Loading...
HomeMy WebLinkAboutPermit M10-130 - RPIRPI 3325 S 116 ST EXPIRED 04 -09 -12 M10 -130 City okukwila Department of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206 - 431 -3670 Inspection Request Line: 206- 431 -2451 Web site: http. / /www.ci.tukwila.wa.us MECHANICAL PERMIT Parcel No.: Address: 0923049068 3325 S 116 ST TUKW Project Name: RPI Permit Number: M10 -130 Issue Date: 10 /11/2010 Permit Expires On: 04/09/2011 Owner: Name: Address: Contact Person: Name: Address: Email: Contractor: Name: Address: Contractor RREEF AMERICA REIT II PO BOX 4900 #207 , SCOTTSDALE AZ 85261 MIKE HEALY 625 NW 45 ST , SEATTLE WA 98107 MIKE@BEACHELECTRIC.BIZ BEACH ELECTRIC LLC 625 NW 45 ST , SEATTLE WA 98107 License No: BEACHEL960JL Phone: 206 - 484 -1244 Phone: Expiration Date: 04/13/2012 DESCRIPTION OF WORK: CONCRETE PAD AND BACK -UP GENERATOR Value of Mechanical: $20,000.00 Type of Fire Protection: UNKNOWN Permit Center Authorized Signature: Fees Collected: International Mechanical Code Edition: $428.56 2009 Date: JU I ( ✓r I hereby certify that I have read and examined this permit and know the same to be true and correct. All provisions of law and ordinances governing this work will be complied with, whether specified herein or not. The granting of this permit does not presume to give authority to violate or cancel the provisions of any other state or local laws regulating construction or the performance of work. I am authorized to sign and obtain this mechanical permit. Signature: Print Name: Date: / O / / / / /0 null permit shall become ull a nd void if t e work is not commenced within 180 days from the date of issuance, or if the work is suspended or abandoned for a period of 180 days from the last inspection. h doc: IMC -4/10 M10 -130 Printed: 10 -11 -20,10 • City of Tukwila De P artment of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206-431-3670 Fax: 206 - 431 -3665 Web site: http://www.ci.tukwila.wa.us Parcel No.: 0923049068 Address: 3325 S 116 ST TUKW Suite No: Tenant: RPI PERMIT CONDITIONS Permit Number: M10 -130 Status: ISSUED Applied Date: 09/24/2010 Issue Date: 10/11/2010 1: ** *BUILDING DEPARTMENT CONDITIONS * ** 2: No changes shall be made to the approved plans unless approved by the design professional in responsible charge and the Building Official. 3: All permits, inspection records, and approved plans shall be at the job site and available to the inspectors prior to start of any construction. These documents shall be maintained and made available until final inspection approval is granted. 4: The special inspections and verifications for concrete construction shall be required. 5: When special inspection is required, either the owner or the registered design professional in responsible charge, shall employ a special inspection agency and notify the Building Official of the appointment prior to the first building inspection. The special inspector shall furnish inspection reports to the Building Official in a timely manner. 6: A final report documenting required special inspections and correction of any discrepancies noted in the inspections shall be submitted to the Building Official. The final inspection report shall be prepared by the approved special inspection agency and shall be submitted to the Building Official prior to and as a condition of final inspection approval. 7: All construction shall be done in conformance with the approved plans and the requirements of the International Building Code or International Residential Code, International Mechanical Code, Washington State Energy Code. 8: All plumbing and gas piping work shall be inspected and approved under a separate permit issued by the City of Tukwila Building Department (206- 431 - 3670). 9: All electrical work shall be inspected and approved under a separate permit issued by the City of Tukwila Building Department (206- 431 - 3670). 10: VALIDITY OF PERMIT: The issuance or granting of a permit shall not be construed to be a permit for, or an approval of, any violation of any of the provisions of the building code or of any other ordinances of the City of Tukwila. Permits presuming to give authority to violate or cancel the provisions of the code or other ordinances of the City of Tukwila shall not be valid. The issuance of a permit based on construction documents and other data shall not prevent the Building Official from requiring the correction of errors in the construction documents and other data. 11: ** *FIRE DEPARTMENT CONDITIONS * ** 12: The total number of fire extinguishers required for an extra hazard occupancy with Class A fire hazards is calculated at one extinguisher for each 1,000 sq. ft. of area. The extinguisher(s) should be of the all purpose" (4A 40 B:C) dry chemical type. The travel distance to any extinguisher must be 75' or less. (IFC 906.3) (NFPA 10, 3 -2.1) 13: Portable fire extinguishers, not housed in cabinets, shall be installed on the hangers or brackets supplied. Hangers or brackets shall be securely anchored to the mounting surface in accordance with the manufacturer's installation instructions. Portable fire extinguishers having a gross weight not exceeding 40 pounds (18 kg) shall be installed so that its top is not more than 5 feet (1524 mm) above the floor. Hand -held portable fire extinguishers having a gross weight exceeding 40 pounds (18 kg) shall be installed so that its top is not more than 3.5 feet (1067 mm) above the doc: Cond -10/06 M10-130 Printed: 10 -11 -2010 • City of Tukwila Department of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206-431-3670 Fax: 206 - 431 -3665 Web site: http. //www.ci.tukwila.wa.us floor. The clearance between the floor and the bottom of the installed hand -held extinguishers shall not be less than 4 inches (102 mm). (IFC 906.7 and IFC 906.9) 14: Fire extinguishers shall not be obstructed or obscured from view. In rooms or areas in which visual obstruction cannot be completely avoided, means shall be provided to indicate the locations of the extinguishers. (IFC 906.6) 15: Extinguishers shall be located in conspicuous locations where they will be readily accessible and immediately available for use. These locations shall be along normal paths of travel, unless the fire code official determines that the hazard posed indicates the need for placement away from normal paths of travel. (IFC 906.5) 16: Fire extinguishers require monthly and yearly inspections. They must have a tag or label securely attached that indicates the month and year that the inspection was performed and shall identify the company or person performing the service. Every six years stored pressure extinguishers shall be emptied and subjected to the applicable recharge procedures. If the required monthly and yearly inspections of the fire extinguisher(s) are not accomplished or the inspection tag is not completed, a reputable fire extinguisher service company will be required to conduct these required surveys. (NFPA 10, 4 -3, 4 -4) 17: Generator installation shall comply with NFPA 37, NFPA 110, NFPA111, Article 445 of NFPA 70 and manufacturers installation guidelines. 18: A stamped licensed engineers' letter may be submitted to the fire inspector at the time of inspecion certifying compliance with the referenced code requirements. 19: An electrical permit from the City of Tukwila Building Department Permit Center (206- 431 -3670) is required for this project. 20: All electrical work and equipment shall conform strictly to the standards of the National Electrical Code. (NFPA 70) 21: Contact The Tukwila Fire Prevention Bureau to witness all required inspections and tests. (City Ordinances #2050 and #2051) 22: Any overlooked hazardous condition and/or violation of the adopted Fire or Building Codes does not imply approval of such condition or violation. 