1. business and industrial
2. energy
3. oil

Submittal Review Cover Sheet
Project#: 11DB-C5-08-61-02-PS14
Project: 11-13-07 Fire Station # 2
Date:
Submittal#:
Architect#
01/09/14
25
Revision#
0
Owner#
1312 Bowman Street
Clermont, FL 34711
Phone (352) 394-1032
To:
Fax: (352) 394-1794
Submitter: Kevin Boutros
City of Zephyrhills
5335 8th Street
Zephyrhills, FL 33540
Phone: (813) 780-0022
Fax:
(813) 780-0025
Our Job#:
50041
Sub or Supplier
Lakeside Electrical Services
2204 W Griffin Rd,
Leesburg, FL 34748
Contact: Shane LeBlanc
Spec#
260000
Paragraph Spec Description
GENERATOR
Item Name
GENERATOR
Item Type
Comment
Reason:
Reviewed By
Pillar Construction Group, LLC
Review is for general design only. Subcontractor and or Supplier are responsible for dimensions, quantities, and full
compliance with the requirements of the contract documents. Review or approval by the architect or engineer does not
relieve the Subcontractor and or Supplier of the responsibilities required by the terms and conditions of the agreement
with Pillar Construction Group, LLC.
Date:
By:
AREA FOR OTHER REVIEW STAMPS AND COMMENTS:
PILLAR CONSTRUCTION GROUP, LLC
Date 01/09/14
By: Kevin Boutros
No Exception Taken
Make Corrections Noted
Revise & Resubmit
Rejected
This shop drawing review is for general
performance with contract documents only and
does not relieve the subcontractor or fabricator
of his responsibility for compliance with
requirements of the drawings and specifications.
Submittal#
25
Spec Section# 260000
Drawing#
Form: SubOne-G1
01/09/14
TAW POWER SYSTEMS
1500 NW 15TH AVENUE
Pompano Beach, Fl 33069
(954) 977-0202 / (954) 977-9249 (FAX)
LETTER OF TRANSMITTAL
TO: RON HUNT
DATE: 11/12/2013
COMPANY: LAKESIDE ELECTRICAL SERVICES
2204 W GRIFFIN ROAD
LESBURG, FL 34748
P.O.No.#: ____________
JOB NAME: ZEPHYRHILLS FS #2
TAW JOB No#: TG1309-0013
_X__ ENGINEERING SUBMITTALS
1 ELECTRONIC COPY
THESE ARE TRANSMITTED as checked below:
_X__ FOR APPROVAL
___ RECORD ONLY
COMMENTS:
1) ONE COPY OF APPROVED SUBMITTAL DATA MUST BE RETURNED
TOGETHER WITH YOUR PURCHASE ORDER, WRITTEN RELEASE OF ORDER,
NOTICE TO OWNER AND CREDIT APPLICATION (see attached).
2) ALL TECHNICAL QUESTIONS PURSUANT TO THIS SUBMITTAL DATA SHOULD BE
DIRECTED TO OUR OFFICE. PHONE (800) 876-0990, FAX (954) 977-9249.
TAW Power Systems
MARIO BRUNO
PROJECT MANAGER
JACK KLINE/GENE RICHARDS
ACCOUNT MANAGER
TAW POWER SYSTEMS, INC.
6312 78TH STREET / RIVERVIEW, FL 33569
P: 813-840-3500 T: 800-456-9449 F: 813-217-8075
Submittal Package
TG1309-0013r ZEPHYRHILLS FIRE
Job Name:
STATI
Quote:
0025992522
Proposal:
Submittal Date: 11/12/2013
We are pleased to offer the following submittal for your consideration.
Thank you, Mario Bruno, Tampa Armature Works
BILL OF MATERIAL
PAGE: 1 OF 2
SERVI NG FLORI DA SI N CE 1921
***************************************************************************************
ONE NEW Kohler Model 150REOZJF Diesel Engine
Driven Generator Set. 150 kW, @ 0.8 P.F., 60 Cycles,
3 Phase, 120/240 Volts.
CONTROLLER: DEC550
Voltmeter, Ammeter
Frequency Meter
Volt/Ammeter Phase Selector Switch
Individual Fault Lamps for:
High Engine Temperature
Low Oil Pressure
Over Speed
Over Crank
Switch NOT in Automatic
System Ready
Battery Low Volts
Battery Charger Fault
Pre Alarm Senders to Include:
Pre-High Engine Temperature
Pre-Low Oil Pressure
Low Water Temperature
Alarm Horn
Over Voltage Protection
Oil Pressure Gauge
Water Temperature Gauge
Battery Charge Voltmeter
Running Time Meter
Cool down timer
Run Relay
GENERATOR ACCESSORIES (Mechanical):
Sound Housing -- Aluminum
Silencer Mounting Kit
Tailpipe and Rain Cap
COOLING:
Unit Mounted Radiator
Low Coolant Level Shutdown
Block Heater 120 Volt, 1800 Watt
FUEL SYSTEM:
Flexible Fuel Lines
Sub-base Fuel Tank 900 Gallon
Double Wall with Leak Detector
Fuel Level Gauge
Low Fuel Level Alarm Contact
Local Fill Cap
Vent Package (Normal & Emergency)
FDEP Package
GOVERNOR ACCESSORIES:
Electronic Isochronous
GENERATOR ACCESSORIES (Electrical):
Line Circuit Breaker 3 Pole, 300 Amp.
with Shunt Trip/Wire to Engine Safeties
Line Circuit Breaker 3 Pole, 200 Amp.
with Shunt Trip/Wire to Engine Safeties
Installed on Generator
Voltage Regulator 0.50%
ENGINE ELECTRICAL ACCESSORIES:
Battery Rack and Cables
Starting Battery, Lead/Acid
Battery Charger: Automatic Float with Alarm contacts
CONTROLLER ACCESSORIES LOOSE:
Remote Emergency Stop, Break Glass
Remote Annunciator Panel
ADDITIONAL ACCESSORIES:
Oil Drain Extension
Lot of Oil and Antifreeze
Corrosion Inhibitor for Radiator
Vibration Isolators - Internal
FOUR Engine, Generator Parts, Maintenance Manuals
TWO Year Warranty
Initial Start Up and Check Out of System,
Not to Exceed 8 Hours
Certified Factory Test @ 0.8 P.F.
Load Bank Test @ FOUR Hours (on site)
AUTOMATIC TRANSFER SWITCH:
1 Kohler Automatic Transfer Switch 120/240 Volt,
400 Amp.,3 Phase, 4 Pole, in a NEMA 3R Enclosure,
MODEL: KCS-DFVC-0400B
1 Kohler Automatic Transfer Switch 120/240 Volt,
230 Amp.,3 Phase, 4 Pole, in a NEMA 3R Enclosure,
MODEL: KCS-DFVC-0230S
Spec Sheets
150REOZJF
Diesel
Standard Features
•
•
•
•
•
•
•
•
Kohler Co. provides one-source responsibility for the
generating system and accessories.
The generator set and its components are prototypetested, 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- and five-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 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.
Generator Set Ratings
Alternator
4S12X
Voltage
120/240
Ph
3
Hz
60
Standby130C
Ratings
kW/kVA
Amps
154/193
463
RATINGS: All three-phase units are rated at 0.8 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 hours is unlimited. A 10%overload capacity is available for one hour in twelve.
Ratings are in accordance with ISO-8528-1 and ISO-3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical information bulletin (TIB-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: 150REOZJF, 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
4RX: 12, Reconnectable 4TX: 4, 120-240
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 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
Governor: type, make/model
Frequency regulation, no-load to-full load
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.)
Dry
33.9 (1197)
510 (950)
7.5 (2.2)
98 (3.86)
Engine Electrical
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)
12 Volt/24 Volt
Negative
12/24
65/45
12/24
One, 640/Two, 570
12
Fuel
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
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
Lubrication System
Type
Oil pan capacity, L (qt.)
Oil pan capacity with filter, L (qt.)
Oil 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)
50 (122)
Engine jacket water capacity, L (gal.)
11.3 (3.0)
Radiator system capacity, including engine, L (gal.) 25.7 (6.8)
Engine jacket water flow, Lpm (gpm)
174 (46)
Heat rejected to cooling water at rated kW, dry
76.3 (4340)
exhaust, kW (Btu/min.)
Heat rejected to air charge cooler at rated kW, dry 31.8 (1810)
exhaust, kW (Btu/min.)
Water pump type
Centrifugal
Fan diameter, including blades, mm (in.)
660 (26)
Fan, kWm (HP)
7.7 (10.3)
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, 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 lbm/ft³)
226.5 (8000)
13.6 (480)
35.9 (2040)
12.3 (700)
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% load
Prime Fuel Consumption at 25% load
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)
Model: 150REOZJF, continued
Dimensions and Weights
Overall Size, L x W x H, mm (in.):
Weight (radiator model), wet, kg (lb.):
2950 x 1120 x 1527 (116.1 x 44.1 x 60.1)
1295-1402 (2855-3090)
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
Generator Set Controller
Kohlerr Decision-Makerr 550 Controller
General Description and Function
The Decision-Makerr 550 generator set controller provides
advanced control, system monitoring, and system diagnostics
for optimum performance and compatibility with selected
engine Electronic Control Modules (ECM).
ECM models only: The Decision-Makerr 550 controller
directly communicates with the ECM to monitor engine
parameters and diagnose engine problems (see Controller
Diagnostics for details).
Standard Features
D
A digital display and keypad provide access to data. The
display provides complete and understandable information,
and the keypad allows easy local access.
D
Measurements selectable in metric or English units.
D
The controller can communicate directly with a personal
computer via a network or via a modem configuration.
D
The controller supports Modbusr protocol. Use with serial
bus or Ethernet networks.
D
Integrated voltage regulator providing ±0.25% regulation.
D
Built-in alternator thermal overload protection.
D
A lockout keyswitch meets appropriate local code
requirements.
Decision-Makerr 550
Optional Features
D
Monitor III, an optional menu-driven Windowsr-based PC
software, monitors engine and alternator parameters and
also provides control capability. See G6-76 spec sheet for
more information.
D
Menu 15 (Protective Relays) is required for optional
protective functions and is only available with the Kohler
PD-Series switchgear.
Modbusr is a registered trademark of Schneider Electric.
Windowsr is a registered trademark of Microsoft Corporation.
G6-46 7/13m Page 1
15
Protective Relays
Decision-Makerr 550
Controller Features
NFPA Requirements
Decision-Makerr 550—Software Version 2.10 or higher
In order to meet NFPA 110, Level 1 requirements, the generator
set controller must monitor specific engine/generator functions
and faults.
Specifications
D
D
D
D
D
D
Power source with circuit protection: 12- or 24-volt DC
Power drain: 700 milliamps (or 400 milliamps without panel lamps)
Humidity range: 5% to 95% noncondensing
Operating temperature range: --40°C to +70°C (--40°F to +158°F)
Storage temperature range: --40°C to +85°C (--40°F to +185°F)
Standards:
d NFPA 99
d NFPA 110, Level 1
d CSA 282-09
d UL 508
D
D
D
D
D
Vacuum fluorescent display
Environmentally sealed 16-button membrane keypad
LED status indicating lights
Three-position (run, off/reset, auto) keyswitch
Latch-type emergency stop switch with International
Electromechanical Commission (IEC) yellow ring identification
Alarm horn
Fuse-protected battery circuits
Controller mounts locally or remotely up to a distance of 12 m (40 ft.)
and viewed from one of four positions
Dimensions—W x H x D,
460 x 275 x 291 mm (18.15 x 10.8 x 11.47 in.)
Hardware Features
D
D
D
D
NFPA 110 Common Alarm
D Engine functions:
d Overcrank
d Low coolant temperature warning
d High coolant temperature warning
d High coolant temperature shutdown
d Low oil pressure shutdown
d Low oil pressure warning
d Overspeed
d Low fuel (level or pressure) *
d Low coolant level
d EPS supplying load
d High battery voltage *
d Low battery voltage *
d Air damper indicator
D General functions:
d Master switch not in auto
d Battery charger fault *
d Lamp test
d Contacts for local and remote common alarm
d Audible alarm silence switch
d Remote emergency stop
* Requires optional input sensors on some generator set models.
G6-46 7/13m Page 2
Controller Functions
D AC Output Voltage Adjustment
The voltage adjustment provides keypad adjustment in 0.1 volt
increments of the average line-to-line AC output voltage with a
maximum adjustment of ±10% of the system voltage.
D Master Switch Fault
The generator set master switch has fault detection at four levels:
1) master switch to off, 2) master switch open, 3) master switch
error, and 4) master switch not in auto. Each of these faults/
warnings provides local display, alarm horn on, and activates
a relay driver output (RDO). By placing the master switch to the
off/reset position, all generator set faults can be reset.
D Alternator Protection
The controller firmware provides generator set overload and short
circuit protection matched to each alternator for the particular
voltage/phase configuration.
D Modbusr Interface
The Modbusr interface provides industry standard open protocol
for communication between the generator set controller and other
devices or for network communications.
D Automatic Restart
The controller automatic restart feature initiates the start routine
and recrank when the generator set slows to less than 390 rpm
after a failed start attempt.
D Number of Starts
Total number of generator set successful starts is recorded and
displayed on the local display and remote PC monitor. This
information is a resettable and total record.
D Battleswitch (Fault Shutdown Override Switch)
The battleswitch input provides the ability to override the fault
shutdowns except emergency stop and overspeed shutdown in
emergency situations and during generator set troubleshooting.
D Programming Access
The setup access and programming information is password
protected. When locally accessing programming information, the
PM (programming mode) LED flashes. When remotely accessing
programming information, the PM LED is steady.
The control functions apply to both the ECM and non-ECM equipped
models unless noted otherwise.
D Clock and Calendar
Real-time clock and calendar functions time stamp shutdowns for
local display and remote monitor. Also use these functions to
determine the generator set start date and days of operation.
D Cooldown Temperature Override
This feature provides the ability to bypass (override) the cooldown
temperature shutdown and force the generator set to run for the full
engine cooldown time delay. Also see Time Delay Engine Cooldown
(TDEC).
D Cyclic Cranking
The controller has programmable cyclic cranking. The customer
selects the number of crank cycles (1--6) and the crank time from 10
to 30 seconds. The crank disconnect depends upon the speed
sensor input information or the generator frequency information.
The default cyclic crank setting is 15 seconds on, 15 seconds off
for three cycles.
D Digital Voltage Regulator
The digital voltage regulator provides ᐔ0.25% no-load to full-load
regulation.
D Display Power Shutdown
To conserve battery power, the display turns off after 5 minutes of
inactivity. Pressing any keypad button activates the display.
D ECM Communication
The controller monitors ECM communication links and provides fault
detection for oil pressure signal loss, coolant temperature signal
loss, and ECM communication loss. Each of these faults provides
local display, alarm horn ON, and relay driver output (RDO) on ECM
models only. See Controller Diagnostics following for additional
information.
D Programmed Run
The programmed run function provides user-selectable time for a
one-time exercising of the generator set. The controller does not
provide weekly scheduled exercise periods.
D Remote Reset
The remote reset function resets faults and allows restarting of the
generator set without going to the master switch off/reset position.
The remote reset function is initiated via the remote reset digital
input.
D Running Time Hourmeter
The running time hourmeter function is available on the local display
and remote monitor. The information displayed uses real time
loaded and unloaded run time as an actual and resettable record.
D Self-Test
The controller has memory protection and a microprocessor
self-test.
D Starting Aid
The starting aid feature provides control for an ether injection
system. This setup has adjustable on time before engine crank from
0 to 10 seconds. This feature is also part of the remote
communication option.
