KOHLER. POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381,Fax 920-459-1846 For the nearest sales/service outlet In the US and Canada, phone 1.800.544-2444 KohlerPowerSystemscom e19.66 12/05a KOHLER POWER SYSTEMS TAWS, 4 t`` TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 Submittal Package Job Name: Quote: 0025850989 Proposal: 31555A-MIAMI FIRE. STATION #1 PRELIMINARY SUBMITTAL PACKAGE FOR MIAMI FIRE STATION # 1 We are pleased to offer the following submittal for your consideration. Thank you, Olga Mestey, Tampa Armature Works. T1t /11W TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 Job Name: 31555A-MIAMI FIRE STATION #1 Offer K300517592 Version 1.0 Page 1 AUTOMATIC TRANSFER SWITCH 3 Pole, 4 Wire, Solid Neutral, 0600 Amps, Kohler automatic transfer switch, Model MODELK, rated 208V, 60Hz, complete with aII standard equipment and housed in a NEMA Type 1 enclosure. Configuration Qty Description y KCT-ACTA-0600B 1 Warranty - ATS, 5 Year Comprehensive 1 Warranty, 1 Year Standard GENERATOR SET Model: 150REOZJF This generator set equipped with a 4S13X alternator operating at 120/208 volts is rated for 154 kW/193 kVA. Output amperage: 534 Configuration Qty Description 1 150REOZJF Generator Set 1 Shunt Trip Wiring, DEC3000 1 Accessory Inner Panel 1 Covers, 4S, J-Box M/P-Frame LCB 1 Neutral, 600A 4S 1 Shunt Trip, 12VDC, MG/PG/RG/RJ Frame 1 Mtg, LCB,M/P-Frame, 600-800A. 4S 1 LCB, 600A, PGP, MICRO, 100% 1 Control & Harness, 150 JD 4SX D3K 1 Controller, DEC3000 800A , 3Ph 1 Air Intake, Standard Duty 1 Skid 8, Plant Mtg. .1 Unit, Mtd. Radiator Cooling 1 Alternator, 4S13X 1 Voltage,60Hz,120/208V,3Ph,4W,0.8PF 1 Decal, UL2200 Listing (Diesel) 1 Nameplate Rating, Standby 130 Degree 1 150REOZJF, 12V, 60Hz, 6068HF 1 Radiator duct Flange 1 Coolant in Genset 6 gals. KO►HLER.POWER SYSTEMS Factory set to 500AI 0.011140 TAW Job Name: 31555A-MIAMI FIRE STATION #1 Offer: K300517592 Version 1.0 Page 2 TAW POWER SYSTEMS, INC. 6312 78TH STREET / RIVERVIEW, FL 33569 P: 813-840-3500 T: 800-456-9449 F: 813-217-8075 1 Power Factor Test,0.8,3Ph Only 1 RSA II, Annunciator Only 1 Warranty, 5 Year Comprehensive 1 Warranty, 1 Year Standby 1 Battery Charger,Floatw/Alarms,12V-10A 1 Weld -On Flange,6" 1 Flexible Exhaust Connection, 6" NPT 1 Silencer,Critica1,6"Flange,SIEO 1 Skid/Tank, 100gal, Day Tank with Return & Supply Pumps 1 Flexible Fuel Lines 1 Block Heater, 120V, 1800W MISCELLANEOUS Part Number Qty Description GM22737-KP 3 Lit Kit, ATS Production, KCP/KCT/KNM GM81777-KP 3 Lit Kit, 150REOZJF,General Maintenance KOHLERsPOWER SYSTEMS KOHLER POWER SYSTEMS Spec Sheets 150REOZJF KOHLER POWER SYSTEMS Diesel 09001 0 1EAn51'ENG NATIONALLY REGISTERED Generator Set Ratings Standard Features • Kohler Co. provides one -source responsibility for the 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 accepts rated load in one step. • The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards. • A one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Alternator Features: o The unique Fast -Response X excitation system delivers excellent voltage response and short circuit capability using a rare-earth, permanent magnet (PM) -excited altemator. o The brushless, rotating -field alternator has broad range reconnectability. • Other Features: o Controllers are available for all applications. See controller features inside. o The low coolant level shutdown prevents overheating (standardlon radiator models only). o Integral vibration isolation eliminates the need,for under -unit vibration spring isolators. o Multiple circuit breaker configurations. Standby130C Ratings Alternator Voltage Ph Hz .kW/kVA Amps 4813X. 120/208 3 '60 154/193 534. RATINGS: All three-phase units are rated at D.8 power factor. All single-phase units are rated at 1:0 power factor. Standby Ratings: The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this rating. Prime Power Ratings: At varying load, the number of generator set operating haws is unlimited. A 10%overload capacity is available for one hour in twelve. Ratings ere In accordance with ISO.6528-1 and ISO-3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical information bulletin (118-101) for ratings guidelines, complete ratings definitions, and site condition derates. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Model: 15OREOZJF, continued Alternator Specifications Specifications Alternator Alternator manufacturer Type Exciter type Leads, quantity Voltage regulator Insulation Insulation: Material Insulation: Temperature Rise Bearing: quantity, type Coupling Amortisseur windings Voltage regulation, no-load to full -load RMS One -Step Load Acceptance Unbalanced Toad capability Kohler 4-Pole, Rotating -Field Brushless, Rare -Earth Permanent -Magnet 12, Reconnectable Solid State, Volts/Hz NEMA MG1 Class H 130°C, Standby 1, Sealed Flexible disc Full Controller Dependent 100% of rating 100% of Rated Standby Current • Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds. • Sustained short-circuit current enabling down stream circuit breakers to trip without collapsing the altemator 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. Engine Engine Specifications • Engine Manufacturer Engine Model Engine: type Cylinder arrangement Displacement, L (cu. in.) Bore and stroke, mm (in.) Compression ratio Piston speed, m/min. (ft./min.), Main bearings: quantity, type Rated rpm Max. power at rated rpm, kWm (BHP) Cylinder head material Crankshaft material Valve (exhaust) material Intake Valve (exhaust) material Exhaust Govemor:_type, make/model Frequency regulation, no-load to -full Toad Frequency regulation, steady state Frequency Air cleaner type, all models John Deere 6068HF285 4-Cycle, Turbocharged, Charge Air -Cooled 6 Inline 6.8 (415) 106 x 127 (4.19 x 5.00) 17.0:1 457 (1500) 7, Replaceable Insert 1800 177 (237) Cast Iron Forged Steel Chromium -Silicon Steel Stainless Steel JDEC Electronic L16 Denso HP3 Isochronous ±0.25% Fixed Dry Model: 150REOZJF, continued Exhaust Exhaust System Exhaust Manifold Type Exhaust flow at rated kW, m3/min. (cfm) Exhaust temperature at rated kW, dry exhaust, °C (°F) Maximum allowable back pressure, kPa (in. Hg) Exh. outlet size at eng. hookup, mm (in.) Engine Electrical Dry 33.9 (1197) 510 (950). 7.5 (2.2) 98 (3.86) . Engine Electrical System Battery charging alternator Battery charging alternator: Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA); Qty., CCA rating each Battery voltage (DC) Fuel 12 Volt/24 Volt Negative 12/24 65/45 12/24 One, 640/Two, 570 12 Fuel System Fuel type Fuel supply line, min. ID, mm (in.) Fuel return line, min. ID, mm (in.) Max. lift, fuel pump: type, m (ft.) Max. fuel flow, Lph (gph) Fuel prime pump Fuel Filter Secondary Fuel Filter Primary Fuel Filter Water Separator Recommended fuel Lubrication Diesel 11.0 (0.44) 6.0 (0.25) Electronic, 1.8 (6.0) 96.9 (25.6) Manual 2 Microns@ 98% Efficiency 30 Microns Yes #2 Diesel Lubrication System Type Oil pan capacity, L (qt.) Oil pan capacity with filter, L (qt.) OI filter. quantity, type Oil cooler Full Pressure 27.0 (28.5) 27.9 (29.5) 1, Cartridge. Water -Cooled Model: 150REOZJF, continued Cooling Radiator System Ambient temperature, °C (°F) Engine jacket water capacity, L (gal.) Radiator system capacity, including engine, L (gal.) Engine jacket water flow, Lpm (gpm) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min:) Heat rejected to air charge cooler at rated kW, dry exhaust, kW (Btu/min.) Water pump type Fan diameter, Including blades, mm (in.) Fan, kWm (HP) 50 (122) 11.3 (3.0) 25.7 (6.8) 174 (46) 76.3 (4340) 31.8 (1810) Centrifugal 660 (26) 7.7 (10.3) Max. restriction of cooling air, intake and discharge 0.125 (0.5) side of radiator, kPA (in. H20) * Enclosure with intemal silencer reduces ambient temperature capability by 5°C (9°F). Operation Requirements Air Requirements Radiator -cooled cooling air, m3/min. (scfm) * Combustion air, m3/min. (cfm) Heat rejected to ambient air: Engine, kW (Btu/min.) Heat rejected to ambient air: Alternator, kW (Btu/ min.) *Air density =1,.20 kg/m3 (0.075 Ibm/ft) Fuel Consumption 226.5 (8000) 13.6 (480) 35.9 (2040) 12.3 (700) Diesel, Lph (gph), at % load Standby Fuel Consumption at 100% Toad Standby Fuel Consumption at 75% load Standby Fuel Consumption at 50% load Standby Fuel Consumption at 25% load Prime Fuel Consumption at 100% load Prime Fuel Consumption at 75% load Prime Fuel Consumption at 50% load Prime Fuel Consumption at 25% load Rating 44.3 Lph (11.7 gph) 35.1 Lph (9.3 gph) 26.3 Lph (6.9 gph) 16.2 Lph (4.3 gph) 40.6 Lph (10.7 gph) 32.3 Lph (8.5 gph) 24.0 Lph (6.3 gph) 14.4 Lph (3.8 gph) Industrial Generator Set Accessories KOHLER®POWER SYSTE \AS Generator Set Controller 09001 NATIONALLY REGISTERED KOHLER. CFCIS!orl-t AKtR. Decision-Makere 3000 Kohler® Decision -Maker® 3000 Controller General Description and Function The Decision -Maker® 3000 generator set controller provides advanced control, system monitoring, and system diagnostics for optimum performance. The Decision -Maker® 3000 controller meets NFPA110, Level 1 when equipped with the necessary accessories and installed per NFPA standards. The Decision -Maker® 3000 controller uses patented software logic to manage sophisticated functions, such as voltage regulation and alternator thermal overload protection, normally requiring additional hardware. Additional features include: • A digital display and pushbutton/rotary selector dial provide easy local access to -data. • Measurements selectable in metric or English units. • The controller can communicate directly with a personal computer via a network or serial configuration using SiteTech' or Monitor III software. • The controller supports Modbus® protocol. Use with serial bus or Ethernet networks. • Scrolling display shows critical data at a glance. • Digital display of power metering (kW and kVA). • Integrated hybrid voltage regulator providing ±0.5% regulation. • Built-in alternator thermal overload protection. Modbus® Is a registered trademark of Schneider Electric. G13-11:01/12b Page I. Emergency Stop Switch Digital Display -, Alarm Hom (located _ — Inside the controller) Master Control Buttons Off-Reset/Auto/Run with Ughts volts Ll-L2: 480.e V J OFF/RESET AUTO RUN /1\ FAULT ALARM sILENce/ LAMP TEST User Interface Controls and Components • Emergency stop switch • Backlit LCD digital display with two lines of 12 characters (see User Interface Displays for menus) • Alarm