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Home My WebLink AboutMANUALSJ, Industrial Generator Set Accessories KOHLER POWER SYSTEMS Battery Charger SeANNED t00% St. Lucie Count%, � �°wt�k srFNs NATIONALLY REGISTERED Specifications Standard Features • 12 VDC output.' Use two battery chargers for 24-volt electrical systems • Automatic 3-stage float/equalize battery charger • Charges both lead -acid and gel -cell type batteries • Indicator lamps: red and green LEDs indicate bulk charge, absorption, and float charge stages • Durable potted assembly for full waterproofing and shockproofing • Reverse -polarity protection • Short-circuit protection • UL 1236 listed • UL 2200 compliant • UL 991 compliant for vibration and shock • UL listed to Canadian safety standards • UL rated inline fuse • FCC Class B-compliant for EMI/RFI (Date code 8/26/04 or later) • 1-year warranty • Easy installation: • Integral mounting flanges • Ring terminals for battery connection • Standard US style 3-prong AC plug Battery Charger Kit M78298-KA1 Input Voltage 0-135 VAC Input Frequency 0/60 Hz DC Output: Bulk 11.8-14.0 VDC @ 5.0-6.0 amps DC Output: Absorption 14.0-14.5 VDC @ 1.5-5.0 amps DC Output: Float 13.3-14.5 VDC @ 0.1-1.5 amps Stead Full -Load Output Current 6 amps Current Limit 7 amps Output Power Limit 70 +2/5 watts DC Voltage Regulation - - -- .01— - - — - - ---- - - Isolation, Input to Output 2500 V Dimensions L x W-x D 1687 z 53 mm G43 5x2- err Weight 1.6 W 3.516. [Temperature Range, Operating and Storage 0°C to 70°C -40°F to 158°F Humidi to 100%(condensing) ST. LUCIE COUNTY BUILI)MG DIMON REVIENVED FOR L REVI MED B ' ), DATE �1J— �- PLANS AND PEI IIT ASUST BE KEPT ON J01i OR NO INSPECTION NVILL BE MIADE; CONTRAICTOR's �Opyl .qerm; �- • , Float/Equalize Battery Charger, continued 164.0 143.5 10.3 52.2 �{ E I I 4XO6.00 I - tZ �i I Output lead length 1.2m (4 It) AGInputlead length 1.8m(6tt) Fuse \ I I I I 'I � 1I ''II IIII Dimensions aro In mm. H l u Battery Connections Lead Length 1.2 m (4 ft.) Battery Connections 9.5 mm (3/8 in.) ring terminals AC Power Connections Lead Length 1.8 m (6 ft.) Connection Standard US style 3-prong AC plug Shipping Information Carton Size 254 x 152 x 89 mm (10 x 6 x 3.5 in.) Shipping Weight 1.8 kg (4 Ib.) Charging Curves a &fl� o D e c Ms'MFloat n 6 55 5 45 ♦ 6! 3 21 4 13 f e6 0-1 Industrial Generator Set Accessories MOHLER POWER SYSTEMS Voltage Regulators 09001 1 c�°Dr�vt�6. NATIONALLY REGISTERED Integral Voltage Regulator with Kohler@ Decision - Maker@ 3000 and Menu -Driven Selections (15-1000 kW Generator Set Models) I IQ il BLU mil �11 Dedslon-Makers 3000 Controller with Integral Voltage Regulator The voltage regulator is integral to the controller and uses patented hybrid voltae regulator design providing t0.5% 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 Regulators with Decision -Maker® 3000 Controllers Calibration Digital Display Range Settings Default Selection Voltage Adjustment Volt Adjust t10% of System Voltage System Voltage Und_erfrequency Unload or Frequency Se(point - - Frequency Setpoint - - - 42 to 62 Hz 2.5 Hz Below Nominal Fre uenc - ------ - Underfrsouencv-Unload Slope Slope 0 to 10% of System Voltage 5% of System Voltage - oisper C ce — continued Specification/Feature Integral with Decision - Maker® 3000 Generator Set Availability 15-1000 kW Type Patented Hybrid Design Status and Shutdown Indicators LEDs and Text LCD 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 Software and Fuses Sensing, Nominal 100-240 Volts (L-L), 50-60 Hz Sensing Mode RMS, Single- or 3-Phase Input Requirements 8-36 VDC Continuous Output 5 VDC @ 100mA max. 5.0 ADC with GM88453 Activator Board Maximum Output 5 VDC @ 100mA max. 7.8 ADC with GM88453 Activator Board Transition Frequency 42.0-62.OHz Exciter Field Resistance 4-30 Ohms with GM88453 Activator Board No -Load to Full -Load Voltage Regulation ±0.5% Thermal Drift <0.5% (-40°C to 70°C) 40°F to 1580Range Response Time Less than 5pS System Voltage Adjust. ±10% Voltage Adjustment Controller Menu Knob Remote Voltage Adjustmen not available Parallelin Ca abili