D Time Delay Engine Cooldown (TDEC)
The TDEC provides a user-selectable time delay before the
generator set shuts down. If the engine is above the preset
temperature and unit is signalled to shut down, unit will continue to
run for the duration of the TDEC. If the engine is at or below the
preset temperature and unit is signalled to shut down or the TDEC is
running, unit will shut down without waiting for the time delay to
expire. Also see Cooldown Temperature Override.
D Idle Speed Function
Idle speed function provides the ability to start and run the engine
at idle speed for a selectable time period. The engine will go to
normal speed should the temperature reach warm-up before the
time delay is complete.
D Time Delay Engine Start (TDES)
The TDES provides a user-selectable time delay before the
generator set starts.
D Lamp Test
Keypad switch verifies functionality of the indicator LEDs, alarm
horn, and digital display.
Modbusr is a registered trademark of Schneider Electric.
D Load Shed
The load shed function provides a load control output (RDO) with
user-selectable load shed level.
G6-46 7/13m Page 3
Controller Diagnostics
The controller features warnings and shutdowns as text messages on
the vacuum fluorescent display. See the table below.
Warnings show yellow LED and signal an impending problem.
Shutdowns show red LED and stop the generator set.
User-Defined Common Fault and Status. The user customizes
outputs through a menu of warnings, shutdowns, and status conditions.
User defines up to 31 relay driver outputs (RDOs) (relays not included).
Note: Menu 15 features are available by purchasing the paralleling
switchgear option.
Warning Shutdown UserUser
Function Function Defined RDOs
Engine Protection
Air damper control,
if equipped
Air damper indicator,
if equipped
Coolant temp. signal loss
High battery voltage
High coolant temperature
High oil temp. shutdown
Low battery voltage
Low coolant level
Low coolant temperature
Low fuel level (diesel) *
Low fuel pressure (gas) *
Low oil pressure
Oil pressure signal loss
Overcrank
Overspeed
Speed sensor fault
Starting aid
Weak battery
General Protection
Auxiliary inputs 0--5 VDC—
up to 7 analog
Auxiliary inputs—
up to 21 digital
Battery charger fault *
Defined common fault [
EEPROM write failure
Emergency stop
Engine cooldown delay
Engine start delay
EPS supplying load
Internal fault
Load shed kW overload
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Note: The available user inputs are dependent on factory reserved
inputs for specific engine types, engine controls, and paralleling
applications.
Warning Shutdown UserUser
Function Function Defined RDOs
Load shed underfrequency
X
X
X
Master switch error
X
X
X
Master switch not in auto
X
X
X
Master switch open
X
X
X
Master switch to off
X
X
X
NFPA 110 common alarm
X
X
SCRDO’s 1--4 (software
X
X
controlled RDOs)
System ready (status)
X
X
Alternator Protection
AC sensing loss
X
X
X
X
Critical overvoltage
X
X
X
Generator running
X
X
Ground fault *
X
X
X
Locked rotor
X
X
X
AC Protection (includes Menu 15 Enabled Enhancements)
Alternator protection (short
X
X
X
circuit and overload)
Breaker trip
]
X
Common protective relay
X
X
output
In synchronization
]
X
Loss of field (reverse VAR)
X
X
X
Overcurrent
X
X
X
X
Overfrequency
X
X
X
Overpower
X
X
X
Overvoltage
X
X
X
Reverse power
X
X
X
Underfrequency
X
X
X
Undervoltage
X
X
X
* Requires optional input sensors on some generator set models.
[ Factory default settings for the defined common fault are emergency stop, high
coolant temperature shutdown, low oil pressure shutdown, overcrank, and
overspeed.
] Factory set inputs that are fixed and not user changeable.
Controller Displays as Provided by the Engine ECM (availability subject to change by the engine manufacturer)
Display
GM/PSI
Doosan
John Deere
Volvo (EMS II)
Volvo (EDC III)
DD/MTU (DDEC)
Ambient temperature
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
G6-46 7/13m Page 4
Controller Monitoring
Standard Equipment and Features
D Alarm horn
D Indicators:
d Not in auto (yellow)
d Program mode (yellow)
d System ready (green)
d System shutdown (red)
d System warning (yellow)
D Switches and standard features:
d Keypad, 16-button multi-function sealed membrane
d Lamp test
d Keyswitch, auto, off/reset, run (engine start)
d Switch, emergency stop (normally closed contacts)
D Vacuum fluorescent display with two lines of 20 characters
Displays
Some engine displays are dependent upon enhanced electronic
engine control availability.
D Engine monitoring data (metric or English units):
d Battery voltage
d Engine model number [
d Engine serial number [
d Engine speed
d Engine start countdown
d ECM—battery voltage [
d ECM—fault codes
d ECM—serial number [
d Fuel rate
d Level—coolant [
d Level—oil [
d Pressure—crankcase [
d Pressure—charge air [
d Pressure—coolant [
d Pressure—fuel
d Pressure—oil
d Rpm
d Temperature—ambient [
d Temperature—charge air [
d Temperature—coolant
d Temperature—fuel [
d Temperature—oil [
d Trip fuel [
D Engine setpoints
d Coolant—high temperature shutdown and warning setpoints
d Oil—low pressure shutdown and warning setpoints
d Temperature—engine cooled down setpoint
d Temperature—engine warmed up setpoint
D Generator monitoring data:
d Current (L1, L2, L3), ᐔ0.25% accuracy
d Frequency, ᐔ0.5% accuracy
d Kilowatts, total per phase (L1, L2, L3), ᐔ0.5% accuracy
d KVA, total per phase (L1, L2, L3), ᐔ0.5% accuracy
d KVAR, total absorbing/generating per phase (L1, L2, L3),
ᐔ0.5% accuracy
d Percent alternator duty level (actual load kW/standby kW rating)
d Power factor per phase, leading/lagging
d Voltage (line-to-line, line-to-neutral for all phases), ᐔ0.25%
accuracy
D Operational records:
d Event history (stores up to 100 system events)
d Last start date
d Number of starts
d Number of starts since last maintenance
d Operating days since last maintenance
d Operating mode—standby or prime power
d Run time (total, loaded and unloaded hours, and total kW hours)
d Run time since maintenance (total, loaded, and unloaded hours
and total kW hours)
d System shutdowns
d System warnings
d Time, date, and day of week
D Time delays—general:
d Crank cycles for on/pause
d Crank cycles for overcrank shutdown
d Engine cooldown
d Engine start
d Load shed
d Voltage, over- and underd Starting aid
D Time delays—paralleling relays (PR) for optional switchgear
applications:
d Current—over (PR)
d Current—over shutdown
d Frequency—over- and under- (PR and shutdown)
d Loss of field (PR and shutdown)
d Loss of field shutdown (PR)
d Power—over (PR)
d Power—over shutdown
d Reverse power (PR)
d Reverse power shutdown
d Synch matching—frequency, phase, voltage
d Voltage—over- and under- (PR and shutdown)
D System parameters:
d Alternator number
d Current, rated (based on kW, voltage, connection settings)
d Frequency
d Generator set model number
d Generator set serial number
d Generator set spec number
d Rating, kW
d Phase, single and three (wye or delta)
d Voltage, AC
d Voltage configuration, wye or delta
Inputs
D Customer and remote inputs:
d Analog inputs 0--5 VDC (up to 7 user-defined analog inputs
with multiple shutdown and warning levels)
d Digital contact inputs (up to 21 user-defined digital inputs with
shutdown or warning levels)
d Ground fault detector *
d Remote emergency stop
d Remote reset
d Remote 2-wire start
D Digital inputs (standard):
d Air damper fault, if equipped
d Battery charger fault *
d Battleswitch
d Emergency stop
d Field overvoltage (350 kW and higher)
d High oil temperature
d Idle mode active (ECM models only) [
d Low coolant level
d Low coolant temperature
d Low fuel warning *
d Low fuel shutdown *
D Switchgear inputs in Menu 15 (to interface with switchgear system):
d Circuit breaker closed
d Enable synch
d Lockout shutdown
d Remote reset
d Remote shutdown
d VAR/PF mode selection
d Voltage—raise/lower (or VAR/PF raise/lower in VAR/PF mode)
Outputs
See the Fault Diagnostics section for a breakdown of the available
shutdown and warning functions.
D Thirty-one user-defined relay driver outputs (relays not included)
d Fifteen NFPA 110 faults
d Defined common faults
Communication
D RS-485 connector for Modbusr RTU communication port
D RS-232 connector for a PC or modem (optional software required)
D SAE J1939 connector for the engine ECM (engine control module)
* Requires optional input sensors on some generator set models.
[ Available on some engines. See page 4, Controller Displays as Provided by the
Engine ECM for availability.
Modbusr is a registered trademark of Schneider Electric.
G6-46 7/13m 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 1-800-544-2444
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455
Decision-Makerr 550 Controller Available Options
Communication and PC Software Available Options
Refer to spec sheet G6-76, Monitor III Software for additional
communication and PC software information including Modbusr
communication.
- Local Single Connection. A PC is connected directly to the
device communication module with an RS-232 cable for
applications where the PC is within 15 m (50 ft.) of the device or
RS-485 cable for applications where the PC is up to 1220 m
(4000 ft.) from the device.
Other Available Options
X Common Failure Relay remotely signals auxiliary fault, emergency
stop, high engine temperature, low oil pressure, overcrank, and
overspeed via one single-pole, double-throw relay with 10-amp
contacts at 120 VAC or 28 VDC maximum.
X
- Controller Cable enables remote mounting of the controller with
distances of up to 12 m (40 ft.) from the generator set.
- Local Area Network (LAN). A PC is connected directly to the
device’s local area network. A LAN is a system of connecting
more than one device to a single PC.
X
- Remote Network (Ethernet): A PC with a NIC card uses an
Ethernet connection to access a remotely located converter
(Modbusr/Ethernet) serving a controller. Refer to G6-79 for system
details.
- Remote Network (Modem): A PC uses a modem to connect to
a remotely located device modem serving a controller. Monitoring
software (Monitor III) runs on the PC to view system operation.
- Monitor III Software for Monitoring and Control
(Windowsr-based user interface)
- Converter, Modbusr/Ethernet. Supports a power system
using a controller accessed via the Ethernet. Converter is supplied
with an IP address by the site administrator. Refer to G6-79 for
converter details.
- RS-232 to RS-485 Port Converters
X
X
Personal
computer
Dry Contact Kit interfaces between the controller signals and
customer-supplied accessories providing contact closure to activate
warning devices such as lamps or horns. Kits are available with
either one or ten single-pole, double-throw relays with 10-amp
contacts at 120 VAC or 28 VDC maximum.
Float/Equalize Battery Charger with Alarm Feature signals
controller of 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 Audiovisual Alarm Panel warns the operator of fault
shutdowns and warning conditions. Kit includes common fault lamp
and horn with silence switch.
X
Device
modem
External PC
modem
Controller Connection Kit provides a cable connecting the
controller output terminals to a terminal strip in the junction box.
- Prealarm Kit for NFPA 110 (gas fuel models only) warns the
operator of low fuel pressure. Select the kit based on LP vapor or
natural gas, combination dual fuel, or LP liquid withdrawal.
X
or
Run Relay provides a three-pole, double-throw relay with 10-amp
contacts at 120 VAC or 28 VDC maximum for indicating that the
generator set is running.
RS-232 to
RS-485 port
converter
Remote Emergency Stop Panel immediately shuts the generator
set down from a remote station.
Remote Serial Annunciator Panel 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. Uses Modbusr
protocol, an industry standard.
Modbusr is a registered trademark of Schneider Electric.
Windowsr is a registered trademark of Microsoft Corporation.
Telephone lines
DISTRIBUTED BY:
Generator Set with the Decision-Makerr 550 controller
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 Kohlerr generator
set distributor for availability.
© 2002, 2003, 2005, 2006, 2007, 2008, 2011, 2012, 2013 by Kohler Co., All rights reserved.
G6-46 7/13m Page 6
Industrial Generator Set Accessories
Line Circuit Breakers 20-- 2250 kW
Standard Features
D 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.
D Circuit breaker kits are mounted to the generator set
and are provided with load-side lugs and neutral bus
bar.
D Kohler Co. offers a wide selection of molded-case
line circuit breaker kits including single, dual, and
multiple configurations for each generator set.
Single Circuit Breaker Kit with Neutral Bus Bar
20-- 300 kW Model Shown
D Four types of line circuit breakers are available:
(see page 2 for definitions and pages 3 and 4 for
application details)
d
d
d
d
Magnetic trip
Thermal magnetic trip
Electronic trip
Electronic with ground fault (LSIG) trip
D In addition, line circuit breakers are offered with 80%
and 100% ratings.
D Single line circuit breaker kits allow circuit protection
of the entire electrical system load.
D Dual line circuit breaker kits allow circuit protection
of selected priority loads from the remaining
electrical system load.
Dual Circuit Breaker Kit with Neutral Bus Bar
20-- 300 kW Model Shown
D Multiple line circuit breaker kits with field connection
barrier allow circuit protection for special
applications (350--2250 kW).
D Line circuit breakers comply with the following codes
and standards unless otherwise stated.
d UL 489 Molded Case Circuit Breakers
d UL 1077 Supplementary Protectors
d UL 2200 Stationary Engine Generator Assemblies
Multiple Circuit Breaker Kits with Neutral Bus Bar
350-- 2250 kW Model Shown
(also applies to some 300 kW models)
G6-88 4/13g Page 1
Line Circuit Breaker Types
Magnetic Trip
The magnetic trip features an electromagnet in series with the
load contacts and a moveable armature to activate the trip
mechanism. When a sudden and excessive current such as
a short circuit occurs, the electromagnet attracts the armature
resulting in an instantaneous trip (UL 1077 circuit breakers).
Thermal Magnetic Trip
Thermal magnetic trip contains a thermal portion with a
bimetallic strip that reacts to the heat produced from the load
current. Excessive current causes it to bend sufficiently to
trip the mechanism. The trip delay is dependant on the duration
and excess of the overload current. Elements are factorycalibrated. 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 current flow in phase
and neutral lines, and trip when current unbalance exists.
Ground fault trip units are an integral part of the circuit breaker
and are not available as field-installable kits. The ground fault
pickup switch sets the current level at which the circuit breaker
will trip after the ground fault delay. Ground fault pickup values
are based on circuit breaker sensor plug only and not on the
rating plug multiplier. Changing the rating plug multiplier has
no effect on the ground fault pickup values.
80% Rated Circuit Breaker
Most molded-case circuit breakers are 80% rated devices.
An 80% rated circuit breaker can only be applied at 80% of its
rating for continuous loads as defined by NFPA 70. Circuit
conductors used with 80% rated circuit breakers are required
to be rated for 100% of the circuit breaker’s rating.
The 80% rated circuit breakers are typically at a lower cost
than the 100% rated circuit breaker but load growth is limited.
100% Rated Circuit Breaker
Applications where all UL and NEC restrictions are met can use
100% rated circuit breakers where 100% rated circuits can carry
100% of the circuit breaker and conductor current rating.
The 100% rated circuit breakers are typically at a higher cost
than the 80% rated circuit breaker but have load growth
possibilities.
When applying 100% rated circuit breakers, comply with the
various restrictions including UL Standard 489 and NEC
Section 210. If any of the 100% rated circuit breaker restrictions
are not met, the circuit breaker becomes an 80% rated circuit
breaker.
Line Circuit Breaker Options
- Alarm Switch
- Lockout Device (padlock attachment)
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-totrip pushbutton. The alarm resets when the circuit breaker is
reset.
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.