horn Indicates generator set shutdown and warning faults • Environmentally sealed membrane keypad with three master control buttons with lights o Off/Reset (red) o Auto (green) o Run (yellow) • Pushbutton/rotary selector dial for menu navigation o Rotate dial to access main menus o Push dial and rotate to access sub menus o Press dial for 3 seconds to return to top of main menu • Annunciatorfaultlight o System shutdown (red) o System warning (yellow) • Alarm sllence/lamp test button o Alarm silence o Lamp test • USB and RS-485 connections o Allows software upgrades o Provides access for diagnostics o PC communication using SiteTech'" or Monitor III software • Dedicated user Inputs o Remote emergency stop switch o Remote 2-wire start for transfer -switch o Auxiliary shutdown • Integrated hybrid voltage regulator • Auto-resettable circuit protection mounted on circult board. • One relay output standard. Optional five relay output available. • One analog and three digital inputs standard. Optional two Inputs available. NFPA 110 Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generator functions and faults shown below. • Engine functions: . o Overcrank o Low coolant temperature warning o High coolant temperature warning o High coolant temperature shutdown o Low oil pressure shutdown o Low oil pressure warning o High engine speed o Low fuel (level or Pressure)* o Low coolant level o EPS supplying load o High battery voltage o Low battery voltage • General functions:. o Master switch not in auto o Battery charger fault* o Lamp test o Contacts for local and remote common alarm o Audible alarm silence button o Remote emergency stop * • Functions require optional input sensors or kits Pushbutton/Rotary Selector Dial Annunciator Faun Ught Red -Shutdown, Yellow -Warning Alarm Silence/Lamp Test Button with Ught USB Communication Connection User Interface Displays The listing below has • denoting main menus and o denoting sub -menus. • Overview o Software version o Active shutdowns and warnings (if any are present) o Engine run time, total hours o Average voltage line -to -line o Frequency o Average current o Coolant temperature o Fuel level or pressure * o Oil pressure o Battery voltage • Engine Metering o Engine speed o Oil pressure o Coolant temperature o Battery voltage • Generator Metering o Total power, VA o Total power, W o Rated power, % o Voltage, L-L and L-N for all phases o Current, L1, 12, L3 o Frequency • GenSet Information o Generator set model number o Generator set serial number o Controller serial number • GenSet Run Time o Engine run time, total hours o Engine loaded, hours o Number of engine starts o Total energy, kWh • GenSet System o System voltage o System frequency, 50 or B0 Hz o System phase, single or three (wye or delta) o Power rating, kW o Amp rating o Power type, standby or prime o Measurement units, metric or English (user selectable) o Alarm silence, always or auto only (NFPA 110) • GenSet Calibration o Voltage, L-L and L-N for all phases o Current, L1, L2, L3 o Reset calibration • Voltage Regulation o Adjust voltage, :10% • Digital lnputs o Input settings and status • Digital Outputs o Output settings and status • Analog Inputs o Input settings and status • Event Log o Event history (stores up to 1000 system events) • Selector Switch (requires initial activation by SiteTech'") • Function requires optional input sensors or kits 06-1001/I2b Page2 Controller Features • AC Output Voltage Regulator Adjustment. The voltage adjustment provides a maximum of *10% of the system voltage. • Alarm Silence. The controller can be set up to silence the alarm hom only when in the AUTO mode for NFPA-110 application or Always for user convenience. • Alternator Protection. The controller provides generator set overload and short circuit protection matched to each alternator for the particular voltage/phase configuration. • Automatic Restart. The controller automatic restart feature Initiates the start routine and recrank after a failed start attempt. • Common Failure Relay. This relay is Integrated on the controller circuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at 120 VAC. • Communication. Controller communication is available. • Cyclic Cranking. The controller has programmable cyclic cranking.' • ECM Diagnostics. The controller displays engine ECM fault code descriptions to help In engine troubleshooting. • Engine Start Aid. The starting aid feature provides control for an optional engine starting aid. • Event Logging. The controller keeps a record (up to 1000 entries) for warning and shutdown faults. This fault information becomes a stored record of system events and can be reset. • Historical Data Logging. Total number of generator set successful starts is recorded and displayed. • Integrated Hybrid Voltage Regulator. The voltage regulator provides *0.5% no-load to full -load regulation with three-phase sensing. • Lamp Test. Press the alarm silence/lamp test button to verify functionality of the Indicator lights. • LCD Display. Adjustable contrast for improving visibility. • Measurement UMts. The controller provides selection of English or metric displays. • Power Metering. Controller digital display provides kW and kVA. • Programming Access (USB). Provides software upgrades and diagnostics. • Remote Reset. The remote reset function resets faults and allows restarting of the generator set without going to the master control switch off/reset position. • RSA II Remote Monitoring Panel. The controller is compatible with the Kohler® Remote Serial Annunciator (RSA 11). • Run Time Hourmeter. The generator set run time is displayed. • Time Delay Engine Cooldown (TDEC). The TDEC provides a time delay before the generator set shuts down. • Time Delay Engine Start (TDES). The TDES provides a time delay before the generator set starts. • Voltage Selection Menu. This menu provides the capability of quickly switching controller voltage calibrations. Requires initial activation using SiteTech" software. NOTE: Generator set output leads require voltage reconnection. Controller Functions The following chart shows which functions cause a warning or shutdown. All functions are available as relay outputs. Warning Function Shutdown Function Aiine'Fanctlons '' . a Critically high fuel level* o ECM communication loss • ECM diagnostics • • Engine over speed •+ Engine start ald active Engine under speed • Fuel tank leak * o 0 High battery voltage • - High coolant temperature • •+ High fuel level* o Low battery voltage - • Low coolant level • Low coolant temperature • Low cranking voltage • Low engine oil level * o o Low fuel level (diesel models) * o 0 Low fuel pressure (gas models) * o Low oil pressure • •t No coolant temperature signal • No oil pressure signal • Overcrank - •t Speed sensor fault • W"wEAW_ nctiOrn +Getreral `Functions,; Alarm hom silenced Analog inputs o o Battery charger fault* • Chicago code active* Common fault (includes t) • Common warning • Digital inputs o o Emergency stop •t Engine cooldown (delay) active Engine start delay active Engine started Engine stopped EPS supplying load Generator running Input/output communication loss • Internal failure • Master swtch not In auto • NFPA 110 alarm active Remote start System ready iGeneratorpFgncitons;,� AC sensing loss • • Alternator protection • Ground fault input* • kW overload • Locked rotor • Overfrequency • Overvoltage (each phase) • Underfrequency • Undervoltage (each phase) • • Standard functions Warning causes the fault light to show yellow and sounds the alarm hom o Available user functions signaling an impending problem. * Functions require optional input sensors or kits t Items included with common fault shutdown Shutdown causes the fault light to show red, sounds the alarm horn, and stops the generator set. e8-100 1112D Pege 3 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1648 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 618159 Phone (65) 8264-6422, Fax (65) 8264-6455 Controller Specifications Decision -Makers 3000—Software Version 3.0.25 or higher • Power source with circuit protection: 12- or 24-volt DC • Power drain: -200 milliamps • 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: o CE Directive o NFPA 99 o NFPA 110, Level 1 o UL508 o ASTM B117 (salt spray test) • Panel dimensions—W x H, 229 x 160 mm (9.0 x 8.3 in.) Decision -Maker® 3000 Available Options ❑ Float/Equalize Battery Charger available with 6 or 10 amp DC volt output. The 10 amp models are available with and without NFPA alarm to signal a battery charger fault: ❑ Prime Power Switch prevents battery drain during generator set . non -operation periods and when the generator set battery cannot be maintained by an AC battery charger. ❑ Remote Emergency Stop Switch available as a wall mounted panel to remotely shut down the generator set. ❑ Remote Monitoring Panel. The Kohler° Remote Serial Annunciator (RSA II) enables the operator to monitor the status of the generator set from a remote location, which may be required for NFPA 99 and NFPA 110 installations. ❑ Run Relay provides a relay indicating that the generator set is running. ❑ Shunt Trip Wiring provides relay outputs to trip a shunt trip circuit breaker and to signal the common fault shutdowns. 'Contacts rated at 10 amps at 28 VDC or 120VAC. ❑ Two Input/Five Output Module provides a generator set mounted panel with two inputs and fiverelay outputs. 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. C 2009, 2010, 2012 by Kohler Co., All rights reserved. 