not available VAR/PF Control Input not available Maker® 3000 Controller The Decision-Maker03000 digital display and pushbutton/rotary dial provide access to data. Atwo-line LCD display provides complete and concise information. The Decision -Maker® 3000 graphical display and pushbutton/rotary dial provide access to data. A five -line, 35characters per line LCD display provides complete and concise information include gain, ramp rate, reactive droop, VAR control (P, 1, D gains) and PF control (P, I, D gains). The controllers provide ISO 8528-5, Class G3, compliance for transient response on some 20-300 kW generator set models. Both cotrollers support Modbus®. These controllers can control Fast ResponseTM 11, Fast ResponseTM X, and wound field alternators using the GM88453 activator board. Voltage Regulator Menu • Voltage adjustment, ±10% of system voltage • V/Hz cut -in, 42-62 Hz • Underfrequency unload slope, 0-10% of system voltage 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 Regulators, continued Activator Board GM88453 i i!li -� •• I•:.■.� � • IS I • u IL .M uu.n • • Interfaces between the controller and alternator assembly using rotor field leads, auxiliary power windings, and optic board leads. • Allows the Decision -Maker® controllers the ability to control a wound -field alternator using the same control signal as Fast ResponseT alternator. • Permits the generator set controller to control the current to the exciter field of a wound -field excited alternator. • Contains two isolated relay driver outputs (RDO) rated at 250 mA. Provides RDO outputs indicating a field over - excitation condition and that the alternator is supplying voltage to the activator. Modbus® is a registered trademark of Schneider Electric. KOHLER POWER SYSTEMS 0I^MI9001 1S15. NATIONALLY REGISTERED Model KCP-ACTC-0400S Transfer Switch Standard Features • UL 1008 listed at 480 VAC file #E58962 (automatic), #E86894 (nonautomatic) • CSA certification available at 600 VAC • IBC seismic certification available • Available in 2, 3, or 4 pole configurations • Electrically operated, mechanically held mechanism • High withstand and close -on ratings • Design suitable for emergency and standby applications on all classes of load, 100%tungsten rated through 400 amps • Silver alloy main contacts • Gold -flashed engine start contacts fated 2 amps @ 30 VDC/250 VAC • Front -accessible contacts for easy inspection • Front -replaceable main and arcing contacts (800-4000 amps) • Reliable, field -proven solenoid mechanism • Switching mechanism lubricated for the expected life of the transfer switch • Internal manual operating handle • Main shaft auxiliary position -indicating contacts rated 10 amps @ 32 VDC/ 250 VAC • NEMA type 1, 12, 3R, 4, and 4X enclosures available • Standard one-year limited warranty. Extended limited warranties are available. Programmed -Transition Models (KCP) • Programmed -transition operation with either automatic or non- automatic control • Programmed -transition operation provides a centerOFF position that allows residual voltages in the load circuits to decay • Programmable OFF time • Double -throw, mechanically interlocked design (break -before - make power contacts) • Solid or switched neutral KCP-ACTC-0400S, continued Decision -Maker® MPAC 1200 Controller LCD display, 4 lines x 20 characters, backlit Complete programming and viewing capability at the door using the keypad and LCD display LED indicators: Source available, transfer switch position, service required (fault), and "not in auto" Programmable voltage and frequency pickup and dropout settings Programmable time delays Programmable generator exerciser Time -based load control Two programmable inputs and two programmable outputs Up to four 1/0 extension modules available Modbus communication standard RS-485 communication standard Ethernet communication optional For more information about Decision -Maker® MPAC 1200 features and functions, see specification sheet G11-127. Environmental S eccations O eratin Temperature -20°C to 70iC -4-F to 158°F Storage Temperature -40°C to 85°C -40°F to 185°F Humidity noncondensincl In ut and Output Connection Specifications com onent Wire Size Ran e Main board 1/0 terminals 1 #12-24 AWG 1/0 module terminals #14-24 AWG Extended Transfer Time elay Specifications Model KCC Adjustment range 0.1 to 10 seconds Connections 12-22 AWG Power 24 VDC Output type Relay contacts, DPDT (2 form C) Rating 10 amps max. resistive at 240 VAC Source Synchronization Settin s Model KCC Parameter Default Adjustment Range Voltage differential 5% 0-5% Frequency differential 0.1 Hz 0-0.3 Hz Phase angle 10 de . 