- Auxiliary Contacts
- Neutral Lugs
Various neutral lug sizes are available to accommodate multiple
cable sizes for connection to the bus bar only.
These switches send a signal indicating whether the main
circuit breaker contacts are in the open or closed position.
- Overcurrent Trip Switch
- Breaker Separators (350--2250 kW)
The overcurrent trip switch indicates that the circuit breaker has
tripped due to overload, ground fault, or short circuit and returns
to the deenergized state when the circuit breaker is reset.
Provides adequate clearance between breaker circuits.
- 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 alternators 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 circuit 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.
X 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
X
- Field Connection Barrier
Connects the shunt trip to the generator set controller.
Provides installer wiring isolation from factory connections.
- Undervoltage Trip, 12 VDC or 24 VDC
- Ground Fault Annunciation
A relay contact for customer connection indicates a ground
fault condition and is part of a ground fault alarm.
The undervoltage trips the circuit breaker when the control
voltage drops below the preset threshold of 35%--70% of the
rated voltage.
G6-88 4/13g Page 2
20--300 kW Line Circuit Breaker Specifications
80% Rating Circuit Breaker
Gen. Set
kW
Alt.
Model
Ampere
Range
100% Rating Circuit Breaker
Trip Type
C. B.
Frame
Size
Gen. Set kW
Alt.
Model
Ampere
Range
Trip Type
15--150
Thermal magnetic
Magnetic, UL 1077
30--100
Magnetic, UL 1077
with 12 V shunt trip
Magnetic, UL 1077
with 24 V shunt trip
4P/4PX/
4Q/4QX
20--80
15--150
60--150
175--250
250
300--400
E
(480 V
max.)
60--150
20--80
Thermal magnetic
Electronic LI
HD
Electronic LSIG
400
Thermal magnetic
Electronic LI
15--150
JD
Electronic LSIG
Thermal magnetic
Magnetic, UL 1077
with 12 V shunt trip
Magnetic, UL 1077
with 24 V shunt trip
15--150
60--150
60--200
4RX/4S/
4SX/
4TX/4V
175--250
250
300--400
400--600
60--150
LA
175--250
250
4UA/
4M6226
300--400
400--600
Electronic LI
400
600--1200
HD
15--150
60--150
JD
Electronic LSIG
Thermal magnetic
Electronic LI
Electronic LSIG
Electronic LI
175--250
LA
200--300
400
MG
600--1200
PG
Electronic LI
HD
Frame Size
E
(480 V max.)
Ampere Range
JD
HD (80%)
HD (100%)
LA
JD (80%)
LG
JD (100%)
15--150
15--150
175
200--250
175--250
MG
LA
300--400
PG
LG
MG
400--600
700-800
600-800
1000-1200
Electronic LSIG
Thermal magnetic
Electronic LI
Electronic LSIG
Thermal magnetic
Electronic LI
Electronic LSIG
Thermal magnetic
Thermal magnetic
Electronic LI
Electronic LSIG
Interrupting Ratings
HD
JD
LA
LG
MG
PG
Thermal magnetic
Electronic LI
JD
Electronic LSIG
Electronic LI
Electronic LSIG
LG
Thermal magnetic
Electronic LI
HD
Electronic LSIG
Thermal magnetic
Electronic LI
JD
Electronic LSIG
Electronic LI
Electronic LSIG
Electronic LI
Electronic LSIG
LG
PG
Thermal magnetic
Electronic LI
HD
Electronic LSIG
Thermal magnetic
Electronic LI
JD
Electronic LSIG
Electronic LI
Electronic LSIG
Electronic LI
Electronic LSIG
LG
PG
Circuit Breaker Lugs Per Phase (Al/Cu)
Thermal magnetic
700--800
240 Volt,
kA
250
LG
PG
Circuit Breaker
Frame Size
4UA/
4M6226
HD
Electronic LSIG
Electronic LSIG
1000--1200
800--1200
250
Thermal magnetic
Thermal magnetic
175--250
60-200
Electronic LSIG
1000--1200
60--150
200--300
Electronic LI
Thermal magnetic
15--150
E
(480 V
max.)
4RX/4S/
4SX/
4TX/4V
Thermal magnetic
700--800
800--1200
175--250
250
Magnetic, UL 1077
30--100
4P/4PX/
4Q/4QX
Electronic LI
C. B.
Frame
Size
480 Volt,
kA
600 Volt,
kA
25
18
14
42
30
22
65
35
18
G6-88 4/13g Page 3
30--100
Wire Range
Up to two wire terminals fitting
10-32 or 1/4-20 stud
One #14 to 3/0
One #14 to 2/0 Cu only
One 1/0 to 4/0
One 3/0 to 350 kcmil
One 3/0 to 300 kcmil Cu only
One #1 to 600 kcmil or
Two #1 to 250 kcmil
Two 2/0 to 500 kcmil
Three 3/0 to 500 kcmil
Three 3/0 to 500 kcmil
Four 3/0 to 500 kcmil
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455
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
20--300 kW Line Circuit Breaker Applications
Single Circuit Breaker Installations
Dual 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.
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 or
priority loads.
Line C.B.
First
Line C.B.
Second
Line C.B.
ATS
ATS
Distribution
Panel
To Remaining
Building Loads
Distribution
Panel
ATS
Distribution
Panel
Distribution
Panel
To Priority Load(s)
Single line circuit breaker configuration where circuit breaker can
trip causing all power to building loads including priority load to
be disrupted.
To Remaining
Building Loads
To Priority Load(s)
Dual line circuit breaker configuration where first circuit breaker
can trip allowing second circuit breaker to continue supplying
power to priority load(s).
Dual Circuit Breaker Combinations
Alternator
Model
All
4P/4PX/4Q/
4QX/4RX/4S/
4SX/4TX/4V/
4UA
4RX/4S/
4SX/4TX/4V
First
C. B. Frame
Size
HD
JD
LA
LG
HD
JD
LA
LG
LG
Second
C. B. Frame
Size
—
—
—
—
HD
HD or JD
HD or JD
HD or JD
LG
MG
PG
HD
JD
LA
LG
MG
PG
—
—
HD
HD or JD
HD, JD, LA
Alternator
Model
Comments
Standard or LSIG
Standard only
Standard or LSIG
4UA/4M6226
Standard only
First
C. B. Frame
Size
Second
C. B. Frame
Size
MG
PG
HD
JD
—
—
HD
HD or JD
HD, JD, or
LA
LA
LG
MG
PG
PG
Standard only
Standard or LSIG
HD, JD, LA,
or LG
PG
Comments
Standard only
Standard or LSIG
Standard only
HD, JD, LG (1 or 2 may
be standard or LSIG)
PG and/or HD, JD, LG
may be LSIG
Standard only
DISTRIBUTED BY:
Standard only
HD, JD, LA,
or LG
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 Kohlerr generator set
distributor for availability.
© 2007, 2010, 2011, 2012, 2013 by Kohler Co. All rights reserved.
G6-88 4/13g Page 6
Powerpact® H- and J-Frame 15A to 250A
Molded Case Circuit Breakers
Delivering unmatched application flexibility
Well-suited to a wide range of applications, the Powerpact H- and
J-Frame Molded Case Circuit Breakers feature a full complement of
field installable accessories, field installable trip units and improved
interrupting ratings. These Molded Case Circuit Breakers deliver
unmatched design flexibility for 15A to 250A applications and share
identical mounting holes, handle locations, trim dimensions and
accessories, allowing customers to standardize equipment designs
for 15A to 250A applications.
HD and HG 2-Pole
Full-Featured Performance
H-Frame – 150A available in both standard and 100% ratings
with standard amperage ratings from 15 to 150A. Interrupting
ratings (AIR) include D-18kA, G-35kA, J-65kA and L-100kA at
480VAC
J-Frame – 250A available in both standard and 100% ratings
with standard amperage ratings from 150A to 250A. Interrupting
ratings (AIR) include D-18kA, G-35kA, J-65kA, and L-100kA
at 480VAC
Field installable accessories are common for H- and J-Frame
Circuit Breakers to make stocking and installation easy
Unique snap-in terminals make converting bus bar and lug
configurations simple and easy
H-Frame 150A
Field-installable trip units lower inventory costs and reduce
stocking space by configuring products at point of use
Allows design standardization for 15A to 250A applications with
common mounting holes, handle locations, and trim dimensions
for both H- and J-Frame Circuit Breakers
Many configuration options provide application flexibility, with
I-Line®, plug-in, drawout, rear connected, distribution lug, crimp
lug and din-rail configurations
Motor operators, rotary handles and cable operators provide
options for integrating into a variety of applications
Certified to global standards, including UL, IEC, CSA and NOM
J-Frame 250A
80
90
100
70
60
50
40
30
20
15
8
9
10
7
6
5
4
3
2
1.5
.8
.9
1
.7
.6
.5
MULTIPLES OF RATED CURRENT
10000
9000
8000
10000
9000
8000
7000
7000
6000
6000
5000
5000
4000
4000
JD, JG, JJ, JL MOLDED CASE CIRCUIT BREAKERS
CHARACTERISTIC TRIP CURVE NO. 50-5
CIRCUIT BREAKER INFORMATION
Continuous
Ampere Rating
Maximum
AC Voltage
Number
of Poles
JD, JG, JJ, JL
150–250
600
2, 3
3000
3000
2000
2000
1500
1500
1000
900
800
1000
900
800
700
700
600
600
500
500
This curve is to be used for application and coordination purposes only. The
EZ-AMP overlay feature at the bottom of the page should be used during
coordination studies.
All time/current characteristic curve data is based on 40°C ambient cold start.
Terminations are made with conductors of appropriate length and ratings.
400
400
MAXIMUM SINGLE-POLE TRIP TIMES
AT 25°C BASED ON NEMA AB-4 2003
8000
9000
10000
7000
6000
5000
4000
3000
2000
1500
800
900
1000
700
600
500
150
400
200
150
150
200
300
300
200
300
100
90
80
100
90
80
70
70
60
60
50
50
40
40
30
30
20
20
15
15
10
9
8
10
9
8
7
7
6
6
5
5
4
4
3
3
2
2
1.5
1.5
1
.9
.8
LIMITS LOW
SETTING
1
.9
.8
LIMITS HIGH
SETTING
.7
.7
.6
.6
.5
.5
.4
.4
.3
.3
.2
.2
.15
.15
MAGNETIC TRIP
ADJUSTMENT RANGE
.1
.09
.08
.1
.09
.08
.07
.07
.06
.06
.05
.05
.04
.04
MAXIMUM CLEARING TIME
(AT 50 Hz)
(AT 60 Hz)
.03
.03
1 CYCLE
(50 Hz)
.02
1 CYCLE
(60 Hz)
.015
.02
.015
1/2
.01
.009
.008
CYCLE
(50 Hz)
1/2
CYCLE
(60 Hz)
.007
.01
.009
.008
.007
© 2004 Schneider Electric All Rights Reserved
250
225
200
175
150
MULTIPLES OF RATED CURRENT
8000
9000
10000
7000
6000
5000
4000
3000
2000
1500
800
900
1000
700
600
400
500
300
200
150
80
90
100
70
60
50
40
30
20
15
8
9
10
7
6
5
4
3
2
1.5
.8
.9
1
.7
.005
.6
.006
.005
.5
.006
TM
Curve No. 0050TC0405
June 2004
Drawing No. 48095-050-05
TIME IN SECONDS
TIME IN SECONDS
Circuit Breaker
Prefix
Classes 660 and 735
Thermal-Magnetic
Molded Case Circuit Breakers
LA, LH and Q4
Circuit Breakers
Description
400-ampere frame circuit breakers with LA and LH circuit breakers rated
125 through 400 amperes and Q4 circuit breakers rated 250 through 400
amperes with the following features:
■
■
■
■
LA Circuit Breaker
■
■
■
■
2- and 3-pole construction
These circuit breakers have 2- and 3- pole construction built in a 3-pole
module.
Push-to-trip
Yellow push-to-trip button mechanically trips the circuit breaker.
Trip indication
The handle moves to the center position when the circuit breaker trips.
ON/OFF indication
ON/OFF markings are on the face of the circuit breaker along with the
international I/O markings.
Endurance (switching operations)
1,000 full-load operations
5,000 no-load operations
Thermal trip element
Thermal trip elements are factory calibrated for 40°C per the UL 489
Standard. Calibration for 50°C is also available without the UL Listing.
Magnetic trip element
The magnetic trip element on the LA, LH and Q4 circuit breakers is set
by a single adjustment on the circuit breaker cover.
Mounting
All LA, LH and Q4 circuit breakers can be mounted and operated in any
position, and are not limited to vertical or horizontal mounting.
Q4 Circuit Breakers
Continued on next page
Ampere Interrupting Ratings (AIR)
UL Listed Ampere Interrupting Ratings (AIR)
Continuous RMS Symmetrical Amperes
No. of
Ampere
AC Volts, 50/60 Hz
Poles
Rating
Unit-mount I-LINE®
120
240
277 480Y/ 480
600
277
Catalog Number
Prefix
DC Volts
125
250
500
Federal
Specs.
W-C-375B/
GEN
IEC Ultimate
Rating 415/240V
50/60 Hz
157-1
947-2
LAL
LA
2, 3
125–400
42K
42K
—
30K
30K
22K
10K
10K
—
21a
30K
—
LHL▲
LH▲
2, 3
125–400
65K
65K
—
35K
35K
25K
10K
10K
—
23a
36K
—
—
2, 3
—
—
—
—
—
—
—
—
—
20K
—
—
—
2, 3
250–400
25K
25K
—
—
—
—
—
—
—
14b
—
—
LHL-DC●
Q4L
▲
●
Q4
Separate UL ratings available for 240Vand 480V grounded B single-phase systems.
UL Listed for 500 Vdc nom. 600 Vdc max. rating. The circuit breakers are suitable only for use with UPS (uninterruptible power supplies) and
ungrounded systems.
Classes 660 and 735
Thermal-Magnetic
Molded Case Circuit Breakers
■
Description—Continued
■
■
Accessories
Accessory
Field
Installable
Shunt Trip▲
LA, LH, Q4
Undervoltage Trip▲
LA, LH, Q4
1A1B Auxiliary Switches▲
LA, LH, Q4
N.O. or N.C. Bell Alarm▲●
Factory
Installed
Only*
■
■
■
LA, LH, Q4
Handle Tie
LA, LH, Q4
Handle Extension
LA, LH, Q4
Handle Padlock Attachment LA, LH, Q4
Electrical Motor Operator
LA, LH, Q4
Walking Beam
LA, LH
Cylinder Lock
LA, LH, Q4
■
■
▲
UL Listed accessory.
Right pole.
* For LA and LH top-feed I-LINE® circuit breakers
(jaws on OFF end) all accessories must be factory
installed.
●
■
2
I-LINE® construction
All LA, LH and Q4 circuit breakers are available in I-LINE® plug-on
construction.
Molded case switches
Automatic molded case switches are available in LH 2- and 3-pole
construction. Molded case switches provide no overcurrent protection.
MAG-GARD® circuit breakers
The LA MAG-GARD® circuit breakers comply with requirements for
instantaneous trip circuit breakers.
Marine applications
LA and LH 2- and 3-pole circuit breakers are available for use on
vessels over 65 feet in length.
Mining applications
LA 2- and 3-pole circuit breakers are available.
DC applications
LAL and LHL 125–400 ampere circuit breakers are suitable for use on
125 and 250 Vdc systems.
LHL-DC 3-pole 250–400 ampere circuit breakers are suitable only for
use with uninterruptible power supplies and ungrounded systems rated
500 Vdc nominal, 600 Vdc maximum.
See AIR table on page 1 for ratings.
Ratings
AIR – See table on page 1.