66-100 1/12b Page 4 Communication and PC Software Available Options Refer to G6-76 Monitor 111 Software and the communication literature for additional communication and PC software information including Modbus° communication. ❑ Monitor III Software for Monitoring and Control (Windows® -based user interface) ❑ Converter, Modbuse/Ethernet. Supports a power system using controllers accessed via the Ethernet. Converter Is supplied with an IP address by the site administrator. Refer to G8-79 for converter details. O Converter, RS-232/RS-485. Supports a power system using controllers accessed via a serial (RS-232) connection. Modbuse Is a registered trademark of Schneider. Electric. WIndarse is a registered trademark of Microsoft Corporation. DISTRIBUTED BY: Industrial Generator Set Accessories KOHLER®POWER SYSTEMS Line Circuit Breakers 20-2250 kW 09001 NATIONALLY REGISTERED Single Circuit Breaker Kit with Neutral Bus Bar 20-300 kW Model Shown 0 0 o Dual Circuit Breaker Kit with Neutral Bus Bar 20-300 kW Model Shown 0 LL g Multiple Circult Breaker Kite with Neutral Bus Ba 350-2250 kW Model Shown (also applies to some 300 kW models) 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 provided with load -side Tugs and neutral bus bar. • Kohler Co. offers a wide selection of molded -case line circuit breaker kits including single, dual, and multiple configurations for each generator set. • Four types of line circuit breakers are available: (see page 2 for definitions and pages 3 and 4 for application details) o Magnetic trip o Thermal magnetic trip o Electronic trip o Electronic with Ground Fault Circuit Interruption (GFCI) trip • In addition, line circuit breakers are offered with 80% and 100% ratings. • Single line circuit breaker kits allow circuit protection of the entire electrical system Toad. • Dual line circuit breaker kits allow circuit protection of selected priority loads from the remaining electrical system load. • Multiple line circuit breaker kits with field connection barrier allow circuit protection for special applications (350-2250 kW). • Line circuit breakers comply with the following codes and standards unless otherwise stated. o UL 489 Molded Case Circuit Breakers o UL 1077 Supplementary Protectors o UL 2200 Stationary Engine Generator Assemblies 58-88 10/11e Page 1 ❑ 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. • ❑ Auxiliary Contacts These switches send a signal Indicating whether the main circuit breaker contacts are in the open or closed position. U Breaker Separators (350-2250 kW) Provides adequate clearance between breaker circuits. U Bus Bars Bus bar kits offer a convenient way to connect load leads to the generator set when a circuit breaker is not present. 20-300 kW. Bus bar kits are avallable on altemators with leads for connection to the generator set when circuit breakers are not ordered. 350-2250 kW. A bus bar kit is provided on the right side of the unit when no circuit breaker is ordered. Bus bars are also available In combination with breakers or other bus bars on the opposite side of the junction box. On medium voltage (3.3 kV and above) units, a bus bar kit is standard. ❑ Field Connection Barrier Provides installer wiring isolation from factory connections. ❑ Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. 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 Line Circuit Breaker Types 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 E 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. Line Circuit, Breaker Options ❑ 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. ❑ Neutral Lugs Various neutral lug sizes are available to accommodate multiple cable sizes for connection to the bus bar only. ❑ Overcurrent Trip Switch The overcurrent trip switch indicates that the circuit breaker has tripped due to overload, ground fault, or short circuit and retums to the deenergized state when the circuit breaker is reset. " 0 Shunt Trip, 12 VDC or 24 VDC E---- 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. _ ❑ Shunt Trip Wiring Connects the shunt trip to the generator set controller. ❑ Undervoltage Trip, 12 VDC or 24 VDC The undervoltage tripsthe circuit breaker when the control voltage drops below the preset threshold of 35%-70%•of the rated voltage. 08-88 10/11e Page2 80% Rating Circuit Breaker Gen. Set kW Alt. Model Ampere Range Trip Type C.B. Frame Slze 15 20 25 30 35 40 45 60 HD 60 70 Thermal Magnetic 80 90 100 110 125 150 - 175 200 JD 225 250 30 9-325 Mag. Trip 50 84-548 Mag. Trip HJ 100 180-1040 Mag. Trip 150. 348-1890 Mag. Trip 250 684-2500 Mag. Trip JJ 300 350 Thermal Magnetic LA 350-2250 kW 400 500-1000 Mag. Trip (also 4M/ 750-1600 Mag. Trip available on 7M 1000-2000 Mag. Trip some • 300 kW) 400 1125-2250 Mag. Trip LA 1250-2500 Mag. Trip 1500-3000 Mag. Trip 1750-3500 Mag. Trip 2000-4000 Mag. Trip 800 Electronic LSI DG Electronic LSIG • 700 Thermal Magnetic MG 800 1000 Thermal Magnetic 1200 800 1000 Electronic LSI PG • 1200 800 1000 Electronic LSIG 1200 1200 Thermal Magnetic 1200 Electronic LSI PJ 1200 Electronic LSIG 1600 2000 Thermal Magnetic 2500 1600 2000 Electronic LSI RJ 2500 1600 2000 Electronic LSIG 2500 350-2250 kW Line Circuit Breaker Specifications 100% Rating Circuit Breaker Gen. Set ' kW Alt. Model Ampere Range Trip Type C. B. Frame Slze 15 20 25 30 35 40 45 50 HD 60 70 Thermal Magnetic 80 • 90 . 100 110 125 150 175 200 JD 225 350-2250 250 150 • . kW (also 4M/ 250 Electronic LSI DG available on �M 400 some . 150 300 kW) 250 Electronic LSIG DG 400 600 Factory set < 800 Electronic LSI 1000 1200 PG 600 800 Electronic LSIG 1000 1200 1200 Electronic LSI PJ 1200 Electronic LSIG 1600 2000 Electronic LSI 2500 RJ 1600 2000 Electronic LSIG 2500 3000 Electronic LSI NW 3000 Electronic LSIG Interrupt ng Ratings Circuit Breaker Frame Slze 240 Volt, kA 480 Volt, kA BOO Volt, kA HD 25 18 14 HJ 100 85 25 JD 25 18 14 JJ 100 65 25 LA 42 30 22 DG 65 35 18 MG 85 35 18 PG 65 35 18 PJ 100 65 25 RJ 100 85 25 NW 100 100 85 G8-88 10/11e Page4 to 500A 350-2250 kW Line Circuit Breaker Specifications Breaker Positions Mulitple Circuit Breaker Combinations 6 7 6 5 U91T PC61tti7N8 JEOX R13117 P08R11A18 1 2 3 4 ALTERNATOR NOTE: Breaker and load bus phasing on right positions is A-B-C and on left positions Is C-B-A. D-Frame GFCI Circuit Breaker Combinations Alternator Model 1or5 Positions 2or6 Positions 3or7 Positions 4or8 Positions DG GFCI Neutral DG GFCI HD/JD Neutral DG GFCI LA Neutral DG GFCI DG Neutral DG GFCI DG GFCI Neutral Neutral 4M/ DO GFCI HD/JD HD/JD Neutral 5M/ 7M DG GFCI LA HD/JD Neutral DG GFCI LA LA Neutral DG GFCI DG HD/JD Neutral DG GFCI DG LA Neutral DG GFCI DG DG Neutral MG/PG DG Neutral NOTE: D-frames with LSIG trip require (2) spaces (one for breaker and one for LSIG neutral). Circuit Breaker Lugs Per Phase (AI/Cu) Frame Size Ampere Range Wire Range HD (80% rating) 15-150 One #14 to 3/0 HD (100% rating) 15-150 One #14 to 2/0 Cu only JD (80% rating) 175 One 1/0to4/0 200-250 One 3/0 to 350 kcmil JD (100% rating) 175-250 One 1/0 to 300 kcmil Cu only LA 300-400 One #1 to 600 kcmil or (2) #1 to 250 kcmil DG 150-400 One #2 to 500 Komi! Al only One #2 to 600 kcmil Cu only 600 Two 2/0 to 500 kcmil Al only Two 2/0 to 350 kcmil Cu only MG 700-800 Three 3/0 to 500 kcmil PG 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) 1/0-750 kcmil or (2) 1/0-300 kcmil NW 2500/3000 Alternator Model 1or5 Positions 2or6 Positions 9or7 Positions 4or8 Positions HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD HD/JD LA LA HD/JD LA IA LA HD/JD HD/JD LA LA HD/JD LA LA LA LA HD/JD HD/JD HD/JD LA LA HD/JD HD/JD LA LA LA H/J LA LA LA LA DG DG HD/JD DG LA DG DG DG HD/JD HD/JD DG LA HD/JD DG LA LA DG DG HD/JD DG DG LA 4M/ DG DG DG 7M 7M DG HD/JD HD/JD HD/JD DG LA HD/JD HD/JD DG LA LA HD/JD DG LA LA LA DG DG HD/JD HD/JD DG DG LA HD/JD DG DG LA LA DG DG DG HD/JD DG DG DG LA DG DG DG DG MG/PG MG/PG HD/JD MG/PG LA MG/PG DG MG/PG MG/PG MG/PG HD/JD HD/JD MG/PG LA HD/JD MG/PG LA LA MG/PG DG HD/JD MG/PG DG LA MG/PG DG DG R NW LOAD BUS 05-e8 10/11e Page 5 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1646 For the nearest sales and service outlet In the US and Canada, phone 1-600-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone.(65) 6264-6422, Fax (65) 6264-6455 20-300 kW Line Circuit Breaker Applications Single Circuit Breaker Installations 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. To Remaining To Priority Load(s) Building Loads Single line circuit breaker configuration where circuit breaker can trip causing all power to building loads including priority load to be disrupted. Dual Circuit. Breaker Combinations Alternator Model First C. B. Frame Size Second C. B. Frame Size Comments 4P/4PX/4Q/ 4QX/4RX/4S/ 4SX/4TX/4V/ 4UA D� — 100% rating, standard or GFCI HD JD — HD HD JD HDorJD 4RX/4S/4SX/ 4TX/4V/4UA LA — MG — PC' — 100% rating, standard or GFCI LA HD, JD, or LA 4P/4PX/40/ 44X/4FIX/4S/ 4SX/4TX/4V DG HD, JD, LA, or DG 100% rating, no GFCI 4UA DG HD, JD, LA, or DG Primary or sec. available as 100% rating, std. or GFCI Availability Is subject to change without notice. Kohler Co. reserves the right to change he design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler® generator set distributor for availability. Dual Circuit Breaker Installations A generator set with dual circuit breakers installed is used to separate 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 Line C.B. Line C.B. 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). Alternator Model First . C. B. Frame Size Second C. B. Frame Size Comments 4RX/4S/ 4SX/4TX/4V MG HD, oJDQ�' 100% rating, no GFCI PG HD, JD, LA, or DG 100% rating, no GFCI 4UA MG HD, JD, LA, or DG • DG available as GFCI PG HD, JD, LA, or DG PG and/or DG available as GFCI PG PG 100% rating, no GFCI DISTRIBUTED BY: 0 2007, 2010, 2011 by Kohler co. All rights reserved. G8-08 10/11e Pegs6 CURRENT IN MULTIPLES OF Ir (Ir a LONG-TIME SETTING x In) 10000 WOO 1—f--'-t-}- 0000 8080 50„ ! 1 4000 ij 200 i- 0 z 0 • W GO f ,A , T d OR WOO Ir iILopar lI j N t tat 11111111111 P u , q M•UII ) I. N ■au • \ �►� iii�'i'iiiiiii i .t �\ \\z� r Wr A �eq�i�►li►I ,' wa` 0• 0 I. �� 1ANf5.Yl . E Miltrl U \ \ ,■, ilk i CON S Ba,lr i SRI 1 ` k U Ilk .4OFF mum111 Jai IL Kg WM= I . ml asE , _-D.70Ff� MICROLOGIC® 5.0/6.0 A/P/H TRIP UNIT CHARACTERISTIC TRIP CURVE NO. 613-4 Long-time Pickup and Delay Short -time Pickup and Pt OFF Delay The time -current curve information Is to be used for application and coordination purposes only. Curves apply from -30°C to +60°C ambient temperature. Notes: 1. There is a thermal -imaging effect that can act 7.0 to shorten the long-time delay. The thermal- ... imaging effect comes into play if a current 1eo above the long-time delay pickup value exists 111 for a time and then is cleared by the tripping of a downstream device or the circuit breaker itself. A subsequent overload will cause the circuit breaker to trip in a shorter time than normal. The amount of time delay reduction is Inverse to the amount of time that has elapsed since the previous overload. Approximately 20 minutes is required between overloads to completely reset thermal -imaging. 000 ,1a 100 00 2. The end of the curve is determined by the interrupting rating of the circuit breaker. 