23: These plans were reviewed by Inspector 511. If you have any questions, please call Tukwila Fire Prevention Bureau at (206)575 -4407. * *continued on next page ** doc: Cond -10/06 M10 -130 Printed: 10 -11 -2010 City of Tukwila Department of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206-431-3670 Fax: 206 -431 -3665 Web site: http: //www.ci.tukwila.wa.us I hereby certify that I have read these conditions and will comply with them as outlined. All provisions of law and this work will be complied with, whether specified herein or not. The granting of this permit does not presume to give authority to violate or cancel the provision of any other work construction or the performance of work. Signature: Print Name: (xt Date: / �/, / / //U ordinances governing or local laws regulating doc: Cond -10/06 M10 -130 Printed: 10 -11 -2010 CITY OF TUKWILA Community Development Department Permit Center 6300 Southcenter Blvd., Suite 100 Tukwila, WA 98188 htto://www.ci.tukwila.wa.us Mechanical Permit No. Project No. M 0--(30 (For office use only) MECHANICAL PERMIT APPLICATION Applications and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mail or by fax. * *Please Print ** King Co Assessor's Tax No.: Dq).- �0 ` l 0 (P 9) rr^ Site Address: 3 3 7. 5 `So U t- L / (6 I( 3 Suite Number: 113 Floor: 1 New Tenant: ❑ Yes ,E'.No Tenant Name: R P Property Owners Name: Mailing Address: City State Zip CONTACT PERSON - Who do contact when your permit is ready to be issued Name: M i Gc e Nee l y Day Telephone: 20 6 T$ ( 2— —7 62.5 /1/i -' t—t „Sea // /t. q3107 Mailing Address: City State Zip E -Mail Address: �1 i 4 e �' c (�j e ( % C C �Vl'C 11/ Z Fax Number: 2O 7 $ 6 ?7 MECHANICAL CONTRACTOR INFORMATION Company Name: Mailing Address: 13 e Pc c fv( c G 2 5 4i -i. q 57'i Sir Contact Person: ,A4 f tic,- /IT 4 i y i 1 E -Mail Address: 141 1 GC e 9.b e Contractor Registration Number: 13,&4 C I1 I$ L? 6 0 T Se9t7L /t• `?8/07 City State Zip • Day Telephone:2- 6 " g if "' (Z =f el 2 Fax Number: 2 0 6 -- 7$ 4— 6 3 Expiration Date: ARCHITECT OF RECORD - All plans must be wet stamped by Architect of Record Company Name: Mailing Address: Contact Person: E -Mail Address: City Day Telephone: Fax Number: State Zip ENGINEER OF RECORD - ` All .plans must be wet stamped by Engineer of Record Company Name: Mailing Address: Contact Person: E -Mail Address: H: Applications\Forms- Applications On Line \2009 Applications \1 -2009 - Mechanical Permit Application. doc Revised: 1 -2009 bh City Day Telephone: Fax Number: State Zip Page 1 of 2 Valuation of Project (contractor's bid price): $ 2 / 0 � p 'i—" — "- C�' t Scope of Work (please provide detailed information): 1 I�CT 4 G c�i�/J e !q e v' 7 p Q(71d Use: Residential: New Commercial: New Fuel Type: Electric ❑ Replacement Replacement Gas a Other: Indicate type of mechanical work being installed and the quantity below: Unit Type: Qty ; Unit Type: Qty Unit Type: Qty Boiler /Compressor: Qty Furnace <100K BTU Air Handling Unit >10,000 CFM Fire Damper 0 -3 HP /100,000 BTU Furnace >100K BTU Evaporator Cooler Diffuser 3 -15 HP /500,000 BTU Floor Furnace Ventilation Fan Connected to Single Duct Thermostat 15 -30 HP /1,000,000 BTU Suspended/Wall/Floor Mounted Heater Ventilation System Wood/Gas Stove 30 -50 HP /1,750,000 BTU Appliance Vent Hood and Duct Emergency Generator 50+ HP /1,750,000 BTU Repair or addition to Heat/Refrig/Cooling System Incinerator — Domestic Other Mechanical Equipment Air Handling Unit <10,000 CFM Incinerator — Comm /Ind PERMIT APPLICATION NOTES Value of Construction — In all cases, a value of construction amount should be entered by the applicant. This figure will be reviewed and is subject to possible revision by the Permit Center to comply with current fee schedules. Expiration of Plan Review — Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The Building Official may grant one extension of time for additional periods not to exceed 90 days each. The extension shall be requested in writing and justifiable cause demonstrated. Section 105.3.2 International Building Code (current edition). I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT. BUILDING OWNER OR AUTHORIZED AGENT: Signature: Print Name: Mailing Address: 25 27 Q ( y Date: 2-y-//o Day Telephone: 2'06 7g V 5-5 5 City State Zip Date Application Accepted: Date Application Expires: .114 Staff Initials: H:1ApplicationsWorms- Applications On Line\2009 Applications \1-2009 - Mechanical Permit Application.doc Revised: 1 -2009 bh Page 2 of 2 • City of Tukwila Department of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206 -431 -3670 Fax: 206 - 431 -3665 Web site: htv://www. ci. tukwi la. wa. us Parcel No.: 0923049068 Address: 3325 S 116 ST TUKW Suite No: Applicant: RPI RECEIPT Permit Number: M10 -130 Status: APPROVED Applied Date: 09/24/2010 Issue Date: Receipt No.: R10 -02032 Initials: User ID: Payee: WER 1655 Payment Amount: $342.85 Payment Date: 10/11/2010 01:57 PM Balance: $0.00 MIKE HEALY TRANSACTION LIST: Type Method Descriptio Amount Payment Credit Crd VISA Authorization No. 095422 ACCOUNT ITEM LIST: Description 342.85 Account Code Current Pmts MECHANICAL - NONRES 000.322.102.00.00 342.85 Total: $342.85 doc: Receiot -06 Printed: 10 -11 -2010 City of Tukwila Department of Community Development 6300 Southcenter Boulevard, Suite #100 Tukwila, Washington 98188 Phone: 206 - 431 -3670 Fax: 206 - 431 -3665 Web site: http: //www. ci. tukwi la. wa. us Parcel No.: 0923049068 Address: 3325 S 116 ST TUKW Suite No: Applicant: RPI RECEIPT Permit Number: M10 -130 Status: PENDING Applied Date: 09/24/2010 Issue Date: Receipt No.: R10 -01898 Initials: User ID: Payee: WER 1655 Payment Amount: $85.71 Payment Date: 09/24/2010 10:43 AM Balance: $342.85 MIKEHEALY TRANSACTION LIST: Type Method Descriptio Amount Payment Credit Crd VISA Authorization No. 067122 ACCOUNT ITEM LIST: Description 85.71 Account Code Current Pmts PLAN CHECK - NONRES 000.345.830 85.71 Total: $85.71 doe: Receiot -06 Printed: 09 -24 -2010 • • INSPECTION N0: • CITY OF TUKWILA BUILDING DIVISI'ON • .6300 Southcenter Blvd., #100, Tukwila. WA 98188 R (206) 431 -3670 Permit Inspection Request Line (206) 431 -2451 • CZ INSPECTION RECORD Retain a copy with permit /r1 id— i 3.6 PERMIT NO. Project: l P Type of Inspection: 1-10,14 L Address: .53 2.5 4' . ra si Date Called: Special Instructions:. Date Wanted: --- / 4-I-- I f Requester: Phone No: im I aApproved'per applicable codes. Corrections required prior to approval. COMMENTS: /y1.►.OyJ,oS /AAh,ni t +C 6 .774 ,P — ,th C Zo ; ;At 0, , Ai /' Date: NSPECTION FEE RE" IRED. Prior it next inspection, fee must be paid at 6300 Southcenter Blvd.. Suite 1 Call to schedule reinspection. ` • " ��"- ,►-_, Pacific Power SenEraticin • d r� July 21, 2010 Beach Electric, LLC 625 NW 45th Street Seattle, WA. 98107 KOHLER. POWER SYSTEMS WWW. PACIFICPOWERGEN.COM .:. FILE COPY Permilt er mw. Attention: Mike Healy Phone: 206 484 -1244 Reference: Tukwila Project Mike, • — REVIEWED FOR CODE COMPLIANCE AP "fnfVED Prj 1 2110 City of Tukwila BUILDING DIVISION We are pleased to provide five (5) copies of our record submittal for the above referenced project. Please return one copy of the submittal to Pacific Power Generation marked "Approved" or "Approved as Noted" for each major item, along with the signature page of the "Clarifications To The Specification" section (Tab 1) and any review comments at your earliest convenience. The generator has been ordered from the factory per this submittal. Current engine and generator lead times are volatile. Expected lead time is 9 - 11 weeks; however, this is subject to change without notice. Lead times will be confirmed at time of order but are not guaranteed without written agreement from PPG. If any changes or revisions are required, they may impact the delivery and /or price of the generator