Standards/Files
Circuit breakers
UL 489/E10027
CSA C22.2 No 5.1/LR7551
IEC 157-1
Molded Case Switches
UL1087/E33117
CSA C22.2 No. 5.2/LR32390
MAG-GARD® UL Recognized Component
UL 489/E10027
CSA C22.2 No. 5.1/LR32390
Marine circuit breakers
UL489/E85161
Rerating
Circuit breakers can be rerated for:
• Ambient temperatures below 25°C or above 40°C
• DC magnetic trip level
• 400 Hz applications
For more information see application guide SD361R1, "Determining
Current Carrying Capacity in Special Applications."
Classes 660 and 735
Thermal-Magnetic
Molded Case Circuit Breakers
Circuit breakers and molded case switches are provided with mechanical
lugs for copper or aluminum conductors. Optional lugs are also available.
■ Reverse connection
All LA, LH and Q4 circuit breakers are UL Listed, CSA Certified and
IEC Rated for reverse connection without restrictions.
Terminations
Mechanical Lug Kit Information
Kit Catalog
Number
(One lug per kit)
AL400LA
CU400LA
AL400LH7
Circuit Breaker Application
Standard
Ampere Rating
Circuit
Breaker
Conductor Size and Type
(one wire per lug)
AWG/kcmil (mm2)
AL400LA
LA, LH, Q4
125–400
(1) #1–600 (50–300) Al/Cu
(2) #1–250 (50–120) Al/Cu
CU400LA
LA, LH, Q4
125–400
(1) #1–600 (50–300) Cu
(2) #1–250 (50–120) Cu
AL400LH7
(optional)
LA, LH, Q4
125–400
350–750 (185–400) Al/Cu
Power Distribution Lugs
Kit Catalog
Number
(One lug per kit)
PDC6LA20
Circuit Breaker Applications
Conductor Size and Type
AWG/kcmil (mm2)
PDC6LA20◆
LA, LH, Q4
(6) #12–#2/0 (2.5–70) Cu
PDC12LA4◆
LA, LH, Q4
(12) #14–#4 (2.5–25) Cu
PDC4LA250◆
LA, LH, Q4
(3) #14–#2 (2.5–35) Cu
(1) #2–250 (35-120) Cu
PDC12LA4
◆
For use in UL580 Industrial Control applications only. Must be used on the OFF
end only when the OFF end is the load end.
PDC4LA250
Crimp Lugs
Kit Catalog
Number
VC400LA35
(Two Lugs Per Kit)
VC400LA3
(Two Lugs Per Kit)
VC400LA5
(One Lug Per Kit)
CVC400LA5
VC400LA3
VC400LA7
(One Lug Per Kit)
CVC400LA3
(Two Lugs Per Kit)
CVC400LA5
(One Lug Per Kit)
Circuit Breaker
Applications
Conductor Size and Type
AWG/kcmil (mm2)
LA, LH, Q4
250–350 (120–185) Al/Cu
LA, LH, Q4
#4–300 (25–150) Al/Cu
LA, LH, Q4
#2/0–500 (70–240) Al/Cu
LA, LH, Q4
500–750 (240–400) Al
500 (240) Cu
LA, LH, Q4
#2/0–300 (70–150) Cu
LA, LH, Q4
250–500 (120–240) Cu
3
Classes 660 and 735
Thermal-Magnetic
Molded Case Circuit Breakers
Dimensions
Electrical Clearance/Wire Bending Space
14.00
[356]
2.81
[71]
1.58
[40]
3.87
[98]
5.98
[152]
2.86
[73]
0.25
[6]
0.44
[11]
4.27
[109]
ON
11.00
[279]
ON
3.73
[95]
9.25
[235]
TRIPPED
OFF
RESET
OFF
4.48
[114]
0.88
[22]
2.00
[51]
4.02
[102]
2.00
[51]
2.00
[51]
5.81
[147]
2.00
[51]
4.56
[116]
0.98
[25]
0.32
[8]
2.05
[52]
Dual Dimensions: INCHES
[Millimeters]
CL
0.34
[9]
CL
CL
1.26
[32]
LA1046A.1
Square D, , and MAG-GARD and I-LINE are Registered
Trademarks of Square D Company.
Order No. 0660HO9601
4
Square D Company
3700 Sixth Street SW
Cedar Rapids, IA 52406
TT-940
6/06b
INSTALLATION INSTRUCTIONS
Original Issue Date:
Model:
Market:
Subject:
7/93
6--2000 kW
Industrial
Remote Emergency Stop Kits PA-293906, PA-293906-SD, and
PA-293906-F
Introduction
The emergency stop kit allows immediate shutdown of
the generator set from a remote location. Mount the
emergency stop switch(es) in a location easily
accessible by operating personnel at a normal
workstation. See Figure 1.
Emergency Stop
Kit Connection
(with multiple switches)
Emergency Stop
Kit Connection
(with single switch)
1
1A
1
1A
1
1
1A
1
1A
1A
1
1A
TB1 Terminal Strip
56
1
1A
Remove jumper
before installing kit
Local Emergency
Stop (if equipped)
Controller Board
Figure 2
TP-6200
Figure 1
Controller Circuit Board Connections
If the emergency stop switch is activated, the controller
emergency stop lamp lights and the unit shuts down.
The generator set cannot be restarted until the
emergency stop switch(es) is reset by replacing the
glass piece and the controller is reset by placing the
generator set master switch in the OFF/RESET
position.
Connect as many emergency stop switches as required;
however, connect multiple switches in series so the
system functions correctly. The emergency stop switch
is connected to controller circuit board terminals TB1-1
and 1A (see Figure 2). On sets without a local
(controller-mounted) emergency stop switch, remove
jumper from terminals TB1-1 and 1A before installing
the kit. When the emergency stop switch is activated,
contacts in the switch open to deenergize the K4 relay
and shut down the generator set.
Remote Emergency Stop Switch
Connections
Safety Precautions
Observe the following safety precautions while installing
the kit.
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
leads to length, strip ends, and connect to circuit
board terminals TB1-1 and 1A (see Figure 2).
10. If the generator set is equipped with a local
(controller-mounted) emergency stop switch,
proceed as follows:
a. Remove local emergency stop leads from
terminals TB1-1 and 1A.
b. Connect remote emergency stop leads to
terminals TB1 and 1A.
Installation Procedure
c. Splice local emergency stop leads in series
with remote switch lead connected to terminal
TB1-1 as shown in Figure 2.
1. Place the generator set master switch in the OFF
position.
2. Disconnect the power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
4. Remove controller cover to access controller
circuit board. Lower controller circuit board panel
to a horizontal position, if so equipped.
5. On generator sets not equipped with a local
(controller-mounted) emergency stop switch,
remove jumper from terminals TB1-1 and 1A.
6. Verify that the emergency stop switch leads are
from the normally closed contacts. Use an
ohmmeter to make the continuity test. Tape to
insulate the normally open contact leads as they
will not be used.
7. Determine the approximate mounting location(s)
for the emergency stop switch(es) and cut two
lengths of 16-gauge (minimum) stranded wire long
enough to connect the controller and switch(es).
Strip one end of each wire length and connect to
switch leads using wire nuts (not supplied).
Connect the two white leads from the switch to lead
from terminal 1. Connect the two black leads from
the switch to lead from terminal 1A.
8. Mount emergency stop switch(es) in desired
location(s). Use #6 round head wood screws (not
supplied). Use supplied machine screws when
mounting in a single-gang electrical box.
9. Route switch leads through controller port and
harness loops to circuit board terminal strip. Cut
2
11. Replace controller cover and hardware.
12. Check that the generator set master switch is in the
OFF position.
13. Reconnect the generator set engine starting
battery, negative (--) lead last.
14. Reconnect power to the battery charger, if
equipped.
Resetting Procedure
1. Replace glass rod on emergency stop switch (an
extra piece of glass is supplied with each switch).
Controller auxiliary lamp is on.
2. Move the generator set master switch to the OFF/
RESET position to reset the controller.
3. Move the generator set master switch to the RUN
position for local starting or to AUTO position for
startup by automatic transfer switch or remove
start switch.
Parts List
Qty. Description
Part Number
1
Switch, emergency stop
A-222654
2
Rod, glass*
2226554
* Part of A-222654 emergency stop switch. One glass rod is
installed on the switch and an additional replacement glass rod
is located inside the switch. Additional glass rods are available
as a service part.
TT-940
6/06
Industrial Generator Set Accessories
Remote Serial Annunciator II (RSA II)
Remote Serial Annunciator II (RSA II)
for Kohlerr Controllers
D
Monitors the generator set equipped with one of the following
controllers:
KPC 1000
Decision-Makerr 3+
Decision-Makerr 3000
Decision-Makerr 550
Decision-Makerr 6000
D
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:
/Aux.
MPACt 1000
MPACt 1500
Failure
D
Configuration via a personal computer (PC) software.
D
RSA II panel includes writable surfaces (four white boxes in
illustration) for user-defined selections.
D
Uses Modbusr protocol, an industry standard.
D
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)
D
RSA II
Meets the National Fire Protection Association Standard
NFPA 110, Level 1.
Dimensions
D
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:
203 x 203 x 56 (8.0 x 8.0 x 2.2)
Flush Mounted:
203 x 203 x 58 (8.0 x 8.0 x 2.3)
Flush mounting plate W1: 229 (9.0)
Modbusr is a registered trademark of Schneider Electric.
W
W
H
H
D
RSA II with ATS Controls
Surface Mounted
G6-95 7/11c
W1
Flush Mounted
D
Fault and Status Conditions
Overcrank Shutdown
System
Ready LED
Fault LEDs Fault Horn
Generator
Running LED
Communication
Status LED
Red
On
Red
Off
Green
High Engine Temperature Warning *
Yellow
On
Red
Green
Green
High Engine Temperature Shutdown
Red
On
Red
Off
Green
Low Oil 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 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
Red
On
Green
Off
Green
Yellow
Off
Green
Green or Off
Green
Red
On
Green
Off
Green
User Input #3 (Warning) (1) [
Yellow
Off
Green
Green or Off
Green
User Input #3 (Shutdown) (1) [
Red
On
Green
Off
Green
Yellow
Off
Green
Green
Green
—
Off
Green or Red
Green or Off
Red
Red
On
Red or Yellow
Green or Off
Green
User Input #1 (Shutdown)
User Input #2 (Warning)
User Input #2 (Shutdown)
EPS Supplying Load
Communications Status (Fault mode)
ATS Fault (RSA II with ATS Controls only)
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
ATS Controls (RSA II with ATS controls only)
D LED indicating lights for status, warning, and/or shutdown.
D ATS position LED (normal or emergency)
D Power source indicator LED (normal or emergency)
D
D
D
D
D
D
D
D
D
D
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:
d NFPA 110, level 1
d UL 508 recognized
d CE directive
d NFPA 99
d EN6II-4-4 fast transient immunity
RS-485 Modbusr isolated port @ 9.6/19.2/38.4/57.6 kbps
(default is 19.2 kbps)
USB device port
NEMA 2 enclosure
D ATS fault LED
D Key-operated spring-loaded test switch
(Re-Transfer/Auto/Test)
NFPA Requirements
D NFPA 110 compliant
D Engine functions:
(1) All generator set controllers except Decision-Makerr 3+ controller.
(2) Decision-Makerr 3+ controller only.
* May require optional kit or user-provided device to enable function and
LED indication.
[ Digital input #3 is factory-set for high battery voltage on the
Decision-Makerr 3+ controller.
Modbusr is a registered trademark of Schneider Electric.
d
d
d
d
d
d
d
d
d
d
d
d
High battery voltage warning *
High engine temperature shutdown
High engine temperature warning *
Low battery voltage warning *
Low coolant level/aux. shutdown
Low coolant temperature warning *
Low cranking voltage
Low fuel warning (level or pressure) *
Low oil pressure shutdown
Low oil pressure warning *
Overcrank shutdown
Overspeed shutdown
D General functions:
d Audible alarm silence
d Battery charger fault *
d Lamp test
d Master switch not-in-auto
G6-95 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 load.
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 horn will reactivate upon additional faults.
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-Makerr 3+ controller, the LED
indicates low coolant level or an auxiliary fault shutdown.
Requires user- supplied low coolant level switch on remote
radiator models.
Aux. See Low Coolant Level/Aux.
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.
Battery Charger Failure. LED lights if battery charger
malfunctions. Requires battery charger with alarm contact.
Low Cranking Voltage. LED lights if battery voltage drops
below preset level during engine cranking.
(High/Low) Battery Voltage. LED flashes if battery or
charging voltage drops below preset level. LED lights steady
if battery voltage exceeds preset level.
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.
Common Fault. LED lights when a single or multiple
common faults occur.
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.
ATS Fault. Red LED lights when ATS fails to transfer.
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-Makerr 550, 3000, and 6000 controllers) or when
transfer switch is in the emergency position
(Decision-Makerr 3+ controller).
Emergency Stop. LED lights and engine stops when
emergency stop is made. May require a local emergency
stop switch on some Decision-Makerr 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.
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 local or remote (generator set or ATS). The
user-defined digital input can be assigned at the controller or via
PC using SiteTecht setup software.
Communications (Shown with RSA II with ATS Controls)
Local Single (Master) Connection
Local Multiple (Master/Slave) Connections
A single RSA II connects directly to the controller’s
communication port with an RS-485 cable.
A single RSA II master connects directly to the controller’s
communication port with an RS-485 cable. Additional RSA IIs
(slaves) can connect to the single master RSA II. Status of the
RSA II (master) is annunciated on the RSA II (slave) panel.
Communication
Module
(16-light only)
Transfer Switch
Transfer Switch
Use RS-485,
see Note*
Use RS-485,
see Note*
Remote
annunciator
(master)
PC
(user-supplied)
Remote
annunciator
(master)
Generator set
controller
Communication
Module
(16-light only)
Generator set
controller
Use RS-485,
see Note*
Remote
annunciator
(slave)
Use RS-485, see Note* (Available on Decision-Makerr
550, 3000, and 6000 controllers only)
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 7/11c
Remote
annunciator
(slave)
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 (65) 6264-6422, Fax (65) 6264-6455
Modbusr/Ethernet, Single Master or Multiple Master/Slave Connections
(Shown with RSA II with ATS Controls)
Note: Combining RSA II remote annunciators with the RSA
1000 is permissible provided that the master remote
annunciator is an RSA II remote annunciator.
An RSA II master communicates with a controller and RSA II
slaves through an Ethernet network. A Modbusr/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 cable connects the Modbusr/Ethernet converter to
the Ethernet.
Note*: Use RS-485 for a total of up to 1220 m (4000 ft.) maximum
from the first device to the last device.
Modbusr/Ethernet
Converter
Remote Annunciator
(Master)
Generator set
Controller
Communication
Module
(16-light only)
Use RS-485,
see Note*
Use RS-485,
see Note*
Use RS-485,
see Note*
Modbusr/Ethernet
Converter
Ethernet
Use RS-485,
see Note*
Remote Annunciator
(Slave)
Modbusr/Ethernet
Converter
Transfer
Switch
Use RS-485,
see Note*
Modbusr/Ethernet
Converter
Accessories
- Power source adapter kit 120/208 VAC, 50/60 Hz.
- Modbusr/Ethernet converter GM41143-KP2 for serial to
Ethernet communication.
- Communication module GM32644-KA1 or GM32644-KP1 is
required with Decision-Makerr 3+ controllers.
Modbusr is a registered trademark of Schneider Electric.
DISTRIBUTED BY:
Availability is subject to change without notice. Kohler Co. reserves the
right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerr generator
set distributor for availability.