3. With zone -selective interlocking on, short -time delay utilized and no restraining signal, the maximum unrestrained short -time delay time band applies regardless of the setting. ,d 4. Total clearing times shown include the response times of the trip unit. the circuit breaker opening, and the extinction of the current. 5. For a withstand circuit breaker, Instantaneous can be turned OFF. See 613-7 for Instantaneous trip curve. See 613-10 for instantaneous override values. 6. Overload indicator illuminates at 100%. 40 v, / O.zOFF 1e OFF_ me Ao't I I C)F+. _L j i 1 III i, I 3 v Merlin Gerin 111 Modicon sr Square D ■ Telemccanique II Federal Pioneer Federal Pacific Sdnr.an EirOk arum A CURRENT IN MULTIPLES OF Ir (U= LONG-TIME SETTING x In) A P 9 9 R AA8 m .m .e. ms m .007 205 Aa Schneider Electric 02000ScNNN7o.402 40 pN,wnaO Cu=Ne. 0112720001 Oapn°n0000 0=255 Ne. BYO%A,aN _Gr P-Frame 1200 A R-Frame Soisdkrrisincarams POWERPACT® P- and R-Frame Molded Case Circuit Breakers (Standard or 100% rated up to 2500A) The most compact and innovative molded case circuit breakers POWERPACT Molded Case Circuit Breakers lead the industry with proven, reliable protection and innovative design. Providing unparalleled performance and control, this generation of P- and R-frame circuit breakers features exclusive MICROLOGIC® Trip Units, which allow for a range of sophisticated applications for metering and monitoring. In addition, units can be interchanged to allow for maximum flexibility and are field -installable for easy upgrades as needed. The compact P- and R-frame circuit breakers permit smaller footprint and higher density installations using I -LINE® Panelboards and Switchboards. These circuit breakers are available in 100% rated construction up to 2500 A to meet a broad range of commercial and industrial application needs. Full -Featured Performance ■ P-frame — 1200A available in both standard and 100% ratings with sensor sizes 250-1200A. Interrupting ratings (AIR) G-35kAIR, J-65kAIR and L-100kAIR at 480 VAC ■ R-frame — 2500A available in both standard and 100% ratings with sensor sizes 600-2500A. Interrupting ratings (AIR) G-35kAIR, J-65kAIR and L-100kAIR at 480 VAC ■ Compact breaker size allows for smaller footprint installations using I -LINE Panelboards and Switchboards. 9" width on P-frame designs and 15" width on R-frame designs provide increased density installations ■ Most field -installable accessories are common to all frame sizes for easier stocking and installation ■ Selection of four interchangeable MICROLOGIC Trip Units with POWERLOGIC® power metering and monitoring capabilities available in advanced trip units ■ Compatible with POWERLOGIC® systems and high amperage power circuit breakers IN Built-in MODBUS® protocol provides an open communications platform and eliminates the need to purchase additional, proprietary network solutions ■ Connection options include bus, cable or I -Line for installation flexibility ■ Additional options are available for 5-cycle closing, stored energy mechanisms and draw -out mounting of 1200A breakers SQUARE D Schneider Electric POWERPACT® P- and R-Frame Molded Case Circuit Breakers (Standard or 100% rated up to 2500 A) Onboard Intelligence For ''smarter breakers," a range of MICROLOGIC® Trip Units provides advanced functionality, such as a communications interface, and power metering and monitoring capabilities. With the appropriate MICROLOGIC Trip Unit, you can communicate with breakers, gather power information, monitor events and remotely control breakers based on predetermined conditions, leading to substantial savings in electrical system operating costs. These interchangeable, microprocessor -controlled, plug-in devices provide the next generation of protection, measure- ment and control functions, delivering not only greater electrical system safety but also improved system integration and coordination. Choose the Model that Meets Your Needs MICROLOGIC 3.0 and 5.0 ■ Basic circuit protection including long-time, instantaneous and optional short -time adjustments MICROLOGIC 3.0A, 5.0A and 6.0A ■ Long-time, instantaneous and optional short -time adjustments • Integrated ammeter and phase loading bar graph • LED trip indicator • Zone selective interlocking with downstream and upstream breakers ■ Optional ground -fault protection • Optional MODBUS® communications interface MICROLOGIC® Trip Units MICROLOGIC 5.0P and 6.0P • Long-time, instantaneous and optional short -time adjustments • Advanced relay protection (current imbalance, under/over voltage, etc.) • Inverse Definite Minimum Time Lag (IdmtL) long-time delay curve shaping for improved coordination • Basic power metering and monitoring functions ■ Standard MODBUS communications interface compatibility with POWERLOGIC® installations ■ Standard GF alarm on 5.0P. 6.0P has equipment ground -fault tripping protection MICROLOGIC 5.0H and 6.0H • All 5.0P and 6.0P functions • Enhanced POWERLOGIC power metering and monitoring capabilities IN Basic power quality (harmonic) measurement • Waveform capture Contact your Square D sales representative for additional Information. Or, visit www.SquareD.com. ® 2002 Schneider Electric All rights reserved Order Number 0612H00201 SQUARE D Schneider Electric Industrial Generator. Set Accessories KOHLER®POWER SYSTEMS Remote Serial Annunciator II (RSA II) 09001 NAtIwuur REGISTEREC SYSTEM STATUS KOHLER. POWER SYSTEMS RSA 1I ( GENERATOR FAULTS 1 ( GENERAL FAULTS ol Overcrnnk r_ — 1110 Egine tetnpOatute o mom Loy, Oil Prossur• over-,,ceed moo Es,ncncy Sto, m Loy, Furl EPS Su ,plying Lord NM Low Cooirrt L.,:l/Ater Not.,,ruto mom L.,: Coolant Tmoper:Rur+: amp Sy:ton, Rarely moo Lour C,:tnkirrr VoRage MOM Cr_ncr:rtor Running am Oa:tcryVoltugc 0101.0) Conlnlurt.C.tlon St,tu0 ( SYSTEM STATUS 1 MON A:r;tery Chn+ger f=.�ilu lt: Common F:;llll .-v RSA II System ID. KOHLER. PONER SiSTEi':1S t♦ ATS Fault SOURCE NI*a���• Era RSA II with ATS Controls Remote Serial Annunciator II (RSA II) for Kohler® Controllers • Monitors the generator set equipped with one of the following controllers: KPC 1000 Decision -Maker® 3+ Decision -Maker® 3000 Decision -Maker® 550 Decision -Maker® 6000 • Allows monitoring of the common alarm, remote testing of the automatic transfer switch, and monitoring of the normal emergency source with one of the following controllers: MPAC' 1000 MPAC'" 1500 • Configuration via a personal computer (PC) software. • RSA II panel includes writable surfaces (four white boxes in Illustration) for user -defined selections. • .. Uses Modbus® protocol, an industry standard. • Controller connections: RS-485 for serial bus network USB device port for PC 12-/24-volt DC power supply 120/208 VAC power supply (available accessory) • Meets the National Fire Protection Association Standard NFPA 110, Level 1. Dimensions ▪ Dimensions—W x H x D, mm (in.). Also fits in a standard 203 mm x 203 mm (8 in. x 8 in.) Hoffman box. Surface Mounted: - 203x203x56 (8.0 x 8.0 x 2.2) Flush Mounted: 203x203x58 (8.0 x 8.0 x 2.3) Flush mounting plate W1: 229 (9,0) macaws. Is'a registered trademark of Schneider Electric. G64, 7/r1c Surface Mounted W1\ Flush Mounted Fault and Status Conditions Fault LEDs Fault Horn System Ready LED Generator Running LED Communication Status LED Overcrank Shutdown Red On Red Off Green High Engine Temperature Waming * Yellow On Red Green Green High Engine Temperature Shutdown Red On Red Off Green Low 011 Pressure Warning * Yellow On Red • Green Green Low 011 Pressure Shutdown Red 0n Red Off ' Green overspeed Shutdown Red On Red Off Green Emergency Stop * Red On Red Off Green Low Coolant Level/Aux. Shutdown Red On Red Off Green Low Coolant Temperature * Yellow On Red Off Green Low Cranking Voltage • Yellow On Red Off Green Low Fuel —Level or Pressure" Yellow On Red Green or Off Green Not -In -Auto Red On Red Green or Off Green Common Fault Red On Green Green or Off Green Battery Charger Fault (1) * Yellow On Red Green or Off Green Battery Charger Fault (2) * Yellow On Green Green or Off Green High Battery Voltage* Yellow Off Green Green or Off Green Low Battery Voltage * Yellow Off Green Green or Off Green User Input #1 (Warning) Yellow Off Green Green or Off Green User Input #1 (Shutdown) Red On Green Off Green User Input #2 (Warning) Yellow Off Green Green or Off Green User Input #2 (Shutdown) Red On Green Off Green User Input #3 (Warning) (1) t Yellow Off Green Green or Off ' Green User Input #3 (Shutdown) (1) t Red On Green Off Green EPS Supplying Load Yellow Off Green Green Green Communications Status (Fault mode) — Off Green or Red Green or Off -Red ATS Fault (RSA II with ATS Controls only) Red On Red or Yellow - Green or Off Green Green LEDs appear as steady on when activated. Yellow LEDs slow flash when activated except steady on with EPS supplying load and high battery voltage. - Red LEDs slow flash when activated except fast flash with loss of communication and not -in -auto. Specifications • LED indicating lights for status, warning, and/or shutdown. See the above chart for details. • Power source with circuit protection: 12- or 24-volt DC • Power source with120/208 VAC, 50/60 Hz adapter (option) • Power draw: 200 mA • Humidity range: 0% to 95%-noncondensing • Operating temperature range: -20°C to +70°C (-4°F to +158°F) • Storage temperature range: -40°C to +85°C (-40°F to +185°F) • Standards: o NFPA 110, level 1 o UL 508 recognized o CE directive o NFPA 99 o EN6II-4-4 fast transient immunity • RS-485 Modbus® isolated port @ 9.6/19.2/38.4/57.6 kbps (default is 19.2 kbps) • USB device port • NEMA 2 enclosure (1) All generator set controllers except Decision-Makere 3+ controller. (2) Decislon-Makere 3+ controller only. • May require optional kit or user -provided device to enable function and LED indication. 