0.10 de . Auxiliary Position Indicating Contacts (rated 10 Amps @ 32 VDC/250 VAC) Switch Rating (Amps) Number of Contacts indicating Normal, Emergency 400 1 8, 8 UL-Listed Solderless Screw -Type Terminals for External Power Connections Range of Wire Sizes Copper or Aluminum' Switch Rating, Amps Normal, Emergency, and Loadl Neutral Ground 400 (1) #4 AWG to 600 KCMIL or (2) 1/0 - to 250 KCMIL (3) #4 AWG to 600 KCMIL or (6) 1/0 - to 250 KCMIL (3) #4 AWG to 600 KCMIL or (6) 1/0-to250KCMIL Use 75 degree C minimum Cu/AI wire for power connections. Note: Data is subject to change. Refer to the transfer switch dimension drawings and wiring diagrams for planning -and installation KCP-ACTC-0400S, continued Withstand and Close -On Ratings (WCR) Programmed Transition Model Maximum current in RMS symmetrical amperes when coordinated with customer -supplied fuses or circuit breakers. All values are available symmetrical RMS amperes and tested in accordance with the withstand and close -on requirements of UL 1008. Application requirements may permit higher withstand ratings for certain size switches. Contact the factory for assistance. Withstand and Closing Current Ratings in RMS Short Time Ratings (sec.)" S mmetrical Amperes Current Limiting Fuses Time -Based Ratio ' 480 V Max. 600 V Max. Switch Amps Amps Amps Fuse Amps Amps Amps 0.1 0.13 0.3 0.5 0.1 0.13 0.3 0.5 Rating, @ 480 @ 600 , Max. Class @ 240 @ 480 @ 600 Amps V V V V V 400 200000 200000 600 J 65000 42,000 35000 - - - - - - - - 400 200000 200000 800 L 65000 42,000 ... 35000 - - - - - - - - Based on a 0.025 seconds (appro)imately 1.5 cycles) for 30-230 amps and 0.050 seconds for 26OA000 amps. Applicable to breakers with instantaneous 'p elements. Short time ratings are provided for applications involving breakers that utilize trip delay settings for system selective coordination. Applicable to 2-pole, 3-pole. and conventional 4-pole switches only. Overlapping neutral switches have any breaker ratings of 35,000 A at 480 V. Weights and Dimensions See ADV drawings for weights and dimensions. Allow 15% additional weight for packing materials. KCP-ACTC-0400S, continued Ratings with Specific Manufacturer's Circuit Breaker The following charts list power switching device withstand and close -on ratings (WCR) in RMS symmetrical amperes for specific manufacturers' circuit breakers. Circuit breakers are supplied by the customer. Molded -Case Circuit Breakers Switch Rating, Amps WCR, Amps, RMS Voltage, Max. Manufacturer Type Max. Size, Amps 400 65000 240 GE THLC4 400 400 42000 480 Eaton HMC 800 400 42000 480 GE THKM3F 500 400 50000 480 Eaton HKD, CHKD, KDC 400 400 50000 480 Eaton HLD, CHLD, LDC, CLDC 600 400 50000 480 Eaton MDL, CMDL, HMDL, CHMDL, NGS, NGH, NGC 800 400 50000 480 GE TBC4 400 400 50000 480 GE SGL1, SGL4, SGL6, SGP1, SGP4, SGP6, TBC6, TJL4V, TJL1 S-6S 600 400 50000 480 GE SKH8, SKL8, SKP8, TBC8, TKL4V, TKH8S-12S 800 400 50000 480 Siemens/ITE HJD, HJXD, SHJD 400 400 60000 480 Siemens/ITE HLD 600 400 50000 480 Siemens/ITE HLMD, HLMXD, HMG, HMD, HMXD, LMD, LMXD, MXD, SMD, SHMD 800 400 50000 480 SquareD CK400N, CK40ONN 400 400 50000 480 SquareD LC 600 400 50000 480 SquareD CK800N, CKSOONN 800 400 42000 600 Eaton KDC 400 400 42000 600 Eaton LDC, CLDC 600 400 42000 600 GE TBC4 400 400 42000 600 GE TBC6, SGL1, SGL4, SGL6, SGP1, SGP4, SGP6 600 400 42000 600 GE TBC8, TKL4V, TKL8S-12S, SKL8, SKP8 800 400 42000 600 Siemens/ITE HLMD, HLMXD, HMSC, SHMD 800 400 50000 1 480 Eaton HKD, CHKD, KDC 400 400 50000 480 Eaton HLD, CHLD, LDC, CLDC 600 400 50000 480 Eaton