© 2009, 2009, 2011 by Kohler Co. All rights reserved.
G6-95 7/11c
Remote Annunciator
(Slave)
Industrial Generator Set Accessories
Float/Equalize
Battery Charger
Standard Features
•
•
•
•
Specifications
Installed Battery
NFPA 110 Alarm Outputs
PAD-292863
Battery Charger Kit
Input Voltage
Input Frequency
DC Voltage Regulation
Dimensions (L x W x D)
Weight
Yes
Kohler automatic battery chargers feature two
charging modes to keep lead-acid and nickelcadmium 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.
Output
Number of Cells
Voltage
Amps
Lead Acid
Ni-Cd
12
10
6
9
PAD-292863
120/240 VAC
120/240VAC, 50/60 Hz
±1%
271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.)
11.8 kg (26 lb.)
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 level.At the
preset equalize level, the battery charger switches to the
constant voltage Equalize Mode until the current required
to maintain this voltage drops to 50% of the battery
charger's high rate current.The battery charger then
switches to the lower constant voltage Float Mode when
the battery nears full charge. The battery charger
continues to operate in this mode until AC input power
disconnects or the current required to maintain the battery
at the float voltage setting exceeds 6 amps.
Temperature Compensation
The battery charger compensates for battery temperature
using a negative temperature coefficient. The battery
charger provides temperature compensation of -2mv/°C
per cell over the ambient temperature range of -40°C up
to 60°C. The temperature compensation automatically
adjusts the float and equalize voltage settings to prevent
the battery from overcharging at high ambient
temperatures and undercharging at low ambient
temperatures.
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 load to full load and AC input line voltage variations of ±10%.
•
UL-1012 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
Industrial Generator Set Accessories
Sound Enclosure
with Lift Base
Package
Sound Enclosure Standard Features
•
•
•
•
•
•
•
•
•
Internal-mounted critical silencer and flexible exhaust
connector.
Lift base-mounted or tank mounted aluminum
construction with hinged doors.
Fade-, scratch-, and corrosion-resistant Kohler®
Power Armor cream beige automotive-grade
textureed finish.
Enclosure has four large access doors which allow for
easy maintenance.
Lockable, flush-mounted door latches.
Vertical air inlet and outlet discharge to redirect air and
reduce noise.
Lift base or tank-mounted, aluminum construction with
hinged doors. Aluminum enclosures are
recommended for high humidity and/or high salt/
coastal regions.
Accoustic insulation that meets UL 94 HF1
flammability classification and repels moisture
absorption.
Sound attentuated enclosure that uses up to 51 mm
(2 in.) of acoustic insulation.
Sound Enclosure with Lift Base Package, continued
Sound Enclosure Features
•
Available in aluminum 3.2mm (0.125 in.) formed panel, solid construction. Preassembled package offering corrosion
resistant, dent resilient structure mounting directly to lift base or fuel tank.
• Power Armor automotive-grade finish resulting in advanced corrosion and abrasion protection as well as enhanced edge
coverage and color retention.
• Internal exhaust silencer offering maximum component life and operator safety.
• Interchangeable modular panel construction. Allows complete serviceability or replacement without compromising
enclosure design.
• Cooling/combustion air intake with a horizontal air inlet. Sized for maximum cooling airflow.
• Service access. Multi-personnel doors for easy access to generator set control and servicing of the fuel fill, fuel gauge, oil
fill and battery.
• Cooling air discharge. Weather protective design featuring vertical air discharge. Redircts cooling air up and above the
enclosure to reduce ambient noise.
• Attenuated design. Acoustic insulation UL 94 HF1 listed for flame resistance offering up to 51 mm (2 in.) mechanically
restrained acoustic insulation.
• Cooling air discharge. The sound enclosures include acoustic insulation with urethane film.
• Note: Installing an additional lenth of exhaust tail pipe may increase backpressure levels. Please refer to the generator set
spec sheet for the maximum backpressure value.
Fuel Tank
Est.
Max.
Max. Enclosure Enclosure Enclosure Enclosure Fuel
Sound
Max. Weight,
Capacity,
Fuel Length, Width, and Fuel
and Fuel
and Fuel
and Fuel
Tank Pressure Height, kg (lb.)
L (gal.)
Supply mm (in.) mm
Tank
Tank
Tank
Tank
Height with full
mm
Hours at
(in.)
Length, Width, mm Weight, kg Height, mm (H), mm load at 7m (in.)
60 Hz
mm (in.)
(in.)
(lb.)
(in.)
(in.)
(23ft.),
with Full
dB(A)
Load
Lift base
0
3532
1153 (45.4)
1724
1753 (69)
0 (0)
75
(139.0)
(3800)
Industrial Generator Set Accessories
Voltage Regulators
Voltage Regulators
The following information provides general features,
specifications, and functions of available voltage
regulators.
Integral Voltage Regulator with Kohler® Decision-Maker®
550 Controller and Menu-Driven Selections (20-3250 kW
Generator Set Models)
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.
The voltage regulator is integral to the controller and uses
microprocessor logic providing ±0.25% no-load to full-load
regulation using root-mean-square (RMS) voltage sensing.
The voltage regulator features three-phase sensing and is
available for 12- or 24-volt engine electrical systems.
Integral Voltage Regulator with Decision-Maker® 550 Controller
Voltage Regulators, continued
Specification/Feature
Integral 550 Controller
Generator Set Availability
20-3250 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
Software 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
±0.25%
Thermal Drift
less than 0.5% (-40 C to 70 C
range) [-40 F to 158 F]
Response Time
Less Than 5µS
Voltage Adjustment (of
system voltage)
±10%
Voltage Adjustment
Controller Keypad
Remote Voltage
Adjustment
Digital Input Standard/
Analog 0-5 VDC Input
Optional
Paralleling Capability
Reactive Droop Standard
VAR/PF Control Input
Standard
DVR® is a registered trademark of Marathon Electric Mfg. Corp.
Integral Voltage Regulator with Decision-Maker®
550 Controller
• A digital display and keypad provide access to data. A two-line
vacuum fluorescent display provides complete and concise
information.
• The controller provides an interface between the generator set and
switchgear for paralleling applications incorporating multiple
generator set and/or utility feeds.
• The controller can communicate with a personal computer directly or
on a network. See spec sheets G6-76, Monitor III Software for more
information.
• Using optional menu-driven, Windows®-based PC software, an
operator can monitor engine and alternator parameters and also
provide control capability.
• The controller supports Modbus® RTU (Remote Terminal Unit), an
industry standard open communication protocol.
• The controller provides ISO 8528-5, Class G3, compliance for
transient response on some 20-300 kW generator set models. See
the respective generator set spec sheet for specific applications.
Voltage Regulator Menu 11 Displays
Average voltage and voltage adjust
• Line-to-line voltage of each phase
Under frequency unload enabled, yes/no
• Frequency Setup
• Slope, volts per cycle
Reactive droop enabled, yes/no
• Voltage droop %
VAR control enabled, yes/no
• Total kVAR (running) kVAR Adjustment
• Generating/absorbing yes/no
Power factor control enabled, yes/no, droop at rated load
0.8 PF
• Average power factor (running), PF adjustment
• Lagging/leading, yes/no
Regulator gain adjustment
NA - Data not available at time of print.
Utility gain adjustment
Accessories
Reset regulator defaults, yes/no
Refer to the respective generator set spec sheet and your
authorized distributor for specific accessories.
Modbus® is a registered trademark of Schneider Electric.
Windows® is a registered trademark of Microsoft Corporation.
Decision-Maker® 550 Controller
•
Utility Paralleling, Protective Relay Functions
Model KCS-DFVC-0230S
MPAC® 1500 Controller
Standard Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Microprocessor-based controller
Environmentally sealed user interface
LCD display, 4 lines x 20 characters, backlit
Dynamic function keypad with tactile feedback pushbuttons
allows complete programming and viewing capability at the door
LED indicators: Source available, transfer switch position,
service required (fault), and “not in auto"
Broadrange voltage sensing (208-600 VAC) on all phases
Phase-to-phase sensing and monitoring with 0.5% accuracy on
both sources
Frequency sensing with 0.5% accuracy on both sources
Anti-single phasing protection
Phase rotation sensing for three-phase systems
Real-time clock with battery backup and automatic adjust for
daylight saving time and leap year
Time-stamped event log
Fail-safe transfer for loaded test and exercise functions
DIP switches: password disable and maintenance
Modbus® RTU and Modbus® TCP/IP protocols
(Modbus® register map available)
RJ45 connector for 10/100 ethernet connection
USB port with read/write compatibility
Isolated RS-485 ports
One-year limited warranty
Programmable Features
• Programming and monitoring methods:
o Monitoring and password-protected programming at
UL 1008 listed at 480 VAC file #E58962 (automatic), #E86894
the door using the keypad and display
(nonautomatic)
o Program and monitor using a PC with Monitor III
CSA certification available
integrated generator set and ATS monitoring software
IBC seismic certification available
o Transfer files through the USB port
Standard-transition or programmed-transition modes of
• System voltage and frequency
operation with either automatic or non-automatic control
• Voltage unbalance
Available in 2, 3, or 4 pole configurations
• Over/undervoltage and over/underfrequency for all phases of the
Electrically operated, mechanically held mechanism
normal and emergency sources
Double-throw, mechanically interlocked design (break-before• Adjustable time delays
make power contacts)
• Load/no load/auto-load test and load/no-load exercise functions
Solid, switched, or overlapping neutral (make-before-break)
• Programmable inputs and outputs
High withstand and close-on ratings
• Time-based and current-based† load control
Design suitable for emergency and standby applications on all • Load bank control for exercise or test
classes of load, 100% tungsten rated through 400 amps
• Pre/post-transfer, nine individual time delays for selected loads
Standard-transition transfer time less than 100 milliseconds (6 • ABC/BAC/none phase rotation selection with error detection
cycles @ 60 Hz)
• Resettable historical data
Silver alloy main contacts
• In-phase monitor
Gold-flashed engine start contacts rated 2 amps @ 30 VDC/250 • Password protection, 3 security levels
VAC
Front-accessible contacts for easy inspection
† Requires current sensing kit.
Front-replaceable main and arcing contacts (800-4000 amps)
Reliable, field-proven solenoid mechanism
Switching mechanisms lubricated for life
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
Transfer Switch Standard Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
KCS-DFVC-0230S, continued
User Interface LED Indicators
Communications
•
•
•
•
•
•
•
•
Contactor position: source N and source E
Source available: source N and source E
Service required (fault indication)
Not in automatic mode
LCD Display
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
System status
Line-to-line voltage
Line-to-neutral voltage
Active time delays
Source frequency
Preferred source selection
System settings
Common alarms
Load current, each phase†
Inputs and outputs
Faults
Time/date
Address
Event history
Maintenance records
Exerciser schedule
Exerciser mode
Time remaining on active exercise
Dynamic Function Tactile Keypad Operations
•
•
•
•
•
•
Scroll up/down/forward/back
Increase/decrease/save settings
End time delay
Start/end test
Reset fault
Lamp test
DIP Switches
• Maintenance mode
• Password disable
Event History
View up to 99 time and date-stamped events on the display or on
a personal computer equipped with optional Monitor III software.
Download up to 2000 events with Monitor III software or download
complete event history file to a PC or a memory device connected
to the USB port.
USB port with read/write capability
Isolated RS-485 ports
RJ-45 connector for 10/100 ethernet connection
Modbus® RTU and Modbus® TCP/IP protocols (Modbus®
register map available)
• USB Port. Upload or download files from a PC or a memory
device through the USB port.
o Application software
o Event history files
o Language files
o Parameter settings
o Usage reports
o Feature configuration
USB Data Logger
• Time-stamped voltage and frequency readings
• Minimum and maximum current and voltage readings for a
selected time period
Programmable Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
System voltage, 208 600 VAC *
System frequency, 50/60 Hz *
Single/three-phase operation *
Standard/programmed-transition operation *
Preferred source selection
Phase rotation: ABC/BAC/none selection with error detection
Voltage and frequency pickup and dropout settings
Voltage unbalance, enable/disable
In-phase monitor: enable/disable and phase angle
Transfer commit/no commit
Source/source mode: utility/gen, gen/gen, utility/utility, or utility/
gen/gen for 3-source systems
Passwords, system and test
Time, date, automatic daylight saving time enable/disable
Time delays (see table)
Exerciser: calendar mode, loaded/unloaded up to 21 events
Test: loaded/unloaded/auto load (1-60 minutes)
Remote test: loaded/unloaded
Automatic override on generator failure (loaded test and
exercise)
Peak shave delay enable/disable
Current monitoring †
Pre/post-transfer, 9 individual time delays for selected loads
Current-based load control settings: high/low current levels and
load add/remove priority for 9 separate loads †
Prime power sequence alternates between two generator sets
Resettable historical data
Main Logic Board Inputs and Outputs
•
• Two (2) programmable inputs
•
• Two (2) programmable outputs, isolated form C (SPDT) contacts
rated 1 amp @ 30 VDC, 500 mA @120 VAC
* System parameters factory-set per order.
Main Board I/O Specifications
Output contact type
Isolated form C (SPDT)
Output contact rating
1 amp @ 30 VDC, 500 mA @ 120 VAC
I/O terminals wire size range #12-24 AWG
† Requires optional current sensing kit
Modus® is a registered trademark of Schneider Electric.
KCS-DFVC-0230S, continued
Programmable Inputs
•
•
•
•
•
External time delay input
External battery fault
External common fault
Inhibit transfer
Load shed to force transfer to OFF (programmed-transition
models only; requires accessory)
• Peak shave/area protection input
• External test
• Three-source system disable
Programmable Outputs
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Chicago alarm control
Common alarm events
Contactor position
Exercise active
Failure to acquire standby source
Failure to transfer
Generator engine start, source N and E
I/O module faults
Load bank control
Load control active (pre/post transfer delay, up to 9 outputs)
Loss of phase fault, source N and E
External battery fault
Non-emergency transfer
Not in automatic mode
Over/underfrequency faults, source N and E (generator)
Over/undervoltage faults, source N and E
Peak shave/area protection active
Phase rotation error, source N and E
Preferred source supplying load
Software-controlled relay outputs (4 maximum)
Source available, preferred and standby
Standby source supplying load
Synchronizing output
Test active
Transfer switch auxiliary contact fault
Transfer switch auxiliary contact open
Voltage unbalance
Voltage and Frequency Sensing
Parameter
Default
Adjustment Range
Undervoltage dropout
90% of pickup
75%-98%
Undervoltage pickup
90% of nominal
85%-100%
Overvoltage dropout *
115% of nominal* 106%-135%
Overvoltage pickup
95% of dropout
95%-100%
Unbalance enable
Disable
Enable/Disable
Unbalance dropout
20%
5%-20%
Unbalance pickup
10%
3%-18%
Voltage dropout time
0.5 sec.
0.1-9.9 sec.
Underfrequency dropout
99% of pickup
95%-99%
Underfrequency pickup
90% of nominal
80%-95%
Overfrequency dropout
101% of pickup
101%-115%
Overfrequency pickup
110% of nominal 105%-120%
Frequency dropout time
3 sec.
0.1-15 sec.
* 690 volts, maximum. Default = 110% for 600 volt applications.
Adjustable Time Delays
Time Delays
Default Adjustment Range
Engine start, Source S2
3 sec. 0-60 sec. †
Engine start, Source S1 (gen/gen)3 sec.
Engine cooldown, Source S2
5 sec.
Engine cooldown, S1 (gen/gen) 2 sec.
Fail to acquire standby source
1 min. 0-60 min.
Fail to acquire preferred source 1 min.
Transfer, preferred to standby
3 sec.