4 Digital Input #3 Is factory -set for hlgh battery voltage on the Decision -Maker® 3+ controller. Modbus© is a registered trademark of Schneider Electric. ATS Controls (RSA II with ATS controls only) • ATS position LED (normal or emergency) • Power source Indicator LED (normal or emergency) • ATS fault LED • Key -operated spring -loaded test switch (Re-Transfer/Auto(Test) NFPA Requirements • NFPA 110 compliant • Engine functions: o High battery voltage warning * o High engine temperature shutdown o High engine temperature warning * o Low battery voltage warning * o Low coolant level/aux. shutdown o Low coolant temperature warning * o Low cranking voltage o Low fuel warning (level or pressure) * o Low oil pressure shutdown o Low oil pressure warning * o Overcrank shutdown o Overspeed shutdown • General functions: o Audible alarm silence o Battery charger fault * o Lamp test o Master switch not -in -auto 08-95 7/11e Fault and Status LEDs and Lamp Test Switch Alarm Horn. Horn sounds giving a minimum 90 dB at Lamp Test Switch. Switch tests all the annunciator Indicator 0.1 m (0.3 ft.) audible alarm when a warning or shutdown LEDs and horn. fault condition exists except on high/low battery voltage or EPS supplying Toad. Alarm Silenced. Red LED lights when alarm hom Is deactivated by alarm silence switch (lamp test switch). Alarm Silence Switch. Switch quiets the alarm during servicing. The horn will reactivate upon additional faults. ATS Fault. Red LED lights when ATS fails to transfer. Aux. See Low Coolant Level/Aux. Battery Charger Failure. LED lights if battery charger malfunctions. Requires battery charger with alarm contact. (High/Low) Battery Voltage. LED flashes If battery or charging voltage drops below preset level. LED lights steady if battery voltage exceeds preset level. Common Fault. LED lights when a single or multiple common faults occur. Communication Status. Green LED lights indicating annunciator communications functional. Red LED indicates communication fault. Emergency Power System (EPS) Supplying Load. LED lights when the generator set is supplying output current (Decision -Maker® 550, 3000, and 6000 controllers) or when transfer switch Is in the emergency position (Decision -Maker® 3+ controller). Emergency Stop. LED lights and engine stops when emergency stop is made. May require a local emergency stop switch on some Decision -Maker® 3+ controllers. Generator Running. LED lights when generator set is in operation. (Generator Switch) Not In Auto. LED lights when generator set master switch is in RUN or OFF/RESET position. High Engine Temperature. Red LED lights if engine has shut down because of high engine coolant temperature. Yellow LED lights if engine coolant temperature approaches shutdown range. Requires warning sender on some models. Low Coolant Level. LED lights when engine coolant level is below acceptable range on radiator -mounted generator sets only. When used with a Decision-Makere 3+ controller, the LED indicates low coolant level or an auxiliary fault shutdown. Requires user- supplied low coolant level switch on remote radiator models. Low Coolant Temperature. LED lights if optional engine block heater malfunctions and/or engine coolant temperature is too low, Requires prealarm sender on some models. Low Cranking Voltage. LED lights if battery voltage drops below preset level during engine cranking. Low Fuel (Level or Pressure). LED lights if fuel level In tank approaches empty with diesel models or fuel pressure is low on gas models. Requires customer -supplied switch. Low 011 Pressure. Red LED lights if generator set shuts down because of insufficient oil pressure. Yellow LED lights if engine oil pressure approaches shutdown range. Requires warning sender on some models. - Overcrank. LED lights and cranking stops if engine does not start in either continuous cranking or cyclic cranking modes. 0verspeed. LED lights if generator set shuts down because of overspeed condition. System Ready. Green LED lights when generator set master switch is in AUTO position and the system senses no faults. Red LED Indicates system fault. User -Defined Digital Inputs #1, #2, and #3. Monitors two digital auxiliary inputs (warnings or shutdowns). Individual red LEDs flash when a fault occurs or the status changes. User -defined digital input #1 and #2 are selected via the RSA II master for local or remote (generator set or ATS). The user -defined digital Input can be assigned at the controller or via PC using SiteTech"' setup software. Communications (Shown with RSA 11 with ATS Controls) Local Single (Master) Connection Local Multiple (Master/Slave) Connections A single RSA II connects directly to the controller's A single RSA II master connects directly to the controller's communication port with an RS-485 cable. communication port with an RS-485 cable. Additional RSA lls (slaves) can connect to the single master RSA II. Status of the RSA II (master) is annunciated on the RSA II (slave) panel. Transfer Switch Remote annunciator (master) Use RS-485, see Note* Communication Module (16-light only) r 1 I PC (user -supplied) I— — — L J Generator set controller Use RS-485, see Note* (Available on Decision -Makers 550, 3000, and 6000 controllers only) Transfe Switch Remote annunciator (master) Use RS-485, see Note* 4 Communication Module (16-1Ight only) a Remote annunciator (slave) Use RS-485, see Note* Generator set controller Remote annunciator (slave) Note*: Use RS-485 for a total of up to 1220 m (4000 ft.) maximum from the first device to the last device. G6.95 7/11e KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441,Fax 920-459-1848 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 819159 Phone (65) 6284-6422, Fax (65) 6264.6455 Modbuse/Ethernet, Single Master or Multiple Master/Slave Connections (Shown with RSA II with ATS Controls). An RSA II master communicates with a controller and RSA II slaves through an Ethernet network. A Modbuse/Ethernet converter is required for each RSA II and controller. RS-485 cable connects the RSA II to the converter. Category 5e (Cat 5e) network cableconnects the Modbus®/Ethernet converter to the Ethernet. Note: Combining RSA II remote annunciators with the RSA 1000 Is permissible provided that the master remote annunciator is an RSA II remote annunciator: Note*: Use RS-485 for atotal of up to 1220 m (4000 ft.) maximum from the first device to the last device, Remote Annunciator (Master) Modbuse/Ethernet Converter Use RS-485, see Note* Use RS-485, see Note* Remote Annunciator (Slave) Modbus®/Ethernet Converter Ethernet • Generator set Controller Use RS-485, see Note* Modbuse/Ethernet Converter Communication Module (18-light only) Use RS-485, see Note* Modbuse/Ethernet Converter Use RS-485, see Note* Transfer Switch. Remote Annunciator (Slave) Accessories O Power source adapter kit 120/208 VAC, 50/60 Hz. ❑ Modbus®/Ethemet converter GM41143-KP2 for serial to Ethernet communication. ❑ Communication module GM32644-KA1 or GM32644-KP1 Is required with Decision -Maker® 3+ controllers. Modbus® Is a registered trademark of Schneider Electric. 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: m 2009, 2009, 2011 by Kohler Co. NI rlphel reserved 08-95 7/11c Industrial Generator Set Accessories KOHLER POWER SYSTEMS Float/Equalize Battery Charger P 09001 NATIONALLY REGISTERED Specifications tawantssup a `rr..' rj At. TOEA8C EAYAO.TA •91GYACM OD ft x e. dais 0 Standard Features • 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. Installed Battery NFPA 110 Alarm Outputs . Output Number of Cells Voltage Amps Lead Acld NI-Cd PAD-292863 Yes 12 10 6 9 Battery Charger Kit PAD-292863 Input Voltage 120/240 VAC Input Frequency 120/240VAC, 50/60 Hz DC Voltage Regulation *1% Dimensions (L x W x D) 271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.) Weight 11.8 kg (26 Ib.) Float/Equalize Battery Charger, continued 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 Ievel.At the preset equalize level, the battery charger switches to the constant voltage Equalize Mode until the current required to maintain this voltage drops to 50% of the battery charger's high rate current.The battery charger then - switches to the lower constant voltage Float Mode when the battery nears full charge. The battery charger continues to operate in this mode until AC input power disconnects or the current required to maintain the battery at the float voltage setting exceeds 6 amps. Temperature Compensation The battery charger compensates for battery temperature using a negative temperature coefficient. The battery charger provides temperature compensation of-2mv/°C per cell over the ambient temperature range of -40°C up to 60°C. The temperature compensation automatically adjusts the float and equalize voltage settings to prevent the battery from overcharging at high ambient temperatures and undercharging(at low ambient temperatures. Figure 1 Figure 2 Float/Equalize Battery Charger, continued Standard Features • Ammeter and voltmeterindicate 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 (140°F). Battery charger float 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 circuitryprotected 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. Float/Equalize Battery Charger, continued tat:Rp J T.DDIYT67 ervr 0 0 • aA MWC. mew*. EA 231B) DUL R1 BOO OR. X 219 O1A. [1$7 X SA KeixOLE 2 PLACES AC TERM OC TERMINAL BLOCK 424101111311161111 pOwttAsTY7Ns asroratarm eow+ecnow rtTdvaHAtetoas 120VOLT WPUT 111,46.o1T PUT a TERrwr.slsGc • M4 T •.• JJ GM .1611, 1 S 8 T rmonto, mw`zanmuacrm vim ODVRTP lcsea E'.fAL.11 DmNGZTm ba,n t OWL AGIIIMINIZMIRS. eionerlItusesp• aaam eiraP, neespnk]. +wrn a, Twine Wall%ABC tOM10O�U1'+M aL� EEWELE. 8m 11R6M•�t. JAE 1a.11.41, 1•11.ATE. 1.R .r, rK,oaLm@. EI.pp NOW ICFOC Nti 11 .111 .4..S..4.m° *nnMW1110 1 ►.1 1=1►. E •1u VIEW B 4 • CUSTOMER CONNECTIONS LV-N.O.CONTACTS, CLOSE ON LOW BATTERY VOLTAGE HV- ND, CONT CLOSE ON HIGH BATTERY VOLTAGE CM-N.O.CONtACTS, CLOSE ON LDSS OF AC INPUT OR LOSS OF OC OUTPUT VIEW A -A OPTIONAL ALARM BOARD AOVa97! Industrial Generator Set Accessories KOHLER POWER SYSTEMS Silencers 09001 01 RAIN-. NATIONALLY REGISTERED � o Legend 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 Type Noise Reduction dB(A) Ambient Noise Level Silencing Requirement Critical 25-35 Low High 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 exhaust piping. Do not exceed the maximum allowable backpressure. Use the information below for identifying the exhaust system components shown In the illustrations on the following pages. Side Inlet End Outlet (SIEO) End Inlet End Outlet (FLED) Flex Exhaust Flex Exhaust (wye) EIEO ■i?,11111t1! Industrial Generator Set Accessories KOHLER POWER SYSTEMS Exhaust Systems ''[=;) REOZJF 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. Legend Use the`information below for identifying the exhaust system components shown In the illustrations on the . following pages. Side Inlet End Outlet (SIEO), End Inlet End Outlet (EIEO) Flex Exhaust Flex Exhaust (wye) ■Itllllltlis.'