set. Thank you for your order. I will be your primary point of contact throughout this project. Please feel free to contact me with any question on this project. We look forward to working with you to successfully complete this project. Regards, Jan Davis Jan Davis Pacific Power Generation 5808 S. 196th Street Kent, WA. 98032 Phone: 253 395 -9077 5808 South 196th Street, • Kent, WA 98032 Phone (253) 395 -9077 • Fax (253) 395 -4145 Toll Free 1- 877 - POWRGEN (1- 877 - 769 -7436) X110 -130 RECEIVED SEP 24 2010 PERMIT CENTER 6100 South 6th Way • Ridgefield, WA 98642 Phone (360) 887 -5986 • Fax (360) 887 -0164 Toll Free 1- 877 - POWRGEN (1- 877 - 769 -7436) TABLE OF CONTENTS • Tab 1 Specification Clarification Letter & Bill of Materials Pacific Power Generation Tab 2 Generator Set Specification Sheets & Bulletins Generator Set 60REZG -spec sheet G4 -132 Control Panel Dec 3000 -spec sheet G6 -100 Alternator data sheet TIB -102 Decrement Curve 1 page Voltage Regulator G6 -58 Batteries — Qty 1 -spec sheet G6 -16 Battery Charger - spec sheet G6 -15 Enclosure, Sound - spec sheet G6 -108 Block Heater 1500 Watt, 120 Volt Kim Hotstart Internal Vibro Mounts Kohler • • Tab 3 Generator Set Dimension Prints Generator Set ADV -7671 Seismic Installation Instructions ADV -7595 Enclosure, Sound ADV -7657 Tab 4 Generator Set Wiring Diagrams & Schematics Generator System - wiring diagram GM72401 - wiring schematics ADV -7861 Input/Output Board - connection schematic TP- 6694 -76 Main Output Circuit Breaker, Qty 1 Kohler, 200 Amp -spec sheet G6 -88 - breaker dimensions ADV -7370 Battery Charger - wiring diagram 233967 Run Relay - bulletin TP- 6694 -85 - interconnection diagram GM67191 Tab 5 Automatic Transfer Equipment Automatic Transfer Switch, Loose — Qty 1 Kohler -spec sheet G11 -108 NEMA 1 - dimension print ADV -7189 - wiring schematic GM46265 - wiring diagram GM46287 • • • Tab 6 Testing and Warranty Information Kohler Generator Test Program Seismic Certificate of Compliance Kohler ISO Certification Emissions Data Sheet EPA Certification Warranty — 1 Year Stationary Standby Tab 7 Miscellaneous Delivery Request Form Start Up Request Form Start Up Notification Preventive Maintenance Contract Customer Freight Damage Claims Policy Tab 8 Installation Guidebook G18-56 G18-172 G15-152 1 page 1 page TP -5374, 5373 & 5820 Pacific Power Generation Pacific Power Generation Kohler Pacific Power Generation Pacific Power Generation Kohler NOTE: Your Kohler Operation and Maintenance Manuals (Qty 3) will be delivered at a later date. • Pacific Power • • Generation CLARIFICATIONS TO THE SPECIFICATION Date: Job Reference: Specification Section: Current Addendum: Tukwilla Project KOHLER. POWER SYSTEMS Clarifications to the specification: Please reference Bill of Materials, page of this section (Tab 1) General notes to the specification: The following are standard exceptions and clarifications which are applicable unless otherwise agreed to in writing: General: • Contractor /customer purchase order terms and conditions subject to Pacific Power Generation management approval. • After submittal approval, any changes in description and /or sequence of operation resulting in any hardware or software modifications will require a formal change order and may result in additional cost and possible shipping delays. • Stated equipment lead times are estimates only and are subject to change without notice. Pacific Power Generation is not liable for any damages for delivery delays, including liquidated damages, that have not been specifically agreed to by us in writing at time of order. • Equipment delivery/lead times are based upon timely submittal review and release to manufacture. • Unless stated in our proposal, one (1) set of factory O &M manuals will be provided. Modifications to factory O &M manuals are not included in our price. 6100 South 6th Way Ridgefield, WA 98642 TEL: 360- 887 -5980 FAX: 360- 887 -0164 Pacific Power Generation www.pacificpowergen.com 5808 S. 196th Street, Suite B100 Kent, WA 98032 TEL: 253- 395 -9077 FAX: 253- 395 -4145 • • • Pacific Power Generation Monday, July 19, 2010 • A minimum cancellation or restocking fee of 30% will be charged for any returned or ordered product. Note: prior authorization is required as cancellation or return will not be allowed on some product. In general, cancellation or return will not be allowed on custom -built equipment and special order parts, including sales kits. • Warranty is limited to the original equipment manufacturer(s) parchment; there is no other expressed or implied warranty. Warranty begins at time of start up /commissioning, not owner acceptance, substantial completion or facility occupancy. • We reserve the right to correct errors and omissions. • Any exceptions and /or clarifications noted in the switchgear and transfer . switch sections are also part of this list and our proposal. Summary of Payment Terms: • Payment terms are subject to credit approval, standard Net 30 days. Invoices are issued at time of shipment. Retainage over 2% is subject to approval by our credit department. • Our packaged price proposal is valid for 60 days. • Unless specifically stated in our proposal, any applicable local, state or federal taxes are not included. • Complete Pacific Power Generation Terms and Conditions can be provided upon request. Delivery /Offloading: • Delivery (if included) is based upon utilization of standard transportation equipment and unrestricted access to site regarding length, height, width and weight. Stated equipment weights are estimates only; Pacific Power Generation is not responsible for offloading issues due to inaccurate weight specifications. Equipment off loading at the job site is by others. Delivery may be via enclosed trailer or open flatbed trailer at Pacific Power Generation's option, unless specific transportation arrangements have been agreed to prior to delivery. • Product delivered on -site must be protected from rain /water and other detrimental environment factors. • Long term storage prior to start-up may affect or limit manufacturer's warranty. Please refer to the specific warranty statement for clarification. No provision for preservation has been made for extended storage of components. • Proposed price includes freight to first destination, on the truck, for a single shipment. If advance shipment of the transfer switch or any other equipment is required, we must be informed during the submittal process before the order is placed, and may result in additional freight charges. Reconsignment of freight to a freight yard or storage facility may result in additional freight and /or storage charges. Page 2 of 4 Pacific Power Generation Pacific Power Generation Monday, July 19, 2010 Suitability of Equipment: • Sound attenuation levels (if provided) are based on a free field condition. Note, ambient sound levels, adjoining structures, and other site conditions can invalidate the results of on -site testing, and can cause other than factory specified sound level readings when on -site testing is performed. • Pacific Power Generation is not responsible for generators that do not function properly due to high harmonics or extreme power factors that are present. Filtering and /or power factor correction is the responsibility of others. Scope of Work/Supply: • Installation or interconnection site work as required, such as plumbing, wiring, exhaust, insulation, mounting pad, anchoring /mounting bolts, etc, including any off - engine /generator wiring, plumbing or ducting between loose items supplied and customer furnished systems is by others. • Any site work that requires a licensed electrician or mechanical contractor to perform the work is not included. • Field wiring hardware is not included. Field hardware shall include all conduit, wire, fittings, supports, terminations and labels. Field labor to install conduit, wire, fittings, supports, termination and labeling of wires and complete check out of control wiring is not included. • Fuel for testing or for initial fill of fuel tank is not included. 