Transfer, standby to preferred
15 min.
Transfer,off to standby
1 sec.
Transfer, off to preferred
1 sec.
Fail to synchronize
30 sec.
Auto load test duration
30 min. 1-60 min.
(1 min. increments)
Prime power run duration
0 min. 6 min. - 100 days.
(6 min. increments)
Load control Time Delays:
Pretransfer to preferred
0 sec.
Post-transfer to preferred
0 sec.
Pretransfer to standby
0 sec. 0-60 min.
Post-transfer to standby
0 sec.
Load add Source1/Source2
0 sec.
Load remove Source1/Source2 0 sec.
Note: Time delays are adjustable in 1 second increments, except
as noted.
† Engine start can be extended to 60 minutes with an External
Battery Supply Module Kit.
KCS-DFVC-0230S, continued
Note: Data is subject to change. Refer to the transfer switch
dimension drawings and wiring diagrams for planning and
installation.
Environmental Specifications
Operating Temperature
-20°C to 70°C (-4°F to 158°F)
Storage Temperature
-40°C to 85°C (-40°F to 185°F)
Humidity
5% to 95% noncondensing
Input and Output Connection Specifications
Component
Wire Size Range
Main board I/O terminals
#12-24 AWG
I/O module terminals
#14-24 AWG
UL-Listed Solderless Screw-Type Terminals for
External Power Connections
Normal, Emergency, and Load Terminals
Switch
Normal,
Neutral (3Ground
Rating, Emergency and
pole)
Amps
Load (per
phase)
0230
(1) #4 AWG to (3) #4 AWG to (3) #4 AWG
600 KCMIL OR 600KCMIL OR
to 600
(2) 1/0- TO 250 (6) 1/0- TO 250 KCMIL or (6)
KCMIL
KCMIL
1/0- to 250
KCMIL
Use 75 degree C minimum Cu/AL wire for power connections
Auxiliary Position Indicating Contacts
(rated 10 Amps @ 32 VDC/250 VAC)
Number of Contacts Indicating
Switch Rating
Normal, Emergency
(Amps)
Standard
0230
2, 2
Ground Bus, Mechanical Lugs (Optional)
Switch Rating, amps Range of Wire Sizes
0230
#14 to 1/0 AWG
Codes and Standards
• The ATS meets or exceeds the requirements of the following
specifications:
• CSA C22.2 No. 178 certification at 600 VAC available, file
#LR58301
• EN61000-4-4 Fast Transient Immunity Severity Level 4
• EN61000-4-5 Surge Immunity Class 4 (voltage sensing and
programmable inputs only)
• EIC Spedifications 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 1000-4-4, Electrical Fast Transients (Bursts)
o IEC 1000-4-5, Surge Voltage
o IEC 1000-4-6, Conducted RF Disturbances
o IEC 1000-4-8, Magnetic Fields
o IEC 1000-4-11, Voltage Dips and Interruptions
• IEC 60947-6-1, Low Voltage Switchgear and Control Gear;
Multifunction Equipment; Automatic Transfer Switching
Equipment
• IEEE Standards 446, IEEE Recommended Practice for
Emergency and Standby Power Systems for Commercial and
Industrial Applications
• IEEE 472 (ANSI C37.90A) Ring Wave Test
• NEMA Standard 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
• Underwriters Laboratories UL 508, Standard for Industrial
Control Equipment
• Underwriters Laboratores UL 1008, Standard for Automatic
Transfer Switches for Use in Emergency Standby Systems fil
#E58962 (automatic), #E86894 (nonautomatic)
Weights and Dimensions
See ADV drawings for weights and dimensions. Allow 15% additional weight for packing materials.
KCS-DFVC-0230S, continued
Withstand and Close-On Ratings (WCR)
Standard 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 Kohler Co.
for assistance.
Withstand Current Ratings in RMS Symmetrical Amperes
Any Circuit Breaker
Current-Limiting Fuses
Fuse Rating, Max. Voltage, Max. Amps
Fuse Class Amps, Max. Max. Voltage, Short Time
Amps
VAC
VAC
Withstand
Ratings**
100000
480
300
J
10000
480
N/A
100000
600
600
J
35000
600
N/A
100000
600
800
L
35000
600
N/A
Short Time
Duration,
Cycles
-
* Any breaker ratings are based on 1.5 cycles for 30-230 amps. Applicable to breakers with instantaneous trip elements.
**Short time ratings are provided for applications involving breakers that do not have instantaneous trips for systems coordination.
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.
WCR, amps RMS Voltage, Max.
Molded-Case Circuit Breakers
Manufacturer
Type
42000
22000
22000
22000
22000
22000
22000
240
480
480
480
480
480
480
Square D
GE
GE
GE
GE
ITE
ITE
22000
22000
22000
22000
22000
22000
22000
22000
22000
42000
42000
42000
42000
42000
42000
42000
480
480
480
480
480
480
480
480
480
600
600
600
600
600
600
600
Square D
Square D
Square D
Cutler-Hammer
Cutler-Hammer
Cutler-Hammer
ABB
Merlin Gerin
Merlin Gerin
Cutler-Hammer
Cutler-Hammer
Cutler-Hammer
GE
GE
GE
Siemens
JG
TEL, THED, THLC1
TFL, THFK, THLC2
SFL, SFP, TFJ, TFK
SGL4, SGP4, TLB4
CFD6, FD6, FXD6, HFD6
CJD6, HHJD6, HHJXD6, HJD6, JD6, JXD6,
SCJD6, SHJD6, SJD6
KA, KC, KH, KI
LC, LI
LA, LH
FD, FDC, HFD
HJD, JD, JDB, JDC
LCL, Tri-Pac LA, HKD, KD, KDB, KDC
S3
CF250
CJ400
HJD, JGC
KDC
LDC, CLDC
TBC4
TBC6, SGL1, SGL4, SGL6, SGP1, SGP4, SGP6
TBC8, TKL4V, TKL8S-12S, SKL8, SKP8
HLMD, HLMXD, HMD, HMXD, SHMD
Max. Size,
Amps
250
150
225
250
400
250
400
250
300
400
150
250
400
150
250
400
250
400
600
400
600
800
800
KCS-DFVC-0230S, continued
Standard-transition models KCS only.
KCS-DFVC-0230S, continued
Accessories
Accessories are available either factory-installed or as loose kits, unless otherwise noted.
Accessory Modules
Warranty
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 Specification, mA
Alarm Module
75
Standard I/O Module
75
High Power I/O Module
100
Standard Input/Output Module
Inputs
Available Inputs
Input Definition
Current
Connection Type
Wire Size
Max Distance
Outputs
Outputs Available
Contact Type
Contact Voltage Rating
Connection Type
Wire Size
Warranty
•
Warranty-1-year
2
Contact closure
5 mA Max
Terminal Strip
#14-24 AWG
700 feet
6
Form C (SPDT)
2 A @ 30 VDC
500 mA @ 125 VAC
Terminal Strip
#14-24 AWG
•
Warranty-2-year
KCS-DFVC-0230S, continued
K
C
S
D
F
V
C
0
2
3
0
S
Model KCS-DFVC-0400B
MPAC® 1500 Controller
Standard Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Microprocessor-based controller
Environmentally sealed user interface
LCD display, 4 lines x 20 characters, backlit
Dynamic function keypad with tactile feedback pushbuttons
allows complete programming and viewing capability at the door
LED indicators: Source available, transfer switch position,
service required (fault), and “not in auto"
Broadrange voltage sensing (208-600 VAC) on all phases
Phase-to-phase sensing and monitoring with 0.5% accuracy on
both sources
Frequency sensing with 0.5% accuracy on both sources
Anti-single phasing protection
Phase rotation sensing for three-phase systems
Real-time clock with battery backup and automatic adjust for
daylight saving time and leap year
Time-stamped event log
Fail-safe transfer for loaded test and exercise functions
DIP switches: password disable and maintenance
Modbus® RTU and Modbus® TCP/IP protocols
(Modbus® register map available)
RJ45 connector for 10/100 ethernet connection
USB port with read/write compatibility
Isolated RS-485 ports
One-year limited warranty
Programmable Features
• Programming and monitoring methods:
o Monitoring and password-protected programming at
UL 1008 listed at 480 VAC file #E58962 (automatic), #E86894
the door using the keypad and display
(nonautomatic)
o Program and monitor using a PC with Monitor III
CSA certification available
integrated generator set and ATS monitoring software
IBC seismic certification available
o Transfer files through the USB port
Standard-transition or programmed-transition modes of
• System voltage and frequency
operation with either automatic or non-automatic control
• Voltage unbalance
Available in 2, 3, or 4 pole configurations
• Over/undervoltage and over/underfrequency for all phases of the
Electrically operated, mechanically held mechanism
normal and emergency sources
Double-throw, mechanically interlocked design (break-before• Adjustable time delays
make power contacts)
• Load/no load/auto-load test and load/no-load exercise functions
Solid, switched, or overlapping neutral (make-before-break)
• Programmable inputs and outputs
High withstand and close-on ratings
• Time-based and current-based† load control
Design suitable for emergency and standby applications on all • Load bank control for exercise or test
classes of load, 100% tungsten rated through 400 amps
• Pre/post-transfer, nine individual time delays for selected loads
Standard-transition transfer time less than 100 milliseconds (6 • ABC/BAC/none phase rotation selection with error detection
cycles @ 60 Hz)
• Resettable historical data
Silver alloy main contacts
• In-phase monitor
Gold-flashed engine start contacts rated 2 amps @ 30 VDC/250 • Password protection, 3 security levels
VAC
Front-accessible contacts for easy inspection
† Requires current sensing kit.
Front-replaceable main and arcing contacts (800-4000 amps)
Reliable, field-proven solenoid mechanism
Switching mechanisms lubricated for life
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
Transfer Switch Standard Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
KCS-DFVC-0400B, continued
User Interface LED Indicators
Communications
•
•
•
•
•
•
•
•
Contactor position: source N and source E
Source available: source N and source E
Service required (fault indication)
Not in automatic mode
LCD Display
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
System status
Line-to-line voltage
Line-to-neutral voltage
Active time delays
Source frequency
Preferred source selection
System settings
Common alarms
Load current, each phase†
Inputs and outputs
Faults
Time/date
Address
Event history
Maintenance records
Exerciser schedule
Exerciser mode
Time remaining on active exercise
Dynamic Function Tactile Keypad Operations
•
•
•
•
•
•
Scroll up/down/forward/back
Increase/decrease/save settings
End time delay
Start/end test
Reset fault
Lamp test
DIP Switches
• Maintenance mode
• Password disable
Event History
View up to 99 time and date-stamped events on the display or on
a personal computer equipped with optional Monitor III software.
Download up to 2000 events with Monitor III software or download
complete event history file to a PC or a memory device connected
to the USB port.
USB port with read/write capability
Isolated RS-485 ports
RJ-45 connector for 10/100 ethernet connection
Modbus® RTU and Modbus® TCP/IP protocols (Modbus®
register map available)
• USB Port. Upload or download files from a PC or a memory
device through the USB port.
o Application software
o Event history files
o Language files
o Parameter settings
o Usage reports
o Feature configuration
USB Data Logger
• Time-stamped voltage and frequency readings
• Minimum and maximum current and voltage readings for a
selected time period
Programmable Features
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
System voltage, 208 600 VAC *
System frequency, 50/60 Hz *
Single/three-phase operation *
Standard/programmed-transition operation *
Preferred source selection
Phase rotation: ABC/BAC/none selection with error detection
Voltage and frequency pickup and dropout settings
Voltage unbalance, enable/disable
In-phase monitor: enable/disable and phase angle
Transfer commit/no commit
Source/source mode: utility/gen, gen/gen, utility/utility, or utility/
gen/gen for 3-source systems
Passwords, system and test
Time, date, automatic daylight saving time enable/disable
Time delays (see table)
Exerciser: calendar mode, loaded/unloaded up to 21 events
Test: loaded/unloaded/auto load (1-60 minutes)
Remote test: loaded/unloaded
Automatic override on generator failure (loaded test and
exercise)
Peak shave delay enable/disable
Current monitoring †
Pre/post-transfer, 9 individual time delays for selected loads
Current-based load control settings: high/low current levels and
load add/remove priority for 9 separate loads †
Prime power sequence alternates between two generator sets
Resettable historical data
Main Logic Board Inputs and Outputs
•
• Two (2) programmable inputs
•
• Two (2) programmable outputs, isolated form C (SPDT) contacts
rated 1 amp @ 30 VDC, 500 mA @120 VAC
* System parameters factory-set per order.
Main Board I/O Specifications
Output contact type
Isolated form C (SPDT)
Output contact rating
1 amp @ 30 VDC, 500 mA @ 120 VAC
I/O terminals wire size range #12-24 AWG
† Requires optional current sensing kit
Modus® is a registered trademark of Schneider Electric.
KCS-DFVC-0400B, continued
Programmable Inputs
•
•
•
•
•
External time delay input
External battery fault
External common fault
Inhibit transfer
Load shed to force transfer to OFF (programmed-transition
models only; requires accessory)
• Peak shave/area protection input
• External test
• Three-source system disable
Programmable Outputs
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Chicago alarm control
Common alarm events
Contactor position
Exercise active
Failure to acquire standby source
Failure to transfer
Generator engine start, source N and E
I/O module faults
Load bank control
Load control active (pre/post transfer delay, up to 9 outputs)
Loss of phase fault, source N and E
External battery fault
Non-emergency transfer
Not in automatic mode
Over/underfrequency faults, source N and E (generator)
Over/undervoltage faults, source N and E
Peak shave/area protection active
Phase rotation error, source N and E
Preferred source supplying load
Software-controlled relay outputs (4 maximum)
Source available, preferred and standby
Standby source supplying load
Synchronizing output
Test active
Transfer switch auxiliary contact fault
Transfer switch auxiliary contact open
Voltage unbalance
Voltage and Frequency Sensing
Parameter
Default
Adjustment Range
Undervoltage dropout
90% of pickup
75%-98%
Undervoltage pickup
90% of nominal
85%-100%
Overvoltage dropout *
115% of nominal* 106%-135%
Overvoltage pickup
95% of dropout
95%-100%
Unbalance enable
Disable
Enable/Disable
Unbalance dropout
20%
5%-20%
Unbalance pickup
10%
3%-18%
Voltage dropout time
0.5 sec.
0.1-9.9 sec.
Underfrequency dropout
99% of pickup
95%-99%
Underfrequency pickup
90% of nominal
80%-95%
Overfrequency dropout
101% of pickup
101%-115%
Overfrequency pickup
110% of nominal 105%-120%
Frequency dropout time
3 sec.
0.1-15 sec.
* 690 volts, maximum. Default = 110% for 600 volt applications.
Adjustable Time Delays
Time Delays
Default Adjustment Range
Engine start, Source S2
3 sec. 0-60 sec. †
Engine start, Source S1 (gen/gen)3 sec.
Engine cooldown, Source S2
5 sec.
Engine cooldown, S1 (gen/gen) 2 sec.
Fail to acquire standby source
1 min. 0-60 min.
Fail to acquire preferred source 1 min.
Transfer, preferred to standby
3 sec.
Transfer, standby to preferred
15 min.
Transfer,off to standby
1 sec.
Transfer, off to preferred
1 sec.
Fail to synchronize
30 sec.
Auto load test duration
30 min. 1-60 min.
(1 min. increments)
Prime power run duration
0 min. 6 min. - 100 days.
(6 min. increments)
Load control Time Delays:
Pretransfer to preferred
0 sec.
Post-transfer to preferred
0 sec.
Pretransfer to standby
0 sec. 0-60 min.