MDL, CMDL, HMDL, CHMDL, NGS, NGH, NGC 800 400-- -50000 - -480- - - - - GE - - - ----TBC4_-_- _ 400 400 50000 480 GE SGL1, SGL4, SGL6, SGP1, SGP4, SGP6, TBC6, 600 - 400 50000 480 GE S_ KHS, SKLS, SKP8,-TBC8, TKL4V,-TKH8S=12S- -800� 400 50000 1 480 Siemens/ITE HJD, HJXD, SHJD 400 400 50000 480 Siemens/ITE HLD 600 400 50000 480 Siemens/ITE HLMD, HLMXD, HMG, HMD, HMXD, LMD, LMXD, MXD, SMD, SHMD 800 400 50000 480 SquareD CK400N,CK40ONN 400 400 50000 480 SquareD LC 600 400 50000 480 SquareD CK800N, CK80ONN 800 400 42000 1 600 Eaton KDC 400 400 42000 600 Eaton LDC, CLDC 600 400 42000 600 1 GE TBC4 400 'KCP-ACTC-0400S, continued 400 42000 600 GE TBC6, SGL1, SGL4, SGL6, SGP1, SGP4, SGP61 600 400 42000 600 1 GE TBC8, TKL4V, TKL8S-12S, SKL8, SKP8 800 400 42000 1 600 1 Siemens/ITE HLMD, HLMXD, HMSC, SHMD 800 'FRCP-ACTC-0400S, continued Codes and Standards The ATS meets or exceeds the requirements of the following specifications. • CSA C22.2 No. 178 certification 208-600 VAC available, file LR58301 • EN610004-4 Fast Transient Immunity Severity Level 4 • EN61000-4-5 Surge Immunity Class 4 (voltage sensing and programmable inputs only) • EIC Spedfications for EMI/EMC Immunity: o CISPR 11, Radiated Emissions o IEC 1000-4-2, Electrostatic Discharge o IEC 1000-4-3, Radiated Electromagnetic Fields o IEC 100044, Electrical Fast Transients (Bursts) o IEC 10004-5, Surge Voltage o IEC 10004-6, Conducted RF Disturbances o IEC 1000-", Magnetic Fields o IEC 10004-11, Voltage Dips and Interruptions • IEC 609047-6-1, Low Voltage Switchgear and Control Gear, Multifunction Equipment; Automatic Transfer Switching Equipment • IEEE Standard 446, IEEE Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications • IEEE 472 (ANSI C37.90A) Ring Wave Test • NEMA Standards ICS 10-2005, Electromechanical AC Transfer Switch Equipment • NFPA 70, National Electrical Code • NFPA 99, Essential Electrical Systems for Health Care Facilities • NFPA 110, Emergency and Standby Power Systems • Seismic certification in accordance with the International Building Code is available. (Accessory kit is required for seismic certification) o IBC 2000, referencing ASCE 7-98 and ICC AC-156 o IBC 2003. referencing ASCE 7-02 and ICC AC-156 o IBC 2006, referencing ASCE 7-05 and ICC AC-156 o IBC 2009, referencing ASCE 7-05 and ICC AC-156 o IBC 2012, referencing ASCE 7-10 and ICC AC-156 • Underwriters Laboratories UL 1008, Standard for Automatic Transfer Switches for Use in Emergency Standby Systems for #E58962 (automatic), #E86894 (nonautomatic) XCP-ACTC-0400S, continued Accessories Accessories are available either factory -installed or as loose kits, unless otherwise noted. Warranty Padlockable User Interface Cover • With or without window • Warranty-5-year comprehensive • Cover without window standard on NEMA 3R enclosures Accessory Modules The mounting kit holds up to five optional modules. The maximum total current draw is 300 mA. If an External Battery Module is installed, there is no current restriction. Module Current Draw S ecification, mA Alarm Module 75 Standard 1/0 Module 175 High Power 1/0 Module 1100 Standard Input/Output Module Inputs Available Inputs 2 Input Definition Contact closure Current 5 mA Max Connection Type Terminal Strip Wire Size #14-24 AWG Max Distance 700 feet Outputs Outputs Available 6 Contact Type Form C SPDT Contact Voltage Rating 2 A @ 30 VDC 500 mA @ 125 VAC Connection Type Terminal Stdp Wire Size #14-24 AWG T 15OREZGC KOHLER POWER SYSTEMS 09001 � n� s4srenns NATIONALLY REGISTERED Generator Set Ratinas SCANNED BY St. Loci Cnlln Standbyl= Ratings Alternator voltage Ph Hz kW/kVA Amps 4S13X 120/208 3 60 1391174 482 RATINGS: All Oaea-phase wilsmmW at 0.8 Po facw- AU 6nalaphmu are glada LP 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,anti.production-tested.. __ _ • The 60 Hz generator set offers a UL 2200 listing. • At 60 Hz, 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- and five-year extended warranties are also available. • EPA -certified for Stationary Emergency Applications • Alternator Features: o The unique Fast -Response X excitation system delivers