110 • Factory standard supplied fuel tank venting only, any additional venting required by local building or fire codes is not included. • The installing contractor is responsible for installation conformance to local codes and ordinances, including but not limited to IFC, IBC, noise and emission regulations. Any requirement by the local AHJ beyond or in addition to national recognized codes will not be covered by Pacific Power Generation and are at the expense of others. • Installation manuals, if provided, are a provided as a general reference guide only. Local codes, engineered drawings and specifications for the specific site installation take precedence over any installation manuals provided. • Coordination studies, arc flash testing, NETA testing, harmonic content testing, emission testing, infrared scanning and site specific testing to be by others, unless specifically called out in our proposal and scope of supply. • Change out/modification of line circuit breaker (supplied by Pacific Power Generation) precipitated by coordination studies must be executed prior to release to manufacture and additional charges may apply. • Any items that require certification or a stamped document by an engineer, other than what has been outlined in our proposal, is not included. • Standard factory testing is provided. Witness testing at the factory is not included. If witness testing is required, additional charges will apply. • Coolant and water treatment additives for remote radiator applications are not included, unless specifically called out in our proposal and scope of supply. • Page 3 of 4 Pacific Power Generation • • • Pacific Power Generation Monday, July 19, 2010 Products used must be approved by the engine manufacturer: • Mounting bolts and anchors are not included. • Generator mounting pad by others. • Factory standard labels and signage supplied. Any additional signage, labels or placards by others. On -Site Startup/Testing/Training: • Pacific Power Generation field testing as outlined within our proposal and the project specification is limited to the equipment within our scope of supply. All testing in our scope of supply to be performed by Pacific Power Generation or its affiliates. Independent or Third Party Testing is not included. • Unless specifically stated in our proposal, on site start up and testing is limited to one (1) 8 hour day on site, performed during normal business hours: Monday through Friday, 8am to 5pm. Any service required at other times, including holidays, is subject to additional charges. • Unless specifically stated in our proposal, on site training will be conducted on same date as start up and testing. If additional trips are required, additional charges may apply. • For issues beyond our control, standby time in excess of an hour for startup or training services will be charged out at standard rates. • Any additional labor or expense incurred due to issues beyond our control will be subject to additional charges. Any stoppage that delays or postpones our testing is subject to additional charges. • For proper systems testing at the jobsite, we require free, clear, unimpeded access to the switchgear, generator sets and transfer switches. • If load bank testing is required and included in our proposal, access within 50' of the generator must be provided for trailer- mounted load banks. • If load bank testing is required and included in our proposal, testing will be with a resistive load bank, unless specifically stated in our proposal. If this application is indoors it is strongly recommended that a complete review is performed on the make up air, engine and radiator exhaust, and fuel systems. Please contact your representative at Pacific Power Generation for air flow information. Accepted by: (must be signed to validate order) Date: Page 4 of 4 Pacific Power Generation • Pacific Power Generation SUBMITTAL BILL OF MATERIAL KOHLER. POWER SYSTEMS We propose to furnish the following detailed bill of material and services: One (1) New KOHLER Natural Gas Engine Driven Generator Set, Model 60REZG rated 60kW, 200 amp output standby duty, 120/208 volts, three phase, 60 Hz, 0.8 PF, 1800 RPM, UL2200 GENERATOR SET IS SEISMIC CERTIFIED BY MANUFACTURER TO MEET IBC 2006 • GAS ENGINE: • EPA Off Road Emission compliant • Block heater (1500 watt, 1 20VAC) • Electronic engine speed control system capable of 0.25% frequency regulation • Standard duty, dry type air cleaner system • GENERATOR: • Brushless, 4 -pole, 2/3 pitch • Permanent Magnet Exciter (PMG) • Voltage regulator +/- .5% steady state regulation • SKID & COOLING • Structural steel • Radiator Cooling • Initial fill of ethylene glycol and corrosion resistant protection • LUBE OIL SYSTEM: • Initial fill of lubrication oil • Lube oil full flow filter • Extended oil drain connection with valve • FUEL SYSTEM — NATURAL GAS: • Flexible fuel lines • Gas solenoid valve • Secondary regulator • Gas strainer (shipped loose) • ENCLOSURE: • Sound - attenuated weather protective, steel construction • 69dBA at 23 ft. in a free field environment • High wind bracing, 150mph • Fade, scratch and corrosion resistant Kohler powder baked finished • Acoustic insulation meets UL94 HF1 flammability classification • EXHAUST SYSTEM: • Critical exhaust silencer (internally mounted) • Exhaust outlet flex connector (mounted) • STARTING SYSTEM: • 12 volt starter • Starting battery • Battery. rack and cables • 12VDC,10 amp battery charger w /alarms (mounted within enclosure, 120VAC) 6100 South 6th Way Ridgefield, WA 98642 TEL: 360 - 887 -5980 FAX: 360- 887 -0164 Pacific Power Generation www.pacificpowergen.com 5808 S. 196th Street, Suite B100 Kent, WA 98032 TEL: 253- 395 -9077 FAX: 253- 395 -4145 Pacific Power Generation Wednesday, July 21, 2010 4111 ❖ ENGINE/GENERATOR CONTROLS: NFPA 110 Compliant • Kohler digital control panel with digital readouts for the following: • Engine Metering: engine speed, oil pressure, coolant temperature, battery voltage • Generator Metering: power metering (kW and kVA) Voltage L -L and L -N for all phases Current L1, L2, L3, Frequency • Gen Set Run Time: engine run time (total hrs), engine loaded hrs, number of engine starts, total energy, kWh • Event Log: Event history (stores up to 1000 system events) for warning and shutdown faults • Historical Data Logging: Total number of generator set successful starts • Time Delay Start (TDES) provides a time delay before the engine starts • Time Delay Cooldown (TDEC) provides a time delay before the generator shuts down • Provides for engine alarm /shutdown for the following conditions: • High coolant temperature • Pre -high coolant temperature • Low coolant level • Low oil pressure • Pre -low oil pressure • Overspeed • Overcrank • Low fuel level* external sender by others • Low /High battery voltage • • Battery charger failure • Emergency stop • Switch not in "auto" • Controller Features: Integrated voltage regulator providing +/- 0.5% Built -in alternator thermal overload protection Dedicated user inputs: Remote emergency stop switch, remote 2 wire start for transfer switch, auxiliary shutdown One analog and three digital inputs standard. One relay output standard. USB connection: provides access for diagnostics, allows for software updates Master control buttons with lights: Off -Reset (red) / Auto (green) / Run (yellow) Alarm horn and silencing switch ❖ ACCESSORIES * INSTALLED • 200 amp mainline circuit breaker, 80% rated (mfg. standard load side lugs only) • Run relay, 2 Input / 5 Output Module • Rodent guards • ACCESSORIES * LOOSE • Operation & Maintenance manuals (qty 3) • Page 2 of 4 Pacific Power Generation • • • Pacific Power Generation Wednesday, July 21, 2010 • AUTOMATIC TRANSFER SWITCH • One New Kohler Automatic Transfer Switch • 200 amp, 120/208 volt, 3 pole, NEMA 1 Indoor Enclosure ■ 30KAIC withstand rating with specific breakers, UL2008 ■ Adjustable time delay engine start • Adjustable time delay normal to emergency • Adjustable time delay emergency to normal ■ Adjustable time delay cooldown • Inphase monitor ■ Pilot Lights • Programmable exercise clock • Auxiliary contact ❖ WARRANTY: • Standby Power limited warranty as provided by the manufacturer for one (1) year or 2000 hours, whichever comes first ❖ FACTORY AND JOB SITE TESTING: • Certified factory testing at rated power factor • On site start up and testing (one 8 hr day), with available bldg load and 1 hr resistive load bank test • Owner training at time of start up. If second trip is required for training it will be at owner's expense and quoted by Pacific Power Generation service department. NOTES: Quoted per customer's request. No formal written specifications or one line diagram provided. Please review our bill of material and verify it meets your requirements. Submitted by: Jan Davis Kohler Power System Sales Page 3 of 4 Pacific Power Generation • • • Pacific Power Generation Wednesday, July 21, 2010 GENERAL CLARIFICATIONS TO OUR PROPOSAL • Contractor /customer to review and verify that proposed Bill of Materials meets project requirements prior to placing order. • Upon receipt of proposal, any changes to description or modifications will require a new proposal and may result in additional charges and possible shipping delays. • Stated equipment lead times are estimates only and are subject to change without notice. • Warranty begins at time of start up /commissioning, not owner acceptance, substantial completion or facility occupancy. • We reserve the right to correct errors and omissions. • Any exceptions and /or clarifications noted in the switchgear and transfer switch sections are also part of this list and our proposal. • Payment terms are subject to credit approval, standard Net 30 days. Complete Terms and Conditions can be provided upon request. • Our packaged price proposal is valid for 60 days. • Unless specifically stated in our proposal, any applicable local, state or federal taxes are not included. • Proposed equipment is FOB Origin, full freight allowed to first destination, on the truck, offloading and offloading equipment is by others. • Sound attenuation levels (if provided) are based on a free field condition. Note, ambient sound levels, adjoining structures, and other site conditions can invalidate the results of on -site testing, and can cause other than factory specified sound level readings when on -site testing is performed. • Installation or interconnection site work as required, such as plumbing, wiring, off engine exhaust piping, insulation, off engine fuel piping and or venting, ducting, generator mounting pad, anchoring /mounting bolts, etc, between loose items supplied and customer fumished systems is by others. • Any site work that requires a licensed electrician or mechanical contractor to perform the work is not included. • Field wiring hardware is not included. Field hardware shall include all conduit, wire, fittings, supports, terminations and labels. Field labor to install conduit, wire, fittings, supports, termination and labeling of wires and complete check out of control wiring is not included. • Fuel for testing or for initial fill of fuel tank is not included. • Factory standard supplied fuel tank venting only, any additional venting required by local building or fire codes is not included unless stated in our bill of material. • The installing contractor is responsible for installation conformance to local codes and ordinances, including but not limited to IFC, IBC, noise and emission regulations. Any requirement by the local AHJ beyond or in addition to national recognized codes will not be covered by Pacific Power Generation and are at the expense of others. • Coordination studies, arc flash testing, NETA testing, harmonic content testing, emission testing, infrared scanning and site specific testing to be by others, unless specifically called out in our proposal and scope of supply. • Change out/modification of line circuit breaker (supplied by Pacific Power Generation) precipitated by coordination studies must be executed prior to release to manufacture and additional charges may apply. • Any items that require certification or a stamped document by an engineer, other than what has been outlined in our proposal, is not included. • Standard factory testing is provided. Witness testing at the factory is not included. If witness testing is required, additional charges will apply. • Coolant and water treatment additives for remote radiator applications are not included, unless specifically called out in our proposal and scope of supply. Products used must be approved by the engine manufacturer. • Factory standard labels and signage supplied. Any additional signage, labels or placards by others. • Pacific Power Generation field testing as outlined within our proposal and the project specification is limited to the equipment within our scope of supply. All testing in our scope of supply to be performed by Pacific Power Generation or its affiliates. Independent or Third Party Testing is not included. • Unless specifically stated in our proposal, on site start up and testing is limited to one (1) 8 hour day on site, performed during normal business hours: Monday through Friday, 8am to 5pm. Any service required at other times, including holidays, is subject to additional charges. • Unless specifically stated in our proposal, on site training will be conducted on same date as start up and testing. If additional trips are required, additional charges may apply. • For issues beyond our control, standby time in excess of an hour for startup or training services will be charged out at standard rates. • Any additional labor or expense incurred due to issues beyond our control will be subject to additional charges. Any stoppage that delays or postpones our testing is subject to additional charges. • For proper systems testing at the jobsite, we require free, clear, unimpeded access to the switchgear, generator sets and transfer switches. • If load bank testing is required and proposed, testing will be with a resistive load bank, unless specifically stated in our proposal. Access within 50' of the generator must be provided for trailer- mounted load bank. Page 4 of 4 Pacific Power Generation • KOHLERPOWER SYSTEMS Model: 6OREZG 190 -600 V Gas 9001 NATIONALLY REGISTERED Ratings Range Standby: kW kVA 60 Hz 49 -64 49 -80 50 Hz 40 -53 40 -66 Generator Set Ratings Standard Features • Kohler Co. provides one - source responsibility for the generating system and accessories. • The generator set and its components are prototype- tested, factory- built, and production- tested. • The 60 Hz generator set offers a UL 2200 listing. o 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. u The 60 Hz generator set engine is certified by the Environmental Protection Agency (EPA) to conform to the New Source Performance Standard (NSPS) for stationary spark - ignited emissions. • A one -year limited warranty covers all systems and components. Two- and five -year extended warranties are also available. Natural Gas LP Gas 130 °C Rise 130 °C Rise Standby Rating Standby Rating Alternat Voltage Ph Hz kW/kVA Amps kW/kVA Amps 120/208 3 60 60/75 208 60/75 208 12 /1220 :t 611--60/75 19 i 61/76 200 120/240 3 60 60/75 180 60/75 180 120/240 1 60 49/49 204 49/49 204 139/240 3 60 60/75 180 62/78 186 220/380 3 60 55/69 104 55/69 