Post-transfer to standby
0 sec.
Load add Source1/Source2
0 sec.
Load remove Source1/Source2 0 sec.
Note: Time delays are adjustable in 1 second increments, except
as noted.
† Engine start can be extended to 60 minutes with an External
Battery Supply Module Kit.
KCS-DFVC-0400B, continued
Note: Data is subject to change. Refer to the transfer switch
dimension drawings and wiring diagrams for planning and
installation.
Environmental Specifications
Operating Temperature
-20°C to 70°C (-4°F to 158°F)
Storage Temperature
-40°C to 85°C (-40°F to 185°F)
Humidity
5% to 95% noncondensing
Input and Output Connection Specifications
Component
Wire Size Range
Main board I/O terminals
#12-24 AWG
I/O module terminals
#14-24 AWG
UL-Listed Solderless Screw-Type Terminals for
External Power Connections
Normal, Emergency, and Load Terminals
Switch
Normal,
Neutral (3Ground
Rating, Emergency and
pole)
Amps
Load (per
phase)
0400
(1) #4 AWG to (3) #4 AWG to (3) #4 AWG
600 KCMIL OR 600KCMIL OR
to 600
(2) 1/0- TO 250 (6) 1/0- TO 250 KCMIL or (6)
KCMIL
KCMIL
1/0- to 250
KCMIL
Use 75 degree C minimum Cu/AL wire for power connections
Auxiliary Position Indicating Contacts
(rated 10 Amps @ 32 VDC/250 VAC)
Number of Contacts Indicating
Switch Rating
Normal, Emergency
(Amps)
Standard
0400
8, 8
Ground Bus, Mechanical Lugs (Optional)
Switch Rating, amps Range of Wire Sizes
0400
#14 to 1/0 AWG
Codes and Standards
• The ATS meets or exceeds the requirements of the following
specifications:
• CSA C22.2 No. 178 certification at 600 VAC available, file
#LR58301
• EN61000-4-4 Fast Transient Immunity Severity Level 4
• EN61000-4-5 Surge Immunity Class 4 (voltage sensing and
programmable inputs only)
• EIC Spedifications 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 1000-4-4, Electrical Fast Transients (Bursts)
o IEC 1000-4-5, Surge Voltage
o IEC 1000-4-6, Conducted RF Disturbances
o IEC 1000-4-8, Magnetic Fields
o IEC 1000-4-11, Voltage Dips and Interruptions
• IEC 60947-6-1, Low Voltage Switchgear and Control Gear;
Multifunction Equipment; Automatic Transfer Switching
Equipment
• IEEE Standards 446, IEEE Recommended Practice for
Emergency and Standby Power Systems for Commercial and
Industrial Applications
• IEEE 472 (ANSI C37.90A) Ring Wave Test
• NEMA Standard 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
• Underwriters Laboratories UL 508, Standard for Industrial
Control Equipment
• Underwriters Laboratores UL 1008, Standard for Automatic
Transfer Switches for Use in Emergency Standby Systems fil
#E58962 (automatic), #E86894 (nonautomatic)
Weights and Dimensions
See ADV drawings for weights and dimensions. Allow 15% additional weight for packing materials.
KCS-DFVC-0400B, continued
Withstand and Close-On Ratings (WCR)
Standard 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 Kohler Co.
for assistance.
Withstand Current Ratings in RMS Symmetrical Amperes
Any Circuit Breaker
Current-Limiting Fuses
Fuse Rating, Max. Voltage, Max. Amps
Fuse Class Amps, Max. Max. Voltage, Short Time
Amps
VAC
VAC
Withstand
Ratings**
200000
600
600
J
35000
600
N/A
200000
600
600
J
42000
480
N/A
200000
600
600
J
65000
240
N/A
200000
600
800
L
35000
600
N/A
200000
600
800
L
42000
480
N/A
200000
600
800
L
65000
240
N/A
Short Time
Duration,
Cycles
-
* Any breaker ratings are based on 1.5 cycles for 30-230 amps. Applicable to breakers with instantaneous trip elements.
**Short time ratings are provided for applications involving breakers that do not have instantaneous trips for systems coordination.
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.
WCR, amps RMS Voltage, Max.
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
50000
42000
42000
42000
42000
42000
42000
480
480
480
480
480
480
480
480
480
480
480
480
480
480
480
600
600
600
600
600
600
Molded-Case Circuit Breakers
Manufacturer
Type
Cutler-Hammer
Cutler-Hammer
Cutler-Hammer
GE
GE
GE
GE
GE
Siemens
Siemens
Siemens
Siemens
Square D
Square D
Square D
Cutler-Hammer
Cutler-Hammer
GE
GE
GE
Siemens
HKD, CHKD, KDC
HLD, CHLD, LDC, CLDC
MDL, CMDL, HMDL, CHMDL, NGS, NGH, NGC
TBC4
TBC6, TJL4V, TJL1S-6S
SGL1, SGL4, SGL6, SGP1, SBP4, SBP6
TBC8, TKL4V, TKH8S-12S, TKL8S-12S
SKH8, SKL8, SKP8
HJD, HJXD, SHJD
HLD, HLXD, SHLD
LMD, LMXK, HLMD, HLMXD, HMG
MD, MXD, HMD, HMXD, SMD, SHMD
CK400N, CK400NN, CM1250HH
LC
CK800N, CK800NN, CM1600HH
KDC
LDC, CLDC
TBC4
TBC6, SGL1, SGL4, SGL6, SGP1, SGP4, SGP6
TBC8, TKL4V, TKL8S-12S, SKL8, SKP8
HMLD, HLMXD, HMD, HMXD, SHMD
Max. Size,
Amps
400
600
800
400
600
600
800
800
400
600
800
800
400
600
800
400
600
400
600
800
800
KCS-DFVC-0400B, continued
KCS-DFVC-0400B, continued
Accessories
Accessories are available either factory-installed or as loose kits, unless otherwise noted.
Accessory Modules
Warranty
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 Specification, mA
Alarm Module
75
Standard I/O Module
75
High Power I/O Module
100
Standard Input/Output Module
Inputs
Available Inputs
Input Definition
Current
Connection Type
Wire Size
Max Distance
Outputs
Outputs Available
Contact Type
Contact Voltage Rating
Connection Type
Wire Size
Warranty
•
Warranty-1-year
2
Contact closure
5 mA Max
Terminal Strip
#14-24 AWG
700 feet
6
Form C (SPDT)
2 A @ 30 VDC
500 mA @ 125 VAC
Terminal Strip
#14-24 AWG
•
Warranty-2-year
KCS-DFVC-0400B, continued
K
C
S
D
F
V
C
0
4
0
0
B
Alternator Data
TIB-102
TECHNICAL INFORMATION BULLETIN
Alternator Data Sheet
Alternator Model:
Frequency:
Speed:
Leads:
4S12X
60 Hz
1800 RPM
12 (6 Lead, 600 Volt)
kW* (kVA)
Class B
Voltage
L--N/L--L
Factor
Connection
3
0.8
Wye
139/240
80°C
90°C
95°C
105°C
130°C
125°C
150°C
Lloyds
ABS
Continuous
Standby
Continuous
Standby
277/480
127/220
3
0.8
3
0.8
3
0.8
120/240
347/600
3
1
3
160.0
168.0
181.0
178.5
189.0
(200.0)
(210.0)
(226.0)
(223.0)
(236.0)
136.0
143.0
146.5
152.5
164.0
162.0
171.5
(170.0)
(178.5)
(183.0)
(190.5)
(205.0)
(202.5)
(214.0)
130.0
136.5
139.0
144.0
154.5
152.5
161.5
(162.5)
(170.5)
(173.5)
(180.0)
(193.0)
(190.5)
(201.5)
118.5
124.5
126.5
131.0
140.5
139.0
147.0
(148.0)
(155.5)
(158.0)
(163.5)
(175.5)
(173.5)
(183.5)
Wye
220/380
120/240
155.0
(193.5)
Wye
240/416
110/190
146.5
(183.0)
Wye
254/440
120/208
0.8
130.0
136.5
139.0
144.0
154.5
152.5
161.5
(162.5)
(170.5)
(173.5)
(180.0)
(193.0)
(190.5)
(201.5)
Delta
1.0
81.0
90.5
95.0
105.0
106.0
106.0
106.0
(81.0)
(90.5)
(95.0)
(105.0)
(106.0)
(106.0)
(106.0)
Dogleg
0.8
Class H
Continuous
Power
Phase
Class F
135.0
143.0
147.0
155.0
172.0
168.0
180.0
(169.0)
(179.0)
(184.0)
(194.0)
(215.0)
(210.0)
(225.0)
Wye
* All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice
and without any obligation or liability whatsoever.
Submittal Data: 139/240 Volts, 0.8 PF, 1800 RPM, 60 Hz, 3 Phase, 130°C Rise
Symbol
PerUnit
Ohms
Typical Cold Resistances
Symbol
Value
Typical Time Constants
Phase Resistance
0.031
0.008
Armature Short Circuit
Ta
0.012 sec.
Rotor Resistance
20.58
5.239
Transient Short Circuit
T’d
0.154 sec.
Transient Open Circuit
Typical Field Current
T’do
1.728 sec.
IfFL
21.1 amps
Typical Reactances
Synchronous
Direct
Xd
4.982
1.268
Quadrature
Xq
2.468
0.628
Transient
Unsaturated
X’du
0.504
0.128
Saturated
X’d
0.443
0.113
Subtransient
Direct
X’’d
0.171
0.044
X’’q
0.169
0.043
Negative Sequence
X2
0.17
0.043
Zero Sequence
X0
0.013
0.003
Quadrature
TIB-102
Full Load
No Load
Typical Short Circuit Ratio
IfNL
3.8 amps
0.201
Harmonic Distortion
RMS Total Harmonic Distortion
4.04%
Max. Single Harmonic
5th
Deviation Factor (No Load, L--L)
<5%
Telephone Influence Factor
Insulation Class
<50
per NEMA MG1--1.66
Phase Rotation
H
4S12X 60 Hz 11/11p
ABC
1
4S12X, 60 Hz, 139/240, 277/480 Volts, Wye
TYPICAL ALTERNATOR EFFICIENCY*
100
98
96
% Efficiency
94
92
90
88
0.8 PF
86
84
82
80
0
25
50
75
100
125
150
175
200
Output (KW)
4S12X, 60 Hz, 139/240, 277/480 Volts, Wye
TYPICAL MOTOR STARTING CHARACTERISTICS*
40
35
% Voltage Dip
30
25
20
15
10
5
0
0
100
200
300
400
500
600
700
Locked Rotor KVA
* All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice
and without any obligation or liability whatsoever.
2
4S12X 60 Hz 11/11p
TIB-102
4S12X, 60 Hz, Low Wye or Delta Connection
SHORT CIRCUIT DECREMENT CURVE
TIB-102
4S12X 60 Hz 11/11p
3
Sound Data
TIB-114
TECHNICAL INFORMATION BULLETIN
Generator Set Sound Data Sheet
Sound Pressure Data in dB(A)
Generator
Set Model
Hz
150REOZJF
60
Load
100% Load
No Load
Raw Exhaust
99.6
90.1
Open Unit,
Isolated Exhaust
Weather
Enclosure
Sound
Enclosure
88.4
87.7
86.5
85.8
75.6
73.7
Note: Sound pressure data is the logarithmic average of eight perimeter measurement points at a distance of 7 m (23 ft.),
except Raw Exhaust data which is a single measurement point at 1 m (3.3 ft.) from the mouth of a straight pipe exhaust.
150REOZJF
60 Hz
Sound Pressure Levels dB(A)
Load
100%
Load
Distance,
m (ft.)
7 (23)
Enclosure
Sound
Octave Band Center Frequency (Hz)
Measurement
Position
63
125
250
500
1000
2000
4000
8000
Overall
Level
Right
Front--Right
Front
Front--Left
Left
Back--Left
Back
Back--Right
53.2
61.7
59.5
57.5
59.6
61.8
54.8
63.5
63.0
66.3
64.6
64.1
66.5
68.0
61.0
68.0
66.7
67.6
66.0
69.1
70.0
68.3
72.0
67.6
70.3
72.4
70.4
72.2
69.5
68.2
69.3
69.1
67.0
66.7
68.6
67.4
66.8
67.4
69.0
68.0
66.9
65.5
66.7
66.6
66.7
66.5
66.2
66.0
63.2
61.7
64.4
65.1
65.0
64.1
60.8
61.3
55.4
52.8
53.2
55.8
57.7
56.7
57.2
56.4
74.8
75.9
75.3
76.2
75.7
75.4
76.0
75.4
8--pos. log avg.
60.1
65.7
68.8
70.4
67.7
66.4
63.5
55.9
75.6
Sound Pressure Levels dB(A)
Load
Distance,
m (ft.)
Enclosure
Measurement
Position
Right
Front-Right
Front
Front-Left
Left
Back-Left
Back
Back-Right
8--pos.
log avg.
100%
Load
7 (23)
Weather
Overall Levels
86.5
87.4
81.3
87.6
86.9
87.3
85.4
86.6
86.5
Sound Pressure Levels dB(A)
Load
100%
Load
Distance,
m (ft.)
7 (23)
Open Unit,
Isolated
Exhaust
Octave Band Center Frequency (Hz)
Measurement
Position
63
125
250
500
1000
2000
4000
8000
Overall
Level
Right
Front--Right
Front
Front--Left
Left
Back--Left
Back
Back--Right
54.7
51.4
51.6
48.5
48.4
47.5
48.4
52.2
64.5
65.6
63.0
61.8
61.1
63.3
64.2
65.3
79.1
72.8
75.6
74.2
76.5
79.6
78.1
80.6
79.3
81.2
80.0
79.1
81.6
81.0
83.0
81.5
80.8
82.8
75.4
85.3
81.8
82.4
81.6
81.3
82.6
83.6
75.0
83.6
82.9
82.4
76.9
82.5
78.9
81.2
70.9
81.9
80.8
81.2
74.8
79.6
75.2
76.3
65.3
76.3
76.2
76.1
67.8
73.5
88.4
89.3
83.2
89.5
88.8
89.2
87.3
88.5
8--pos. log avg.
51.0
63.8
77.8
81.0
82.1
82.0
79.7
74.6
88.4
Sound Pressure Levels dB(A)
Load
Distance,
m (ft.)
100%
Load
1 (3.3)
TIB-114
Exhaust
Raw Exhaust (No Silencer)
Octave Band Center Frequency (Hz)
63
125
250
500
1000
2000
4000
8000
Overall
Level
65.9
77.8
83.6
88.2
92.8
94.7
93.6
91.2
99.6
150REOZJF 60 Hz 8/12
1
150REOZJF
60 Hz
Sound Pressure Levels dB(A)
Load
No
Load
Distance,
m (ft.)
7 (23)
Enclosure
Sound
Level 2
Octave Band Center Frequency (Hz)
Measurement
Position
63
125
250
500
1000
2000
4000
8000
Overall
Level
Right
Front--Right
Front
Front--Left
Left
Back--Left
Back
Back--Right
49.4
47.8
51.7
49.2
53.0
53.2
50.7
53.9
59.2
56.9
58.9
57.7
59.2
60.4
57.9
61.2
64.9
66.6
65.4
68.3
68.4
63.6
71.3
66.9
69.6
71.7
70.1
71.7
68.1
67.6
68.7
68.5
65.5
66.0
67.6
65.7
64.1
65.5
67.8
66.4
64.3
63.8
64.6
63.8
63.4
63.6
63.4
63.4
55.2
55.7
57.4
57.1
56.5
56.5
56.6
55.5
48.8
46.9
47.8
48.1
48.8
47.5
48.2
46.7
73.0
74.3
73.8
74.6
73.0
72.0
74.8
73.1
8--pos. log avg.