! All exhaust systems require a flexible connection between the engine exhaust and the rest of the exhaust system. Seamless stainless steel connectors are availible for each .generator set. Item Exhaust System Kits Engine Type Bum. Qty. in Kit Size, In/ Out Note Flex Exhaust 6 1 0 Kit includes the exhaust clamp. Industrial Generator Set Accessories KOHLER POWER SYSTEMS Flange Kits 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. 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. ANSI Class 150 Flange Dimensions Nominal Pipe Size, A B . C D deg. mm in. mm (in.) Qty., mm (in.) 0 45 241.30 (9.50) Weld Flange Dimensions c Outside diameter Quantity sji bolts, boa hde diameter Wed flange Weld ikage Gasket Weld flange Gasket and mounting hardwre Customer -Supplied exhaust pipe Gasket and haunting hardware .Flex exhaust Customer -supplied exhaust pipe Industrial Generator Set Accessories Voltage Regulators KOHLER POWER SYSTEMS 09001 NATIONALLY REGISTERED Integral Voltage Regulator with Kohler® Decision- Maker® 3000 Controller (20-300 kW Generator Set Models) Dedslon-Makeri 9000Controller with integral Voltage Regulator The voltage regulator is integral to the controller and uses microprocessor logic providing ±0.5% no-load to full -load regulation using root -mean -square (RMS) voltage sensing. The voltage regulator features three-phase sensing and is available for 12- or 24-volt engine electrical systems. 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 Decislon-Maker® 3000 Controller Adjustment Digital Display Range Setting Default Selection VoRege Adlust . Van nal, *10% ofSystem %Mega System Voltage cy Unload of Frequency Frey e2 to BP Hz 2.5Hz Below system Frequency UndeArequaloy Unload Skye. $lone 0-1016 of System tillage (lbtts par [yde) 5 Vans pet Clyde Voltage Regulato rs, continued Specification. Integral with DEC 3000 Controller Generator Set Availability 20-300 kW Models Type Microprocessor based Status and Shutdown Indicators LEDs and Digital Display Operating Temperature -40°C to 70°C (-40°F to 158°F) Storage Temperature -40°C to 85°C (-40°F to 185°F) Humidity 5-95% Non -Condensing Circuit Protection. Solid -State, Redundant Softward and. Fuses Sensing, Nominal 100-240 Volts (L-N), 50-60 Hz Sensing Mode RMS, Single- or 3-Phase Input Requirements 8-36 VDC Continuous Output 100 mA at 12 VDC Maximum Output 100 mA at 12 VDC Transition Frequency 50-70 Hz Exciter Field Resistance NA No -Load to Full -Load Voltage Regulation t0.5% Thermal Drift less than 0.5% (-40 C to 70 C) [-40 F to 158 F] Range Response Time Less Than 5pS Voltage Adjustment (of system voltage) ±10% Voltage Adjustment Controller Menu Knob Remote Voltage Adjustment NA Paralleling Capability NA VAR/PF Control Input NA DVR® Is a registered trademark of Marathon Electric Mfg. Corp. NA - Data not available at time of print. Integral Voltage Regulators with Decision - Maker® 3000 Controller A digital display and pushbutton/rotary dial provide access to data. A two-line LCD display provides complete and concise information. • The 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 • See G6-100 Decision -Maker® 3000 for more information. Generator Set Calibration Menu • L1-L2 Volts • L2-L3 Volts (3-phase) • L3-L1 Volts (3-phase) • L1-N Volts • L2-N Volts L3-N Volts (3-phase) Voltage Regulation Menu • Adjust voltage, i10% KOHLER POWER S`gEMS Alternator Data ICOHLER. POWER SYSTEMS TIB-1 02 Alternator Model: Frequency: Speed: Leads: TECHNICAL INFORMATION BULLETIN Alternator Data Sheet 4S13X 60 Hz 1800 RPM 12 (6 Lead, 600 Volt) Voltage L-N/L4_ Phase Power Factor • Connection kW* (kVA) Class B ' Class F Class H 80°C Continuous 90°C Lloyds 95°C ABS 105°C Continuous 130°C Standby 125°C Continuous 150°C Standby 139/240 277/480 3 0.8 Wye 176.0 (220.0) 184.5 (230.5) 189.5 (236.5) 197.5 (246.5) 211.0 (263.5) 208.5 (260.5) 221.0 (276.0) 127/220 254/440 3 0.8 Wye 162.5 (203.0) 170.0 (212.5) 174.0 (217.5) 182.0 (227.5) 194.0 (242.5) 191.5 (239.0) 203.0 (253.5) ' 120/208 240/416 3 0.8 Wye 154.5 (193.0) 162.0 (202.5) 165.5 (206.5) 173.5 (216.5) 184.0 (230.0) 182.0 (227.5) 192.5 (240.5) 110/190 220/380 3 0.8 Wye141.0 (176.0) 147.5 (184.0) 151.0 (188.5) 158.0 (197.5) 168.0 (210.0) 166.0 (207.5) 175.5 (219.0) 120/240 3 0.8 Delta 154.5 (193.0) 162.0 (202.5) 165.5 (206.5) 173.5 (216.5) 184.0 (230.0) 182.0 (227.5) 192.5 (240.5) 120/240 1 1.0 Dogleg 109.0 (109.0) 111.0 (111.0) 112.5 (112.5) 113.0 (113.0) 113.0 (113.0) 113.0 (113.0) 113.0 (113.0) 347/600 3 0.8 Wye 175.5 (219.0) 184.0 (230.0) 189.0 (236.0) 197.0 (246.0) 210.5 (263.0) 206.0 (260.0) 220.5 (275.5) * 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, 80 Hz, 3 Phase, 130°C Rise Typical Cold Resistances Phase Resistance Rotor Resistance Typical Reactances Synchronous Direct Quadrature Transient Unsaturated Saturated Subtransient Direct Quadrature Negative Sequence Zero Sequence Symbol ,PerUnit Ohms Xq X'd° X'd X"d X'q x2 Xo Typical Time Constants 4.578 0.029 Armature Short Circuit 26.43 5.774 Transient Short Circuit Transient Open Circuit Typical Field Current 4.926 1.076 Full Load 2.428 0.530 No Load Typical Short Circuit Ratio 0.474 0.104 Harmonic Distortion 0.417 0.091 RMS Total Harmonic Distortion Max. Single Harmonic 0:144 0.031 Deviation Factor (No Load, L-L) 0.143 0.031 Telephone Influence Factor 0.143 0.031 Insulation Class 0.012 0.003 per NEMA MG1 1.66 Phase Rotation Symbol Value T. 0.011 sec. T'd 0.149 sec. T'd° 1.759 sec. IfFL Ifrn 21.6 amps 3.9 amps 0.203 3.59% 5th <5% <50 H ABC TIB-102 4S13X 60 Hz 5/11n 1 100 98 96 94 u 92 90 88 86 84 82 80 0 40 35 30 0. 25 Et I 20 15 10 5 0 0 4S13X, 60 Hz, 139/240,-277/480 Volts, Wye TYPICAL ALTERNATOR EFFICIENCY* 0.8 PF 25 50 75 100 125 150 175 200 Output (KW) 4S13X, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 225 100 200 300 400 Locked Rotor KVA 500 600 700 • 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 4S13X 60 Hz 5/11n TIB-102 1000 100 E 10 1 0.1 0.01 4S13X, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 1 r 1 1 r 1 1 11 l 1 t I 1 1 1 1 1 1 10 100 Armature Current (A)` 000 10000 Altemator damage curve . Line to Lirie'1 ph 3 phase symmetrical • Line to Neutral 1ph 'Instantaneous current WO) Is asymmetric. Divide by 1.73 for. symmetric. TIB-102 4S13X 60 Hz 5/11n 3 1000 100 10 w E 0.1 0.01 10 4S13X, 60 Hz, High Wye Connection SHORT CIRCUIT DECREMENT CURVE 1 1 1 1 1 1 Ikk • 100 1000 Armature Current (A)" 10000 Alternator damage curve Line to Line 1 ph 3 phase symmetrical ®• Line to Neutral 1 ph Instantaneous current (t=0) Is asymmetric. Divide by 1.73 for symmetric. 4 4S13X 60 Hz 5/11n TIB-102 KOHLER POWER SYSTEMS Emissions Data KOHLER. POWER SYSTEMS 150REOZJF 60 HZ. DIESEL INDUSTRIAL GENERATOR SET EMISSION DATA SHEET Model: Nameplate BPH @ 1800 RPM: Type: Aspiration: Compression Ratio ENGINE INFORMATION John Deere, 6068HF285K Bore: 106mm (4.19 in.) 237 Stroke: 127mm (5.00 in.) 4-Cycle, 6 Cylinder, Inline • Displacement: 6.79 L (414 cu. in.) Turbocharged, Charge Air-cooled 17.0:1 EPA Family: CJDXL06.8120 EPA Certificate: CJDXL06:8120-016 PERFORMANCE DATA: Engine bkW @ Stated Load Fuel Consupumtion (g/kWh) Exhaust Gas Flow (mils) Exhaust Temperature ('C) EPA CERTIFICATE EXHAUST EMISSION DATA: DATA HC (Total Unburned Hydrocarbons) 0.1 NOx (Oxides of Nitrogen as NO2) 3.8 CO (Carbon Monoxide) 1.2 PM (Particular Matter) 0.12 Smoke (Pierburg) 1/4 1/2 3/4 Full Standby Standby Standby Standby 74.67 99.56 132.75 177.00 249.60' 243.50 222.00 214.40 1674.00 528.00 0.250 3.350 1.760 0.239 0.140 2.950 1.110 0.129 0.070 4.030 0.700 0.109 0.060 5.080 0.540 0.080 Values are in g/kWh TEST METHODS AND CONDITIONS ISO 8528 D2 Data and specifications subject to change without notice For further information, please contact Todd Loes at John Deere Power Systems, 319-292-6050 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 2012 MODEL YEAR CERTIFICATE OF CONFORMITY WITH THE CLEAN AIR ACT OF 1990 OFFICE OF TRANSPORTATION AND AIR QUALITY ANN ARBOR, MICHIGAN 48105 rtificate Issued To: Deere & Company (U.S. Manufacturer or Importer) rtificate Number: CJDXL06.8120-016 Effective Date: 10/07/2011 Expiration Date: 12/31/2012 Karl J. SiIg n, Director Compliance and In ative Strategies Division Issue Date: 10/07/2011 Revision Date: N/A idel Year: 2012 tnufacturer Type: Original Engine Manufacturer gine Family: CJDXL06.8120 Mobile/Stationary Indicator: Stationary Emissions Power Category: 130<=kW<225 Fuel Type: Diesel After Treatment Devices: No After Treatment Devices Installed Non -after Treatment Devices: Engine Design Modification, Non-standard Non -After Treatment Device Installed, Smoke Puff Limiter, Electronic Control ouant to Section 111 and Section 213 of the Clean Air Act (42 U.S.C. sections 7411 and 7547) and 40 CFR Part 60, and subject to the terms and conditions prescribed in those provisions, this certificate fortuity is hereby issued with respect to the test engines which have been found to conform to, applicable reqttirements and which represent the following engines, by engine family, more fully described i locumentation required by 40 CFR Part 60 and produced in the stated model year. ''r:-;' : certificate of conformity covers only those new compression -ignition engines whiclfconform in all material respects to the design specifications that applied to those engines described in the umentation required by 40 CFR Part 60 and which are produced during the moc(r l year stated on this ce tificate of th(said manufacturer, as defined in 40 CFR Part 60. a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 1068 and authorized ina,warrant or court order. Failure to comply with the requirements of such a rant or court order may lead to revocation or suspension of this certificate or_reasons specified in 40 CFR Part 60. It is°also a term of this certificate that this certificate may be revoked or suspended or lered void ab initio for other reasons specified in 40 CFR Part 60. "_° certificate does not cover engines sold, offered for sale, or introduced, or dii4ered for introduction, into commerce in the &.S. prior to the effective date of the certificate. actual engine power may lie outside the limits of the Emissions Power Categor)r shown above. See the certificate application for details. Legal Owner or Operator: SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865 East Copley Drive, Diamond Bar, CA 91765 DEERE POWER SYSTEMS GROUP P.O. BOX 5100 WATERLOO, IA 50704-8000 ATTN: RICHARD A. BISHOP Application No. 462955 Page 1 Granted as of November 21, 2006 Expires December 31, 2010 ID 92796 Equipment Location: SAME AS ABOVE The equipment described below and as shown on the approved plans and specifications are subject to the special conditions or conditions listed. Equipment Description INTERNAL COMBUSTION ENGINE, JOHN DEERE, 6 CYLINDER, TURBOCHARGED/AFTERCOOLED, MODEL 6068HF285K, 237 BHP, DIESEL FUELED, DRIVING AN EMERGENCY ELECTRICAL GENERATOR. Manufacturer Condition 1. THIS CERTIFIED EQUIPMENT PERMIT (CEP) IS NOT A PERMIT TO CONSTRUCT OR OPERATE. THE PERSON CONSTRUCTING, INSTALLING OR OPERATING THE EQUIPMENT AT EACH SPECIFIC SITE SHALL OBTAIN ALL NECESSARY PERMIT(S) TO CONSTRUCT AND PERMIT(S) TO OPERATE AND COMPLY WITH ANY OTHER DISTRICT RULES AND REGULATIONS INCLUDING THE REQUIREMENTS OF REGULATION XIII End User Conditions 1. OPERATION OF THIS EQUIPMENT SHALL BE CONDUCTED IN ACCORDANCE WITH ALL DATA AND SPECIFICATIONS SUBMI'TED WITH THE APPLICATION UNDER WHICH THIS PERMIT IS ISSUED UNLESS OTHERWISE NOTED BELOW. 