104 277/480 3 60 60/75 90 62/78 93 347/600 3 60 60/75 72 62/78 75 110/190 3 50 48/60 182 50/62 188 115/200 3 50 46/58 187 46/58 167 110/220 1 50 40/40 182 40/40 182 110/220 3 50 48/60 157 50/62 163 220/380 3 50 48/60 91 50/62 94 230/400 3 50 46/58 84 46/58 84 120/208 3 60 60/75 208 63/79 219 127/220 3 60 60/75 197 64/80 210 120/240 3 60 60/75 180 63/79 189 120/240 1 60 57/57 238 59/59 246 139/240 3 60 60/75 180 64/80 192 220/380 3 60 60/75 114 63/79 120 277/480 3 60 60/75 90 64/80 96 347/600 3 60 60/75 72 64/80 77 110/190 3 50 48/60 182 50/62 188 115/200 3 50 49/61 176 53/66 191 120/208 3 50 49/61 169 53/66 183 110/220 1 50 45/45 205 47/47 214 110/220 3 50 48/60 157 53/66 173 220/380 3 50 48/60 91 53/66 100 230/400 3 50 48/60 87 53/66 95 240/416 3 50 49/61 85 53/66 92 120/240 1 60 55/55 229 55/55 229 110/220 1 50 46/46 209 50/50 227 120/240 1 60 60/60 250 60/60 250 110/220 1 50 47/47 214 51/51 232 RATINGS: All three -phase units are rated at 0.8 power factor. NI single -phase units are rated 811.0 power factor. Standby Ratings: Standby ratings apply to installations served by a reliable utility source. The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this rating. Ratings are in accordance with ISO-3046/1, as 5514, AS 2789, and DIN 8271. Prime Power Ratings: Prime power ratings apply to installations where utility power is unavailable or unreliable. At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is available for one hour in twelve. Ratings are in accordance with ISO - 8528/1, overload power In accordance with ISO - 3046/1, B5 5514, AS 2769, and DIN 6271. For limited running time and base load ratings, consult the factory. Obtain the technical information bulletin (TIB -101) on ratings guidelines for the complete ratings definitions. The generator sat manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. GENERAL GUIDELINES FOR DERATION: Altitude: Derate 1.3% per 100 m (328 tt. elevation above 200 m (858 ft). Temperature: Derate 3.0% per 10 °C (18 °F) temperature above 25 °C (77 °F). For dual fuel engines, use the natural gas ratings for both the primary and secondary fuels. 4S7 4Q10 4V9 G4 -132 (60RE2G) 4/10d • Alternator Specifications Specifications Manufacturer Type Exciter type Leads: quantity, type 4P8, 4S7 4Q10, 4V9 Voltage regulator Insulation: Material Temperature rise Bearing: quantity, type Coupling Amortisseur windings Voltage regulation, no -load to full -load Decision -Maker 550 controller (with 0.5% drift due to temp. variation) Decision -Maker 3000 controller One -step load acceptance Unbalanced load capability Peak motor starting kVA: 480 V, 380 V 4P8 (12 lead) 480 V, 380 V 4S7 (12 lead) 240 V, 220 V 4Q10 (4 lead) 240 V, 220 V 4V9 (4 lead) Engine •Engine Specifications Manufacturer Engine: model, type • Alternator Kohler 4 -Pole, Rotating -Field Brushless, Permanent - Magnet 12, Reconnectable 4, 110- 120/220 -240 Solid State, Volts /Hz NEMA MG1 Class H 130 °C, Standby 1, Sealed Flexible Disc Full 3 -Phase Sensing, :0.25% 3 -Phase Sensing, ±0.5% 100% of Rating 100% of Rated Standby Current (35% dip for voltages below) 212 (60 Hz), 145 (50 Hz) 270 (60 Hz), 190 (50 Hz) 155 (60 Hz), 133 (50 Hz) 246 (60 Hz), 213 (50 Hz) • NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting. • Sustained short- circuit current of up to 300% of the rated current for up to 10 seconds. • Sustained short- circuit current enabling downstream circuit breakers to trip without collapsing the alternator field. • Self- ventilated and dripproof construction. • Vacuum - impregnated windings with fungus- resistant epoxy varnish for dependability and long life. • Superior voltage waveform from a two- thirds pitch stator and skewed rotor. • Fast - Response"' II brushless alternator with brushless exciter for excellent load response. Application Data Engine Electrical 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, kW (HP) Cylinder head material Piston type and material Crankshaft material Valve (exhaust) material Governor type Frequency regulation, no -load to full -load Frequency regulation, steady state Frequency Air cleaner type, all models Exhaust 60 Hz 50 Hz General Motors Industrial Powertrain Vortec 5.7 L, 4 -Cycle Natural Aspiration V -8 5.7 (350) 101.6 x 88.4 (4.00 x 3.48) 9.1:1 318 (1044) 265 (870) 5, M400 Copper Lead 1800 1500 78.3 (105) 65.6 (88) Cast Iron High Silicon Aluminum Nodular Iron Forged Steel Electronic Isochronous x0.5% Fixed Dry 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) Exhaust outlet size at engine hookup, mm (in.) 60 Hz 50 Hz Dry 16.4 (580) 13.6 (480) 649 (1200) 10.2 (3.0) 76 (3.0) OD Engine Electrical System Ignition system Battery charging alternator: Ground (negative /positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Qty., rating for -18 °C (0 °F) Battery voltage (DC) Fuel 60 Hz 50 Hz Electronic Negative 12 70 12 1, 630 12 Fuel System Fuel type Fuel supply line inlet Natural gas /LPG fuel supply pressure, measured at the generator set fuel inlet downstream of any fuel system equipment accessories, kPa (in. H2O) 60 Hz 50 Hz LP Gas, Natural Gas, or Dual Fuel 1 NPTF 1.74 -2.74 (7 -11) Fuel Composition Limits * Nat. Gas LP Gas Methane, % by volume Ethane, % by volume Propane, % by volume Propene, % by volume C4 and higher, % by volume Sulfur, ppm mass Lower heating value, kJ /m3 (Btu/ft3), min. 90 min. 4.0 max. 1.0 max. 0.1 max. 0.3 max. 85 min. 5.0 max. 2.5 max. 25 max. 26.6 (890) 67.5 (2260) * Fuels with other compositions may be acceptable. If your fuel is outside the listed specifications, contact your local distributor for further analysis and advice. G4 -132 (60REZG) 4/10d • • • Application Data Lubrication Lubricating System Type Oil pan capacity, L (qt.) Oil pan capacity with filter, L (qt.) Oil filter: quantity, type Cooling 60 Hz 50 Hz Full Pressure 4.7 (5.0) 6.2 (6.5) 1, Cartridge Radiator System Ambient temperature, °C ( °F) * Engine jacket water capacity, L (gal.) Radiator system capacity, including engine, L (gal.) Engine jacket water flow, Lpm (gpm) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu /min.) Water pump type Fan diameter, including blades, mm (in.) Fan, kWm (HP) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H2O) 60 Hz 50 Hz 50 (122) 6.8 (1.8) 20.8 (5.5) 117.3 (31) 98.4 (26) 54.8 (3120) 45.7 (2600) Centrifugal 533 (21) 4.5 (6.0) 2.6 (3.5) 0.125 (0.5) * Enclosure with enclosed silencer reduces ambient temperature capability by 5 °C (9 °F). Operation Requirements Air Requirements Radiator - cooled cooling air, m3 /min. (scfm)t Combustion air, m3 /min. (cfm) Heat rejected to ambient air: Engine, kW (Btu /min.) Alternator, kW (Btu /min.) t Air density = 1.20 kg/m3 (0.075 Ibm/ft3) 60 Hz 50 Hz 170 (6000) 5.2 (185) 30.9 (1760) 7.7 (440) 136 (4800) 4.4 (155) 26.5 (1510) 6.9 (390) Fuel Consumption Natural Gas, m3/hr. (cfh) at % load: 100% 75% 50% 25% LP Gas, m3/hr. (cfh) at % load 100% 75% 50% 25% 60 Hz 50 Hz Standby Ratings 22.4 (790) 19.4 (685) 14.7 (520) 9.9 (350) 18.1 (640) 15.6 (550) 11.8 (415) 7.8 (275) Standby Ratings 9.3 (330) 7.9 (280) 7.1 (250) 6.2 (220) 5.4 (190) 4.7 (165) 3.8 (135) 3.1 (110) $ Fuel consumption is based on 1015 Btu /standard cu. ft. natural gas. LP vapor conversion factors: 8.58 ft.3 = 1 lb. 0.535 m3 = 1 kg. 36.39 ft.3 = 1 gal. Controllers C � eooa 0 oaa 000a Decision -Maker 550 Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Programmable microprocessor logic and digital display features. Alternator safeguard circuit protection. 12- or 24 -volt engine electrical system capability. Remote start, remote annunciation, and remote communication options. Refer to G6 -46 for additional controller features and accessories. Decision -Maker 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility. • Digital display and menu control provide easy local data access • Measurements are selectable in metric or English units • Scrolling display shows critical data at a glance • Integrated hybrid voltage regulator with ±0.5% regulation • Built -in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6 -100 for additional controller features and accessories. 