51.6
59.1
67.6
69.8
66.2
63.8
56.4
47.9
73.7
Sound Pressure Levels dB(A)
Load
Distance,
m (ft.)
Enclosure
Measurement
Position
Right
Front-Right
Front
Front-Left
Left
Back-Left
Back
Back-Right
8--pos.
log avg.
No
Load
7 (23)
Weather
Overall Levels
85.0
86.9
83.0
86.3
86.4
86.7
84.2
86.2
85.8
Sound Pressure Levels dB(A)
Load
No
Load
Distance,
m (ft.)
7 (23)
Open Unit,
Isolated
Exhaust
Octave Band Center Frequency (Hz)
Measurement
Position
63
125
250
500
1000
2000
4000
8000
Overall
Level
Right
Front--Right
Front
Front--Left
Left
Back--Left
Back
Back--Right
46.5
46.5
47.2
45.2
46.5
47.0
46.4
48.1
61.7
60.5
62.3
60.7
58.8
60.7
62.2
60.2
77.6
72.8
73.5
72.7
77.6
82.8
79.8
79.3
81.0
81.2
82.2
77.7
83.7
83.0
80.7
82.1
80.2
83.9
79.9
83.8
80.8
82.2
80.4
81.6
81.0
84.4
76.1
82.6
80.6
81.4
76.0
80.5
76.7
81.5
72.9
80.2
78.3
78.4
72.3
78.2
72.7
74.8
66.3
75.3
73.7
73.5
65.4
73.1
86.9
88.8
84.9
88.2
88.3
88.6
86.1
88.1
8--pos. log avg.
46.7
61.0
78.3
81.7
81.9
81.1
78.2
72.9
87.7
Sound Pressure Levels dB(A)
Load
No
Load
2
Octave Band Center Frequency (Hz)
Distance,
m (ft.)
Exhaust
1 (3.3)
Raw Exhaust (No Silencer)
63
125
250
500
1000
2000
4000
8000
Overall
Level
62.7
74.5
79.1
83.8
83.4
82.0
80.2
75.7
90.1
150REOZJF 60 Hz 8/12
TIB-114
Emissions Data
150REOZJF
60 HZ. DIESEL INDUSTRIAL GENERATOR SET
EMISSION DATA SHEET
ENGINE INFORMATION
Model:
John Deere, 6068HF285K
Bore:
106mm (4.19 in.)
Nameplate BPH @ 1800 RPM:
237
Stroke:
127mm (5.00 in.)
Type:
4-Cycle, 6 Cylinder, Inline
Displacement:
6.79 L (414 cu. in.)
Aspiration:
Turbocharged, Charge Air-cooled
Compression Ratio
17.0:1
EPA Family:
DJDXL06.8120
EPA Certificate: DJDXL06.8120-002
Table 1
PERFORMANCE DATA:
1/4
Standby
1/2
Standby
3/4
Standby
Full
Standby
Engine bkW @ Stated Load
44.25
88.50
132.75
177.00
Fuel Consumption (g/kWh)
Exhaust Gas Flow (m3/min)
249.60
243.50
222.00
214.40
33.90
Exhaust Temperature (°C)
510.00
Table 2
EXHAUST EMISSION DATA:
HC (Total Unburned Hydrocarbons)
EPA CERTIFICATE DATA
0.1
3.8
NOx (Oxides of Nitrogen as NO2)
CO (Carbon Monoxide)
1.2
PM (Particular Matter)
0.12
Values are in g/kWh unless otherwise noted
TEST METHODS AND CONDITIONS
The EPA Certificate Data in Table 2 is a weighted average value per 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
Dimensional Drawings
Warranty
Stationary Standby and Prime Power
Industrial Generator Set 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 end user,
Kohler Co. warrants, for the period indicated below, each product to be free from defects in materials and workmanship. In the event of a
defect in materials or workmanship, Kohler Co. will repair, replace, or make appropriate adjustment at Kohler Co.’s option 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 service representative must perform startup.
Kohler Product
Stationary Standby Generator Set & Accessories
Stationary Prime Power Generator Set & Accessories
Warranty Coverage
One (1) year from registered startup or two thousand (2000) hours
(whichever occurs first). In any event, the warranty period will expire not
later than thirty (30) months from the date of shipment from Kohler Co.’s
factory.
One (1) year from registered startup or two thousand (2000) hours
(whichever occurs first). In any event, the warranty period will expire not
later than thirty (30) months from the date of shipment from Kohler Co.’s
factory.
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
Kohler 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. Additional expenses for repair after normal business
hours, i.e. overtime or holiday labor rates.
9. Rental of equipment during performance of warranty
repairs.
10. Removal and replacement of non-Kohler-supplied
options and equipment.
11. Replacement of a failed Kohler part with a non-Kohler
part voids the warranty on that part.
12. Radiators replaced rather than repaired.
13. Fuel injection pumps not repaired by an authorized
Kohler service representative.
14. Non-Kohler-authorized repair shop labor without prior
approval from Kohler Co. Warranty Department.
15. Engine fluids such as fuel, oil, or coolant/antifreeze.
16. Shop supplies such as adhesives, cleaning solvents,
and rags.
17. Expenses
incurred
investigating
performance
complaints unless the problem is caused by defective
Kohler materials or workmanship.
18. Maintenance items such as fuses, lamps, filters, spark
plugs, loose or leaking clamps, and adjustments.
19. Travel time and mileage exceeding 300 miles round trip.
To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., Kohler
Power Systems Service Department, MS072, Kohler, WI 53044 USA.
KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, AND/OR CONSEQUENTIAL DAMAGES OF ANY KIND
including, but not limited to, incidental and/or consequential labor costs, installation charges, telephone charges, or
transportation charges in connection with the replacement or repair of defective parts.
This is our exclusive written warranty. We make no other express warranty nor is anyone authorized to make any on our behalf.
ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR 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 and/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 CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com
TP-5374 8/13d
Stationary Standby Industrial Generator Set
Extended Two-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 end user,
Kohler Co. warrants, for the period indicated below, each product to be free from defects in materials and workmanship. In the event of a
defect in materials or workmanship, Kohler Co. will repair, replace, or make appropriate adjustment at Kohler Co.’s option 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 service representative must perform startup.
Kohler Product
Stationary Standby Generator Set & Accessories
Warranty Coverage
Two (2) years from registered startup or two thousand (2000) hours
(whichever occurs first).
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 registered startup. The extended warranty start date is determined by the standard warranty
requirements and runs concurrent with the standard warranty during the first year. To receive extended warranty coverage, the
provisions of the standard warranty registration must be met.
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
Kohler 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. Additional expenses for repair after normal business
hours, i.e. overtime or holiday labor rates.
9. Rental of equipment during performance of warranty
repairs.
10. Removal and replacement of non-Kohler-supplied
options and equipment.
11. Replacement of a failed Kohler part with a non-Kohler
part voids the warranty on that part.
12. Radiators replaced rather than repaired.
13. Fuel injection pumps not repaired by an authorized
Kohler service representative.
14. Non-Kohler-authorized repair shop labor without prior
approval from Kohler Co. Warranty Department.
15. Engine fluids such as fuel, oil, or coolant/antifreeze.
16. Shop supplies such as adhesives, cleaning solvents, and
rags.
17. Expenses
incurred
investigating
performance
complaints unless the problem is caused by defective
Kohler materials or workmanship.
18. Maintenance items such as fuses, lamps, filters, spark
plugs, loose or leaking clamps, and adjustments.
19. Travel time and mileage exceeding 300 miles round trip.
To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., Kohler
Power Systems Service Department, MS072, Kohler, WI 53044 USA.
KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, AND/OR CONSEQUENTIAL DAMAGES OF ANY KIND
including, but not limited to, incidental and/or consequential labor costs, installation charges, telephone charges, or
transportation charges in connection with the replacement or repair of defective parts.
This is our exclusive written warranty. We make no other express warranty nor is anyone authorized to make any on our behalf.
ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR 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 and/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 CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com
TP-5497 8/13d
Transfer Switch and Bypass Isolation Transfer Switch
One-Year Limited Warranty
Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original consumer,
Kohler Co. warrants, for the period indicated below, each product to be free from defects in materials and workmanship. Repair,
replacement, or appropriate adjustment at Kohler Co.’s option will be furnished if the product, upon Kohler Co.’s inspection, is found to
be properly installed, maintained, and operated in accordance with Kohler Co.’s instruction manuals. A Kohler distributor, dealer, or
authorized representative must 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*
Transfer Switch and Bypass Isolation Switch
One (1) year from date of startup
*Some restrictions may apply. Contact your Kohler distributor/dealer for full details.
The following will not be covered by the warranty:
1. Normal wear, periodic service, and routine adjustments.
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 above or below rated
capacity, voltage, or frequency; modifications; or
installation contrary to published specifications, codes,
recommendations, and accepted industry practices.
4. Original installation charges and startup costs.
5. Damage caused by negligent maintenance such as:
a. Failure to provide a clean, dry environment.
b. Failure to perform recommended exercising.
c. Failure to perform scheduled maintenance as
prescribed in supplied manuals.
d. Use of other than factory-supplied or -approved repair
parts and/or procedures.
6. Rental of equipment during performance of warranty
repairs.
7. Non-Kohler-authorized repair shop labor without prior
approval from the Kohler Co. Warranty Department.
8. Expenses incurred investigating performance complaints
unless the problem is caused by defective Kohler
materials or workmanship.
9. Maintenance items such as fuses, lamps, 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 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 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-5373 12/99d
Extended Two-Year Transfer Switch
Limited Warranty
This Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original purchaser,
Kohler Co. warrants for two years that the system will be free from defects in material and workmanship if properly installed, maintained,
and operated in accordance with Kohler Co. 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 be furnished 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 returned to
Kohler Co. or an authorized service station, if requested. This extended warranty expires two years after date of startup.*
This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while in your
possession.
*Some restrictions may apply. Contact your Kohler distributor/dealer for full details.
The following will not be covered by the warranty:
1. Normal wear, periodic service, and routine adjustments.
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 above or below rated
capacity, voltage, or frequency; modifications; or
installation contrary to published specifications, codes,
recommendations, and accepted industry practices.
4. Original installation charges and startup costs.
5. Damage caused by negligent maintenance such as:
a. Failure to provide a clean, dry environment.
b. Failure to perform recommended exercising.
c. Failure to perform scheduled maintenance as
prescribed in supplied manuals.
d. Use of other than factory-supplied or -approved repair
parts and/or procedures.
6. Rental of equipment during performance of warranty
repairs.
7. Non-Kohler-authorized repair shop labor without prior
approval from the Kohler Co. Warranty Department.
8. Expenses incurred investigating performance complaints
unless the problem is caused by defective Kohler
materials or workmanship.
9. Maintenance items such as fuses, lamps, and
adjustments.
10. Transfer switch main contacts.
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. Product 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 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 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-6085 2/00b
Kohler Standby/Prime Generator Set Test Program
Testing is an integral part of quality assurance. In keeping with our uncompromising commitment to quality, safety,
and reliability, every Kohler Standby/Prime power generator set undergoes an extensive series of prototype and
production testing.
Prototype Testing
D Generator set cooling and air flow tests to verify
maximum operating ambient temperature.
Prototype testing includes the potentially destructive
tests necessary to verify design, proper function of
protective devices and safety features, and reliability
expectations. Kohler’s prototype testing includes the
following:
D 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.
D Alternator temperature rise test per NEMA
MG1-32.6. Standby and prime ratings of the
alternator are established during this test.
D Acoustical noise intensity and sound attenuation
effects tests.
D Maximum power test to assure that the prime
mover and alternator have sufficient capacity to
operate within specifications.
Production Testing
D Alternator overload test per NEMA MG1-32.8.
D Steady-state load test to ensure voltage regulation
meets or exceeds ANSI C84.1, NEMA MG1-32.17
requirements and to verify compliance with steadystate speed control specifications.
D Transient test to verify speed controls meets or
exceeds specifications.
D 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.
D Motor starting tests per NEMA MG1-32.18.5 to
evaluate capabilities of generator, exciter, and
regulator system.
D Three-phase symmetrical short-circuit test per
NEMA MG1-32.13 to demonstrate short circuit
performance, mechanical integrity, ability to
sustain short-circuit current.
D Harmonic analysis, voltage waveform deviation
per NEMA MG1-32.10 to confirm that the
generator set is producing clean voltage within
acceptable limits.
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:
D 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.
D One-step, full-load pickup tests to verify that the
performance of each generator set, regulator, and
governor meets published specifications.
D Regulation and stability of voltage and frequency
are tested and verified at no load, 1/4 load, 1/2 load,
3/4 load, and full-rated load.
D Voltage, amperage, frequency and power output
ratings verified by full-load test.
D The proper operation of controller logic circuitry,
prealarm warnings, and shutdown functions is
tested and verified.
D 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 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
KohlerPowerSystemscom
G18-56 12/05a
Prestartup Checklist
TAW POWER SYSTEMS
PHONE: 954-977-0202
FAX: 954-977-0611
GENERATOR STARTUP CHECK LIST
JOB NAME:
DATE: ______________
1. ARE VIBRATION ISOLATORS INSTALLED?
X
Y___ N___ NA___
2. IS TRANSFER SWITCH MOUNTED & WIRED?
Y___ N___ NA___
3. IS COMMERCIAL POWER AVAILABLE?
Y___ N___ NA___
4. ARE REMOTE START WIRES PULLED FROM ATS(S) TO
THE GENERATOR IN SEPARATE CONDUITS?
Y___ N___ NA___
5. IS REMOTE ANNUNCIATOR MOUNTED AND WIRED FROM
GENERATOR & ATS(S)?
Y___ N___ NA___
6. IS BATTERY CHARGER MOUNTED AND WIRED WITH BOTH AC WIRES
AND DC WIRES?
Y___ N___ NA___
7. IS EXHAUST SYSTEM INSTALLED COMPLETELY?
Y___ N___ NA___
8. IS TRANSITION DUCT INSTALLED FROM RADIATOR?
Y___ N___ NA___
9. ARE FUEL LINES CONNECTED AND PRIMED FROM TANK
TO ENGINE. (N/A ON SUB BASE TANKS)?
X
Y___ N___ NA___
10. IS DAYTANK INSTALLED AND WIRED?
X
Y___ N___ NA___
11. IS FUEL AVAILABLE?
TANKS UNDER 500 GAL REQUIRE 100%
TANKS OVER 500 GAL REQUIRE 50%
Y___ N___ NA___
Y___ N___ NA___
Y___ N___ NA___
12. IS ALL CONSTRUCTION MATERIAL & DEBRIS REMOVED FROM
THE GENERATOR ROOM AND THE GENERATOR CLEANED FROM
CONSTRUCTION?
Y___ N___ NA___
START UP DATE REQUESTED:
NAME:
CONTACT PHONE: _______________________
AUTHORIZED SIGNATURE:
NOTE: MULTIPLE TRIPS DUE TO INCOMPLETE PREPARATION WILL RESULT IN ADDITIONAL CHARGES
ALL CONTROL WIRING MUST BE STRANDED OR BELDEN AS REQUIRED
RETURN THIS FORM VIA FAX TO TAW PRIOR TO START UP @ 954-977-0611
TAW SERVICE DEPARTMENT REQUIRES 5 WORKING DAYS NOTICE TO SCHEDULE ANY STARTUP.
112
120
X
120
X
X
200
X
2
240
X
X
LAKESIDE ELECTRICAL SERVICES
ZEPHYRHILLS FS #2
1800