excellent voltage response and short circuit capability using a rare-earth permanent magnet (PM) -excited alternator. o The brushless, rotating -field alternator has broad range reconnectability. • Other Features: o Kohler designed controllers for guaranteed system integration and remote communication. See controller features inside. o The electronic, isochronous governor incorporates an integrated drive -by -wire throttle body actuator delivering precise frequency regulation. : The studby mUM Is eppk, to Im IswmtWd.'At0%,mdoad Model: 15OREZGC, continued Altemator Specifications SpeciUcaUons Alternator Alternator manufacturer Kohler 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 4-Pole, Rotating -Field Brushless, Rare -Earth Permanent -Magnet 4RX: 12, Reconnectable 4TX: 4, 110-120/220-240 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 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. Engine Engine Speol ications Engine Manufacturer PSI Engine Model 8.81- Engine: type Industrial 8.8L, 4-Cycle, Turbocharged and Charge Cooled Cylinder arrangement V-S Displacement, L (cu. in.) 8.8(537) Bore and stroke, mm (in.) Compression ratio Piston speed, m/min. (ft./min.) Main bearings: quantity, type Rated rpm 110 x 114 (4.35 x 4.5) 10.1:1 411(1350) 5, Bi-Metal Steel and Aluminum 1800 Max. power at rated rpm,.kWm (BHP) __ — 169 (227) — --- -- -- - -- Cylinder head material Cast Iron 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 Forged Steel, Induction Hardened, Tangential Fillet Int: A193 Ehc. Incohel Electronic Isochronous t0.5% Fixed Dry Model: 15OREZGC, continued Exhaust Exhaust System Exhaust Manifold Type Dry Exhaust flow at rated kW, m3/min. (cfm) 27.5 (971) Exhaust temperature at rated kW, dry exhaust, °C 649 (1200) (OF) Maximum allowable back pressure, kPa (in. Hg) 10.2 (3.0) Exh. outlet size at eng. hookup, mm (in.) Flanged Outlet at Catalyst, see ADV drawing Engine Electrical - Engine Electrical System Ignition system Individual Coil Near Plug Ignition Battery charging alternator. Ground (negative/positive) Negative Volts (DC) 12 Ampere rating 70 Starter motor rated voltage (DC) 12 Battery, recommended cold cranking amps (CCA): Qty., CCA rating each One, 630 Battery voltage (DC) 12 Fuel Fuel System Fuel type LP Fuel supply line inlet 1.5 NPTF LPG vapor withdrawal fuel supply pressure, kPa (in. 1.24 - 2.74 (5 -11) H2O) Fuel Composition Fuel Composition LP: Methane, % by volume 1.2 max. LP: Ethane, % by volume 10 max. LP: Propane, % by volume 96 max. LP: Propene, % by volume 3 max. LP: C4 and higher, % by volume 3 max. - ---LP:.Sulfur,-ppm mass - -- — --25 max. - - - -- — -- -- - -- - LP: Lower heating value, MJ/m3 (Btu/ft3), min. 78.8 211 _ ' Faelsti+i-ltfi�ot�compos ons "_beacceptable-. If yourluel is.outside_the listed,specifications,.contact=your-local distributor- - `forfur W analysis and advice. Lubrication Lubrication System Type Full Pressure Oil pan capacity, L (qQ 8.0 (8.5) Oil pan capacity with filter, L (qt.) 8.5 (9.0) Oil filter: quantity, type 1, Cartridge Model: 150REZGC, continued Cooling Arnment temperature, -t; t-r/ 50 (122) Engine jacket water capacity, L (gal.) 13.4 (3.54) Radiator system capacity, including engine, L (gal.) 25.5 (5.61) Engine jacket water flow, Lpm (gpm) 125 (33) Heat rejected to cooling water at rated kW, dry 88,2 (5021) exhaust, kW (Btu/min.) Heat rejected to engine oil at rated kW,kW (Btu/ 1.4(81) min.) Water pump type Centrifugal Fan diameter, including blades, mm (in.) 711 (28.0) Fan, kWm (HP) 18.7 (25) Max. restriction of cooling air, intake and discharge 0.125 (0.5) side of radiator, kPA (in. H20) Enclosure with enclosed silencer reduces ambient temperature capability by 50C (90F). Operation Requirements Radiator -cooled Combustion air, m3/min. (cfm) Heat rejected to ambient air. Engine, kW (Btulmin.) Heat rejected to ambient air. Altemator, kW (Btu/ min.) 