04 -132 (60REZG) 4/10d ( -IQ O tsa - 6 ae m e Decision -Maker 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility. • Digital display and menu control provide easy local data access • Measurements are selectable in metric or English units • Scrolling display shows critical data at a glance • Integrated hybrid voltage regulator with ±0.5% regulation • Built -in alternator thermal overload protection • NFPA 110 Level 1 capability Refer to G6 -100 for additional controller features and accessories. 04 -132 (60REZG) 4/10d KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 - 459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Additional Standard Features • Alternator Protection • Battery Rack and Cables • Electronic, lsochronous Governor • Gas Fuel System (includes fuel mixer, electronic secondary gas regulator, gas solenoid valve, and flexible fuel line between the engine and the skid - mounted fuel system components) • Integral Vibration Isolation • Local Emergency Stop • Oil Drain Extension • Operation and Installation Literature Available Options Approvals and Listings ❑ CSA Approval �[ IBC Seismic Certification ® UL 2200 Listing Enclosed Unit ® Sound Enclosure (with enclosed critical silencer) ❑ Weather Enclosure (with enclosed critical silencer) Open Unit ❑ Exhaust Silencer, Critical (kit: PA- 352663) ❑ Flexible Exhaust Connector, Stainless Steel Fuel System ❑ Dual Fuel NG /LPG (automatic changeover) ® Flexible Fuel Line (required when the generator set skid is spring mounted) SI Gas Filter $) Secondary Gas Solenoid Valve Controller ❑ Common Fault Relay ❑ Communication Products and PC Software (550 controller only) ❑ Customer Connection (550 controller only) ❑ Dry Contact (isolated alarm) (550 controller only) NJ Input/Output Module (3000 controller only) ❑ Remote Annunciator Panel ❑ Remote Audiovisual Alarm Panel (550 controller only) ❑ Remote Emergency Stop g) Run Relay Cooling System NJ Block Heater [recommended for ambient temperatures below 10 °C (50 °F)] Electrical System ❑ Alternator Strip Heater Ig] Battery ® Battery Charger, Equalize/Float Type ❑ Battery Heater X) Line Circuit Breaker (NEMA1 enclosure) ❑ Line Circuit Breaker with Shunt Trip (NEMA1 enclosure) Miscellaneous N] Air Cleaner Restrictor Indicator N) Engine Fluids (oil and coolant) Added �j Rated Power Factor Testing ® Rodent Guards Literature ® General Maintenance 3 copies ❑ NFPA 110 ❑ Overhaul ❑ Production Warranty ❑ 2 -Year Basic ❑ 2 -Year Prime ❑ 5 -Year Basic ❑ 5 -Year Comprehensive Other Options 0 0 Dimensions and Weights Overall Size, Lx W x H, mm (in.): Wide Skid 2200 x 1040x 1172 (86.6 x 40.9 x 46.1) Narrow Skid 2200 x 864 x 1172 (86.6 x 34.0 x 46.1) Weight (radiator model), wet, kg (lb.): 755 (1665) L F NOTE: This drawing is provided for eterence only end should not be used for planning installation. Contact your local distributor for more detailed information. DISTRIBUTED BY: C 2009, 2010 by Kohler Co. All rights reserved. G4 -132 (60REZG) 4/10d Industrial Generator Set Accessories � KOHLERPOWER SYSTEMS • • Generator Set Controller 09001 con b NATIONALLY REGISTERED KOHLER DECISION - MAKER. Decision - Maker® 3000 Kohler® Decision - Maker® 3000 Controller General Description and Function The Decision - Maker® 3000 generator set controller provides advanced control, system monitoring, and system diagnostics for optimum performance. The Decision - Maker® 3000 controller meets NFPA 110, Level 1 when equipped with the necessary accessories and installed per NFPA standards. The Decision - Maker® 3000 controller uses patented software logic to manage sophisticated functions, such as 'voltage regulation and alternator thermal overload protection, normally requiring additional hardware. Additional features include: • A digital display and pushbutton /rotary selector dial provide easy local access to data. • Measurements selectable in metric or English units. • Scrolling display shows critical data at a glance. • Digital display of power metering (kW and kVA). • Integrated hybrid voltage regulator providing ±0.5% regulation. • Built -in alternator thermal overload protection. G6 -100 10/09 Page 1 • • • Emergency Stop Switch Digital Display Alarm Horn (located _ inside the controller) Master Control Buttons Off- Reset/Auto/Run with Lights User Interface Controls and Components • Emergency stop switch • Backlit LCD digital display with two lines of 12 characters (see User Interface Displays for menus) • Alarm horn indicates generator set shutdown and warning faults • Environmentally sealed membrane keypad with three master control buttons with lights o Off/Reset (red) o Auto (green) o Run (yellow) • Pushbutton /rotary selector dial for menu navigation o Rotate dial to access main menus o Push dial and rotate to access sub menus o Press dial for 3 seconds to return to top of main menu • Annunciator fault light o System shutdown (red) o System warning (yellow) • Alarm silence /lamp test button o Alarm silence o Lamp test • USB connection o Allows software upgrades o Provides access for diagnostics • Dedicated user inputs o Remote emergency stop switch o Remote 2 -wire start for transfer switch o Auxiliary shutdown • Integrated hybrid voltage regulator • Auto - resettable circuit protection mounted on circuit board • One relay output standard. Optional five relay output available. • One analog and three digital Inputs standard. Optional two inputs available. NFPA 110 Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine /generator functions and faults shown below. • Engine functions: o Overcrank o Low coolant temperature warning o High coolant temperature warning o High coolant temperature shutdown o Low oil pressure shutdown o Low oil pressure warning o High engine speed o Low fuel (level or pressure) * o Low coolant level • o EPS supplying load o High battery voltage o Low battery voltage • General functions: o Master switch not in auto o Battery charger fault * o Lamp test o Contacts for local and remote common alarm o Audible alarm silence button o Remote emergency stop * • Functions require optional input sensors or kits Pushbutton /Rotary Selector Dial Annunciator Fault Light Red - Shutdown, Yellow- Warning Alarm Silence /Lamp Test Button with Light USB Connection User Interface Displays The listing below has • denoting main menus and o denoting sub - menus. • Overview o Active shutdowns and warnings (if any are present) o Engine run time, total hours o Average voltage line -to -line o Frequency o Average current o Coolant temperature o Fuel level or pressure * o Oil pressure o Battery voltage o Software version • Engine Metering o Engine speed o Oil pressure o Coolant temperature o Battery voltage • Generator Metering o Total power, VA o Total power, W o Rated power, % o Voltage, L -L and L -N for all phases o Current, L1, L2, L3 o Frequency • GenSet Information o Generator set model number o Generator set serial number o Controller serial number • GenSet Run Time o Engine run time, total hours o Engine loaded, hours o Number of engine starts o Total energy, kWh • GenSet System o System voltage o System frequency, 50 or 60 Hz o System phase, single or three (wye or delta) o Power rating, kW o Amp rating o Power type, standby or prime o Measurement units, metric or English (user selectable) o Alarm silence, always or auto only • GenSet Calibration o Voltage, L -L and L -N for all phases o Current, L1, L2, L3 o Reset calibration • Voltage Regulation o Adjust voltage, ±10% • Digital Inputs o Input settings and status • Digital