2. THIS EQUIPMENT SHALL BE PROPERLY MAINTAINED AND KEPT IN GOOD OPERATING CONDITIONS AT ALL TIMES. 3. A NON-RESETTABLE TOTALIZING TIMER SHALL BE INSTALLED AND MAINTAINED TO INDICATE THE ENGINE ELAPSED OPERATING TIME. 4. AN ENGINE OPERATING LOG SHALL BE KEPT AND MAINTAINED ON FILE TO RECORD WHEN THIS ENGINE IS STARTED MANUALLY. THE LOG SHALL LIST THE DATE OF OPERATION, THE TIMER READING IN HOURS AT THE BEGINNING AND END OF OPERATION, AND THE REASON FOR OPERATION FOR A MINIMUM OF THREE YEARS FROM THE DATE OF ENTRY AND MADE AVAILABLE TO DISTRICT PERSONNEL UPON REQUEST. THE TOTAL HOURS OF OPERATION (INCLUDING HOURS FOR MANUAL AND AUTOMATIC OPERATION) ORIGINAL (copy) Application No. 462955 Page 2 SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT 21865 East Copley Drive, Diamond Bar, CA 91765 SHALL BE RECORDED SOMETIME DURING TIIE FIRST 15 DAYS OF JANUARY OF EACH YEAR. 5. TFIIS ENGINE SHALL NOT OPERATE MORE THAN 200 HOURS IN ANY ONE YEAR, WHICH INCLUDES NO MORE THAN 50 HOURS IN ANY ONE YEAR FOR MAINTENANCE AND TESTING PURPOSES. 6. THE OPERATOR SHALL NOT PURCHASE ANY DIESEL FUEL UNLESS THE FUEL IS LOW -SULFUR DIESEL FOR WHICH THE SULFUR CONTENT DOES NOT EXCEED 15 PPM BY WEIGHT. EFFECTIVE JANUARY 1, 2006, THE OPERATOR SHALL ONLYJAE DIESEL FUEL WITH A SULFUR CONTENT THAT DOES NOT EXCEED 15 PPM BY WEIGHT, UNLESS THE OPERATOR DEMONSTRATES IN WRITING TO THE EXECUTIVE OFFICER THAT SPECIFIC ADDITIONAL TIME 15 NECESSARY. 7. OPERATION BEYOND THE 50 HOURS PER YEAR ALLOTTED FOR ENGINE MAINTENANCE AND TESTING SHALL BE ALLOWED ONLY IN THE EVENT OF A LOSS OF GRID POWER OR UP TO 30 MINUTES PRIOR TO A ROTATING OUTAGE, PROVIDED THAT: (A) THE UTILITY DISTRIBUTION COMPANY HAS ORDERED ROTATING OUTAGES IN THE CONTROL AREA WHERE THE ENGINE IS LOCATED OR HAS INDICATED THAT IT EXPECTS TO ISSUE SUCH AN ORDER AT A CERTAIN TIME; AND (B) THE ENGINE IS LOCATED IN A UTILITY SERVICE BLOCK THAT IS SUBJECT TO THE ROTATING OUTAGE. ENGINE OPERATION SHALL BE TERMINATED IMMEDIATELY AFTER THE UTILITY DISTRIBUTION COMPANY ADVISES THAT A ROTATING OUTAGE IS NO LONGER IMMINENT OR IN EFFECT. 8. THIS ENGINE SHALL BE A US EPA CERTIFIED, NON -ROAD COMPRESSION -IGNITION ENGINE, AS EVIDENCED BY THE MANUFACTURER'S ENGINE TAG. Please notify RAMAN PATEL at 909/396-2466 when SCAQMD information packets are needed or if you have any questions concerning the Certification/Registration Program. This Certified Equipment Permit is based on the plans, specifications, and data submitted as it pertains to the release of air contaminants and control measures to reduce air contaminants. No approval or opinion concerning safety and other factors in design, construction or operation of the equipment is expressed. or implied. This Certified Equipment Permit will became invalid if this application is cancelled. THIS PERMIT SHAL L EXPIRE ONE YEAR FROM THE DATE OF ISSUANCE unless an extension is granted by the Executive Officer. N C. PATEL, P.E. Se or Air Quality Engineer ORIGINAL (copy) Subbase Fuel Tank Electrical Removable stub -up area engine supply open to bottom diptube Emergency Inner tank relief vent Normal vent Low fuel level switch Additional fitting for optional accessory e0 0 0 B 0 n o 00o @ \.o\t0/,,,,,//// V O 0 \ 4 ;o)'or._, I/ o e 0 o�j 00 B CO 0 / e , \ 0 0 e 0 Fuel leak detection switch Removable fuel • return diptube Fuel fill with \ lockable cap and Fuel level 203 mm is In.) riser gauge Emergency outer tank relief vent Ban ................ 11 --- -......-4+ O 11 II l,. 11 II j 1, I O V J 4, Note: 20-60REOZJC models shown, other models are similar. Refer to the respective ADV drawings for detalls. Bashi drain ADV•743e- Standard Subbase Fuel Tank Features • Extended operation. Usable tank capacity offers full load standby operation of up to 72 hours.. • UL listed. Secondary containment generator set base tank meeting UL 142 requirements. • NFPA compliant. Designed to comply with the installation standards of NFPA 30 and NFPA 37. • Integral external lift lugs. Enables crane with spreader -bar lifting of the complete package (empty tank, mounted generator set, and enclosure) to ensure safety. • Emergency pressure relief vents. Vents ensure adequate venting of the Inner and outer tank under extreme pressure and/or emergency conditions. • Normal vent with cap. Vent is raised above lockable fuel fill. • Low fuel level switch. Annunciates a 50% low fuel level condition at generator set control. • Leak detection switch: Annunciates a contained primary tank fuel leak condition at generator set control. • Electrical stub -up. • State tank designed to comply with the installation standards of the Florida Dept. of Environmental Protection:(FDEP) File No. EQ-634. Tank to include factory installed return pump, supply pump, and level switches to be used as day tank fed from remote main tank. Tank Capacity -100gal. Tank Footprint - 112" X 44" G8-99 9/12t Page 3 8 I 7 I 6 I 5 1 4 , I 3 I 2 I I OPTIONAL BATTERY HEATER/CHARGER CONDUIT LOCATION • CONDUIT ENTRY AREA OR GENERATOR LOAD LEADS (BOTTOM ENTRY), CIRCUIT BREAKER OPTION. REMOTE CONNECTION NSFER SWITCH AND REMOTE ANNUNCIATOR I. • • 111e • • NIP 0 taw T 50.0 11ggIp .61 [13.781 4 2025 [19.71 0p605 [23.81 4 24VZ5gBjjIAT[[TERYggLOCATION Ii5.71 I2V BATTERY LOCATION /! // SUGGESTED LOCATION FOR FUEL AND RETURN FLEXIBLE FUEL LINE: 3/8 N.P.T. (MALE) FLEXIBLE FUEL LINE MUST REACH THE FLOOR AT REAR FACE OF BLOCK AND SUBBASE TANK FITTINGS. • 0 0 0. 550.0 [21.65) ENCLOSED GENSETS ONLY •PT IONAL BLOCK HEATER CONDUIT LOCATION 01 725 [28.51 75 13.01 TYP 2000 (78.71 CONTROLLER LOCATION •o 0• -.0 12 00 (47.2] •9 6 les en 1524 160.01 017.5 (.681 8 2185 186.01 1337 460 (18.11 885 (34.81 OIL DRAIN 987 138.81 FUEL INLET 1318 [5I 61'1 512z ' 3X) 1374 (54.11 (4S13X) CENTER OF BALANCE 2035 [80.1) 7 2340 (92.1] 2950 (116 1] 6 5 155 (6.11 W YODEL, 4R[11f, 47DX 4St2X. RECONIECTAL WROVED MOTOR STORM NAM TTABE JOHN DEEiEE BMW T 4 Base Rail to be Factory trimmed to 112"L 0 1045 141.11 1120 (44.11 OVSRATIATION NOTE IF SUBASE FUEL TANK AND/OR SOUND HOUSING IS USED. REFER TO SUBBASE FUEL TANK DRAWING TO DETERMINE MOUNTING LOCATIONS 150 4R13X. 4T13X 150 4SI2X 150 4S13X OENSET WEIGHT 89m 1342 KO (2959 LBS1 1295 KG (2855 LBS1 1402 KG 13090 LBS1 NOTES DIMENSIONS IN [ 1 ARE INCH EOUIVALENT: IF AN ENCLOUSURE IS USED THE FUEL LINE MUST BE STUBBED UP FROM DIRECTLY UNDER THE UNIT OR BROUGHT IN FROM THE END OF THE SKID. REFER TO ENCLOSURI ADV. ® 4 HOLES FOR STANDARD MOUNTING 017.5 10 HOLES FOR IBC MOUNTING 017.5 1.8 F IBC CERTIFICATION IS REOIURED SEE SEISMIC ADV FOR NSTALLATION INSTRUCTII REV DATE 00 t0tro9rt0 000. St7 rt17 .0. 700 nnuol t[ttt By 5.20.11 MEW DRAWING 191370.41 111P n."[mji 1t tt6l Y•O.1IO ILVIIILERCO IETRIC IPt9 pt�OY{*. WI p[t74. ) 111t t0410000 4Yil i7 "ODi07t IM�i ot1°I•iG: 0i1 1,121 n711[M�i'nn.ut t- 02200Iµ1 9Art IMP "PP. PLO 5 20 11 5.20.11 1301E18510h1 PRNT, TDO 6 2 GDT S.20.11 .o o. atoho la ADW8183 KOHLER POWER SYSTEMS Warranty C. Stationary Standby and Prime Power One -Year or Two Thousand (2000)-Hour Limited Warranty Your Kohler product has been manufactured and Inspected with care by experienced craftsmen. If you are the original consumer, Kohler Co. warrants, for the period indicated below, each product to be free from defects in materials and workmanship. Repair, replacement, or appropriate adjustment at Kohler Co.'s option will be furnished if the product, upon Kohler Co.'s Inspection, is found to be properly installed, maintained, and operated In accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, repair or service by unauthorized persons, or normal wear and tear. Kohler Product Warranty Coverage* Generator Set & Accessories Prime Power Generator Set 20 kW or Larger One (1) year or 2000 hours (whichever occurs first) from date of Initial startupt One (1) year or 2000 hours (whichever occurs first) from date of Initial etartupt 'Soma restrictions may apply. Contact your Kohler distributor/dealer for full details. tStartup must occur within 24 months of original shipment by Kohler Co. The following will not be covered by the warranty: 1. Normal engine wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage caused by accidents, Improper installation or handling, faulty repairs not performed by an authorized service representative, or Improper storage. 3. Damage caused by operation with improper fuel or at speeds, Toads, conditions, modifications, or installation contrary to published specifications or recommendations. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficient quantity of lubricating oil b. Failure to keep the air Intake and cooling fin areas clean. c. Failure to service the air cleaner. d. Failure to provide sufficient coolant and/or cooling air. e. Failure to perform scheduled maintenance as prescribed In supplied manuals. f. Failure'to regularly exercise the generator set under load (stationary applications only). 5. Original installation charges and startup costs. 6. Starting batteries and the following related expenses: a. Labor charges related to battery service. b. Travel expense related to battery service. 7. Engine coolant heaters, heater controls, and circulating pumps after the first year. 8. Rental of equipment during performance of warranty repairs. 9. Parts purchased from sources other than Kohler Co. Replacement of afailed Kohler part with a non -Kohler part voids warranty on that part. 10. Radiators replaced rather than repaired. 