'Air density = 1.20 kg/m3 (0.0751bm/fP) Fuel Consumption Standby Fuel Consumption at 100% loa Standby Fuel Consumption at 75% load Standby Fuel Consumption at 50% load Standby Fuel Consumption at 250% load Standby Fuel Consumption at 0% load 340 (12000) 8.9(314) 24.9 (1476) 15.7 (893) 20.2 m3/hr. (713 cfh) 15.5 m3/hr. (547 cfh) 11.3 m3/hr. (399 cfh) 7.2 m3/hr. (254 cfh) 4.6 m3/hr. (164 cfh) Dimensions and Weights Overall Size, L_x W x H, m_m (in.): _ _ 2800 x 1120 x1538 (110.2 x 44.1-x 60:6)- -- --- -- — -- Weight (radiator model), wet, kg (lb.): 1440 (3175) n o 0 L- - --�I NOTE: This drawing is provided for reference only and should not be used for planning installation. Contact your local distributor for more detailed information. Industrial Generator Set Accessories KOHLER. Power Svstems Generator Set Controller Decision -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 a patented hybrid voltage regulator and unique software logic to manage alternator thermal overload protection features 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 S teTech- 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 WA). • Integrated hybrid voltage regulator providing x0.5% regulation. • Built-in altemator thermal overload protection. Modbae Lvarag19emdtmdemakarSdmelde r]eWa G6lw an" Pagel Emergency Sto{ Digital Display Alarm Horn (loci inside the contrc Master Control Off-Reset/Aute/ with Lights 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 • Annunciator fault light o System shutdown (red) o System warning (yellow) • Alarm silence/lamp test button o Alarm silence o Lamptest • USB and RS-485 connections o Allows software uppgrades o Provides access for diagnostics - o PC communication using SfteTech- or Monitor III software • Dedicated user inputs o Remote emergency stop switch o Remote 2-wire star 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 monftors the engine/generator functions/faults shown below. • Engine functions:-— o Overcrank o Low coolanttemperatum wamina Pushbutton/Rotary Selector Dial Annunciator Fault Light Red -Shutdown, Yellow -Warning Alarm Silence/Lamp Test Button with Light USB Communication Connection User Interface Displays The risting below has • denoting main menus and o denoting sub -menus. • Overview o Software version o Active shutdowns and warnings (ff any are present) o Engine run time, total hours o Average voltage line-to-ene 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, 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 • GenSst System o System voltage o System frequency, 50 or 60 Hz o System phase, single or three (wile or clefts) o Power rating; kW -- --- - --- o Amp rating o Powertvoe. standhv or orime o Low oil pressure warning • GenSet Calibration o High engine speed o Voltage, L-L and L-N for all phases o Low (u Qevel or pressure) * o Curren, Lt. L2, L3 o Low coolant level o Reset calibration o EPS supplying load • Voltage Regulation o High battery voltage o Adjust voltage, it 0% o Low battery voltage • Digital Inputs General functions: o Input settings and status o Master switch not in auto • Digital Outputs o Battery charger fault • o Output settings and status o Lamp test • o Contacts for local and remote common alarm o np settings and status o Audible alarm silence button • Event Log o Remote emergency stop' o Event history (stores up to 1000 system events) Funcfionrequlres optionalinputsensorsorkiis and isenginedependerd, • Selector Switch (requires initial activation by StteTech'") see Controller Displays as Provided by the Engine ECM. • Functionmquimsoptionalinputsensorsorkfls and lsenglnedependent, see Controller Displays as Provided by the Engine ECM. G6100 3110 Page2 Controller Features • AC Output Voltage Regulator Adjustment The voltage adjustment provides a maximum of xt 0% of the system voltage. • Alarm Silence. The controller can be set up to silence the alarm ham 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 aitemator 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 Dlagnostles. 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 enures) 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 s0.5% 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 WA. • Programming Access (USS). 