11. Fuel Injection pumps not repaired locally by an authorized servicing dealer. 12. Non -Kohler -authorized repair shop labor without prior approval from Kohler Co. Warranty Department. 13. Engine fluids such as fuel, oil, or coolant/antifreeze. 14. Shop supplies such es adhesives, cleaning solvents, and rags. 15. Expenses incurred investigating performance complaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, lamps, filters, spark plugs, loose or leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. ship date as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND including, but not limited to, incidental consequential labor costs, installation charges, telephone charges, or transportation charges in connection with the replacement or repair of defective parts. This Is our exclusive mitten warranty. We make no other express warranty nor Is anyone authorized to make any on our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental orr consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state. KOHLER. `POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920-585-3381, Fax 920-459.1848 For the nearest sales/service pullet In the US and Canada, phone 1-600-544-2444 KohlerPowerSystems.com TP-5374 12/9eo,"" Extended Five -Year or Three Thousand (3000)-Hour Comprehensive Stationary Standby Limited Warranty This Kohler Standby Generator System has been manufactured and Inspected with care by experienced craftsmen. If you are the original purchaser, Kohler Co. warrants for five years or three thousand (3000) hours, whichever occurs flint, that the system will be free from defects In material and workmanship if properly installed, maintained, and operated in accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty Is not effective unless a proper extended warranty registration form and warranty fee have been sent to Kohler Co. within one year of supervised startup. During the warranty period, repair or replacement at Kohler Co.'s option will befurnished free of charge for parts, provided an inspection to Kohler Co.'s satisfaction discloses a defect in material and workmanship, and provided that the part or parts are retumed to Kohler Co. or an authorized service station, if requested. This extended warranty expires five full years after date of startup or after 3000 hours of operation, whichever occurs first. This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while In your possession. The following will not be covered by this warranty: 1. Normal engine wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage caused by accidents, improper installation or handling, faulty repairs not performed by an authorized service representative, or improper storage. 3. Damage caused by operation with improper fuel or at speeds, loads, conditions, modifications, or installation contrary to published specifications or recommendations. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficient lubricating oil. - b. Failure to keep the air intake and cooling fin areas clean. c. Failure to service the air cleaner. d. Failure toprovide sufficient coolant and/or cooling air. e. Failure to perform scheduled maintenance as prescribed in supplied manuals. f. • Failure to exercise with load regularly. 5. Original installation charges and startup costs. 6. Starting batteries and the following related expenses: a. Labor charges related to battery service. b. Travel expense related to battery service. 7. Engine coolant heaters, heater controls, and circulating pumps after the first year. 8. Rental of equipment during performance of warranty repairs. 9. Non -Kohler -authorized repair shop labor without prior approval from the Kohler Co. Warranty Department. 10. Parts purchased from sources other than Kohler. Replacement of afailed Kohler partwhh a non -Kohler part voids warranty on that part. 11. Radiators replaced rather than repaired. 12. Fuel injection pumps not repaired locally by an authorized servicing dealer. 13. Engine fluids such as fuel, oil, or coolant/entifreeze. 14. Shop supplies such as adhesives, cleaning solvents, and rags. 15. Expenses incurred investigating performance complaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, filters, spark plugs, loose/leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co. within 80 days after the date of Initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. ship date as the startup date. To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative, or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND Including, but not limited to, Incidental consequential labor costs, Installation charges, telephone charges, or transportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty, nor is anyone authorized to make any in our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURCHASE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you. may also have other rights which vary from state to state. KOHLER, POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1645 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSyste ms.com TP-5581 12/88c J KOHLER POWER SYSTEMS Certification Certificate US95/0189 The managemed system of Kohler Power Systems Americas N7650 County Road LS Sheboygan, WI 53083 United States tee been messed and cem99adas m seEng to wqubementaol ISO 9001:2008 Footle taming sahibs Design, manufacture, and distributor support for electrical generators, alternators, automatic transfer switches, and switchgear. Further chastens regarding the seeps eledeoamGtateandteawlealtyel ISO 9001200e tYgidrem sets may be dibbled by consaig the oegembatm This certificate is valid from 17 November 2009 until 16 November 2012 and remains valid subject to satisfactory surveillance audits. Recerblication audit due a minimum of 30 days before the expiration date. Issue 8. Certified since February 1995 This lea multi -site certification. Additional site details are listed on subsequent pages. Autmorind by pedive,e,,„„ 7echay Mame Axaegelom M nn% North Arnett SOS US Tesemg Coma, ht.. Systems arel Secrets Caftan 201 Route 17 North, Pomertord, New Jersey, 07070 USA 1 +1201508 3000 1 +1201925 4555 wee us.sas.com The renth e the properly of SOS and Shell be returned upon :armlet Pagelof2 Maur Mao WINIase„t.104. haWNa6 aaaM.aa,WNadwM, °'?©08 SGS Certificate US8510188, continued Kohler Power Systems Americas ISO 9001:2008 Issue 8 Detailed save Further Pariffeadona rooming the scope od fhb cedificate and the applicability a ISO 90012008te may beobtained by ccattingthe organisalca Additional &Mao 300 N. Dokora Woods Blvd, SaukvIlle, WI 53080, United Stabs ACCREDITED Kohler Standby/Prime Generator Set Test Program Testing is an integral part of quality assurance. In keeping with our uncompromising commltmentto quallty, safety, and reliability, every Kohler Standby/Prime power generator set undergoes an extensive series of prototype and production testing. Prototype Testing Prototype testing Includes the potentially destructive tests necessary to verify design, proper function of protective devices and safety features, and reliability expectations. Kohler's prototype testing includes the following: • Alternator temperature rise test per NEMA MG1-32.6. Standby and prime ratings of the alternator are established during this test. • Maximum power test to assure that the prime mover and alternator have sufficient capacity to operate within specifications. • Alternator overload test per NEMA MG1-32.8. • Steady-state load test to ensure voltage regulation meets or exceeds ANSI 084.1, NEMA MG1-32.17 requirements and to verify compliance with steady- state speed control specifications. • Transient test to verify speed controls meets or exceeds specifications. • Transient load tests per NEMA MG1-32.18, and ISO 8528 to verify specifications of transient voltage regulation, voltage dip, voltage overshoot, recovery voltage, and recovery time. • Motor starting tests per NEMA MG1-32.18.5 to evaluate capabilities of generator„ exciter, and regulator system. • Three-phase symmetrical short-circuit test per NEMA MG1-32.13 to demonstrate short circuit performance, mechanical integrity, ability to sustain short-circuit current. • Harmonic analysis, voltage waveform deviation per NEMA MG1-32.10 to confirm that the generator set Is producing clean voltage within acceptable limits. • Generator set cooling and air flow tests to verify maximum operating ambient temperature. • Reliability tests to demonstrate product durability, followed by root cause analysis of discovered failures and defects. Corrective action is taken to improve the design, workmanship, or components. • Acoustical noise intensity and sound attenuation effects tests. Production Testing In production, Kohler Standby/Prime generator sets are built to the stringent standards established by the prototype program. Every Kohler Generator set is fully tested prior to leaving the factory. Production testing includes the following: • Stator and exciter winding high -potential test on all generators. Surge transient tests on stators for generators 180 kW or larger. Continuity and balance tests on all rotors. • One-step, full -load pickup tests to verify that the performance of each generator set, regulator, and governor meets published specifications. • Regulation and stability of voltage and frequency are tested and verified at no load, 1/4load, 1 /2 load, 3/4 load, and full -rated load. • Voltage, amperage, frequency and power output ratings verified by full -load test.. • The proper operation of controller logic circuitry, prealarm warnings, and shutdown functions is tested and verified. • Any ,defect or variation from specification discovered during testing is corrected and retested prior to approval for shipment to the customer. Torsional analysis data, to verify torsional effects are not detrimental and that the generator set will provide dependable service as specified, is available upon request. Kohler offers other testing at the customer's request at an additional charge. These optional tests include power factor testing, customized load testing for specific application, witness testing, and a broad range of MIL-STD-705c testing, A certified test report is also available at an additional charge. KOHLER. POWER SYSTEMS KOHLER CO. Kohler, Wlsconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystemscom e18.50 12/05a r,%