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 11 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-EnglnoStart-(IDES).the-TDESprovides=atimo delay= beforethe 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 Thefollowing chart shows which functions cause awaming or shutdown. All functions are available as relay outputs. Warning Function Shutdown Function Critically high fuel level * 0 ECM communication loss ECM diagnostics • • Engine over speed at Engine start aid active Engine under speed Fuel tank leak * 0 0 High battery voltage • High coolant temperable • •t High fuel level * o Low battery voltage Low coolant level • Low coolant temperature Low cranking voltage • Low engine oil level * 0 0 Low fuel level (diesel models) * 0 0 Low fuel pressure (gas models) * 0 Low oil pressure • •t No coolant temperature signal • No oil pressure signal • Overcrank •t Speed sensor fault • General"FinWons Alarm horn silenced Analog inputs 0 0 Battery charger fault* Chicago code active Common fault Qncludes f) • Common warning Digital inputs o 0 Emergency stop at Engine cooldown (delay) active Engine start delay active Engine started Engine stopped EPS supplying load Generator running InpWoutput communication loss Internal failure Master switch not in auto • NFPA 110 alarm active Remote start System ready GeeeratorFunctl_ohs_--` _ — �. — 7777:7777- - AC sensing loss -- — • - •_ , --• Alternator protection Ground fault input kW overload • Locked rotor Overtrequency • Overvohage (each phase) • Underbequency • Undervoltage each phase) • • Standard functions Warning causes the fault light to show yellow and sounds the alarm ham 0 Available user functions signaling an impending problem. * Function requires optional inputsensorsorkitsand isenginedependem, Shutdown causes the fault light to show red, sounds the alarm ham, and see Controller Displays as Provided by the Engine ECM. stops the generator set t Items included with common fault shutdown G&100 a/10 Page KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920457-4441, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPowercom Kohler Power Systems Asia Pacific Headquarters 7 Juicing Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264.6455 Cordroller Displays as Provided by the Engine ECM (availability subject to change by the engine manufacturer) Display GM/PSI I Doosan John Deere (JDEC) Volvo (EMS II) Volvo (EDC 10) DD/MTU (ADEC) Ambient temperature I X Charge air pressure X. X X X X Charge air temperature X X X X X Coolant level X X X Coolant pressure X X Coolant temperature X X X X X X Crankcase pressure X X ' ECM battery voltage X X X ECM fault codes X X X X X X ECM serial number X Engine model number X X Engine serial number X X Engine speed X X X X X X Fuel pressure X X Fuel rate - X X X X X X Fuel temperature X - X X X Oil level X Oil pressure X X X X X X Oil temperature X X X Trip fuel X X X Controller Specifications Decision -Maker• 3000--Software Version 3.11 or higher • Power source with circuit protection: 12- or 24-voh 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, a NFPA 110, Level 1 o GSA 282-09 o UL508 o ASTM 13117 (salt spray test) • Panel dimensions—W x H, 229 x 160 mm (9.0 x 6.3 in.) Communication and PC Software Available Options Refer to GB-76 Monitor III 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) cunuouers awessea via me tmemeL t nvisrter is suppsea wim an IF address by the site administrator. Refer to G6-79 for converter details. ❑ Converter, RS-232/RS4N. Supports a power system using controllers accessed via a serial (RS-232) connection. Availability is subject to change without notice. Kohler Go, reserves the right to change the design or specficationswithoutnotice and without my obligation or liability whatsoever. Contact your local Kohler• generator set distributor for availability. Decision -Maker® 3000 Available Options --F> FloaVEqualize Battery Charger available with 6 or 10 amp DC volt output The 10 amp models are ava0able with and without NFPA alarm to signal battery charger fault ❑ Manuel Speed Adjust available for applications using closed transition ATS. ❑ 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 Kohlere Remote Serial Annunciator (RSA) enables the operator to monitor the status of the generator set from a remote location, which may be required for NFPA99 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 Modulo. provides a generator set mounted panel with two inputs and five relay outputs. vademark e1 rAaaaoa CorporAw. BY: Newmans Power Systems Inc. 3076 N Kings Hw. Fort Pierce, FL 34951 772-465=2490 ®200a201a2o12,201a2014bYnohwC+ , P➢rightsresme& e&100 3114e Pa9e4 Industrial Generator Set Accessories KOHURe Power Systems Line Circuit Breakers 15-2250 kW ,lam Standard Features TEEED • 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 Q O manually disconnect the generator set from the load during generator set service. ° • Circuit breaker kits are mounted to the generator set and are provided with load -side lugs and neutral bus ° bar. • Kohler Co. offers a wide selection of molded -case line circuit breaker kits including single, dual, and multiple configurations for each generator set. O O O Single Circuit Breaker Kit with Neutral Bus Bar 15-300 kW Model Shown Dual Ctrwit Breaker lQt with Neutral Bus Bar 15-300 kW Model Shown Multiple Clrwit.Breaker Kits with Neutral Bus Bar 350-2250 kW Model Shawn (also applies to some 300 kW models) • 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 (LSIG) 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 1077 Supplementary Protectors o UL 2200 Stationary Engine Generator Assemblies Ge85 5114h Pege1 Line Circuit Breaker Types Magnetic Trip pickup switch sets the current level at which the circuit breaker will trip after the ground fault delay. Ground fault pickup values The magnetic trip features an electromagnet in series with the are based on circuit breaker sensor plug only and not on the load contacts and a moveable armature to activate the hip rating plug multiplier. Changing the rating plug multiplier has mechanism. When a sudden and excessive current such as no effect on the ground fault pickup values. a short circuit occurs, the electromagnet attracts the armature resulting in an instantaneous trip (UL 1077 circuit breakers). 80% Rated Circuit Breaker Thermal Magnetic Trip Thermal magnetic trip contains a thermal portion with a bimetallic ship that reads to the heat produced from the load current Excessive current causes itto.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 referred to as LSIG in this document Models with LSIG compare currentflow 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 ❑ Alarm Switch Most molded -case circuit breakers are 800/. rated devices. An 800% rated circuit breaker can only be applied at 80% of its rating for continuous loads as defined by NFPA70. Circuit conductors used with 80% rated circuit breakers are required to be rated for 100% of the circuit breakers rating. The 801. 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 1000% 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 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 undervohage 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 dosed position. ❑ Breaker Separators (350-2250 kW) Provides adequate clearance between breaker circuits. ❑ Bus Bars Bus bar kits offers, convenient way to connect load leads to the generator set when a circuit breakeris not present - - 15-800-kW Bus=barkiLssre=availabte-ol�emaTrs wRFrade — __for connection to:the generator set -when circuit -breakers -are •no 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 circuit breakers or other bus bars on the opposite side of the junction box. On medium voltage (3.3 W 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. ❑ 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 returns to the deenergized state when the circuit breaker is reset. El Shunt Trip, 12 VDC or 24 VDC breaker to be tripped by customer -selected faults such as aftemator 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 undervohage trips the circuit breaker when the control voltage drops below the preset threshold of 35%-70% of the rated voltage. 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