Outputs o Output settings and status • Analog Inputs o Input settings and status • Event Log o Event history (stores up to 1000 system events) • Function requires optional input sensors or kits G6 -100 10/09 Page 2 V/ Volts Ll -L2: 480.0 v . OFF/RESET 0 O. 0 0 ,s, `D J AUTO RUN ALARM LAMP FAULT 0 ,�, • SILENCE/ TEST I User Interface Controls and Components • Emergency stop switch • Backlit LCD digital display with two lines of 12 characters (see User Interface Displays for menus) • Alarm horn indicates generator set shutdown and warning faults • Environmentally sealed membrane keypad with three master control buttons with lights o Off/Reset (red) o Auto (green) o Run (yellow) • Pushbutton /rotary selector dial for menu navigation o Rotate dial to access main menus o Push dial and rotate to access sub menus o Press dial for 3 seconds to return to top of main menu • Annunciator fault light o System shutdown (red) o System warning (yellow) • Alarm silence /lamp test button o Alarm silence o Lamp test • USB connection o Allows software upgrades o Provides access for diagnostics • Dedicated user inputs o Remote emergency stop switch o Remote 2 -wire start for transfer switch o Auxiliary shutdown • Integrated hybrid voltage regulator • Auto - resettable circuit protection mounted on circuit board • One relay output standard. Optional five relay output available. • One analog and three digital Inputs standard. Optional two inputs available. NFPA 110 Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine /generator functions and faults shown below. • Engine functions: o Overcrank o Low coolant temperature warning o High coolant temperature warning o High coolant temperature shutdown o Low oil pressure shutdown o Low oil pressure warning o High engine speed o Low fuel (level or pressure) * o Low coolant level • o EPS supplying load o High battery voltage o Low battery voltage • General functions: o Master switch not in auto o Battery charger fault * o Lamp test o Contacts for local and remote common alarm o Audible alarm silence button o Remote emergency stop * • Functions require optional input sensors or kits Pushbutton /Rotary Selector Dial Annunciator Fault Light Red - Shutdown, Yellow- Warning Alarm Silence /Lamp Test Button with Light USB Connection User Interface Displays The listing below has • denoting main menus and o denoting sub - menus. • Overview o Active shutdowns and warnings (if any are present) o Engine run time, total hours o Average voltage line -to -line o Frequency o Average current o Coolant temperature o Fuel level or pressure * o Oil pressure o Battery voltage o Software version • Engine Metering o Engine speed o Oil pressure o Coolant temperature o Battery voltage • Generator Metering o Total power, VA o Total power, W o Rated power, % o Voltage, L -L and L -N for all phases o Current, L1, L2, L3 o Frequency • GenSet Information o Generator set model number o Generator set serial number o Controller serial number • GenSet Run Time o Engine run time, total hours o Engine loaded, hours o Number of engine starts o Total energy, kWh • GenSet System o System voltage o System frequency, 50 or 60 Hz o System phase, single or three (wye or delta) o Power rating, kW o Amp rating o Power type, standby or prime o Measurement units, metric or English (user selectable) o Alarm silence, always or auto only • GenSet Calibration o Voltage, L -L and L -N for all phases o Current, L1, L2, L3 o Reset calibration • Voltage Regulation o Adjust voltage, ±10% • Digital Inputs o Input settings and status • Digital Outputs o Output settings and status • Analog Inputs o Input settings and status • Event Log o Event history (stores up to 1000 system events) • Function requires optional input sensors or kits G6 -100 10/09 Page 2 • • Controller Features • AC Output Voltage Regulator Adjustment. The voltage adjustment provides a maximum of ±10% of the system voltage. • Alternator Protection. The controller provides generator set overload and short circuit protection matched to each alternator for the particular voltage /phase configuration. • Automatic Restart. The controller automatic restart feature initiates the start routine and recrank after a failed start attempt. • Cyclic Cranking. The controller has programmable cyclic cranking. • Engine Start Aid. The starting aid feature provides control for an optional engine starting aid. • Event Logging. The controller keeps a record (up to 1000 entries) for warning and shutdown faults. This fault information becomes a stored record of system events and can be reset. • Historical Data Logging. Total number of generator set successful starts is recorded and displayed. • Integrated Hybrid Voltage Regulator. The voltage regulator provides ±0.5% no -load to full -load regulation with three -phase sensing. • Lamp Test. Press the alarm silence /lamp test button to verify functionality of the indicator lights. • Power Metering. Controller digital display provides kW and kVA. • Programming Access (USB). Provides software upgrades and diagnostics. • Remote Reset. The remote reset function resets faults and allows restarting of the generator set without going to the master switch off/reset position. • RSA II Remote Monitoring Panel. The controller is compatible with the Kohler® Remote Serial Annunciator (RSA II). • Run Time Hourmeter. The generator set run time is displayed. • Time Delay Engine Cooldown (TDEC). The TDEC provides a time delay before the generator set shuts down. • Time Delay Engine Start (TDES). The TDES provides a time delay before the generator set starts. Controller Functions The following chart shows which functions cause a warning or shutdown. Al functions are available as relay outputs. Warning causes the fault light to show yellow and sounds the alarm horn signaling an impending problem. Shutdown causes the fault light to show red, sounds the alarm horn, and stops the generator set. • Standard functions o Available user functions * Functions require optional input sensors or kits t Items included with common fault shutdown 08 -100 10/09 Page 3 Warning Function Shutdown Function Engin`efFynctl iiii `s. 1 1 'x, 72` q•%�k , itf ": b?1A Critically high fuel level * o ECM communication loss • ECM diagnostics • • Engine over speed •t Engine start aid active Engine under speed • Fuel tank leak * 0 0 High battery voltage • High coolant temperature • •t High fuel level * o Low battery voltage • Low coolant level • Low coolant temperature • Low cranking voltage • Low engine oil level * 0 0 Low fuel level (diesel models) * o o Low fuel pressure (gas models) * o Low oil pressure • at No coolant temperature signal • No oil pressure signal • Overcrank •t Speed sensor fault • (Oenerel Func .- .., °a '( '''ci �%.,.. `. M:. Alarm horn silenced Analog Inputs o o Battery charger fault * • Chicago code active * Common fault (Includes t) • Common warning • Digital inputs o o Emergency stop St Engine cooldown (delay) active Engine start delay active Engine started Engine stopped EPS supplying load Generator running Input/output communication loss • Internal failure • Master switch not in auto e NFPA 110 alarm active Remote start System ready rd eneratorEFunctlonsn,F,; ` -60 -60.4. � < .jai,.:,_ 54 AC sensing loss • • Alternator protection • Ground fault input * • kW overload • Locked rotor • Overfrequency • Overvoltage (each phase) • Underfrequency • Undervoltage (each phase) • • Standard functions o Available user functions * Functions require optional input sensors or kits t Items included with common fault shutdown 08 -100 10/09 Page 3 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 -459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 -544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Controller Specifications Decision - Maker© 3000 — Software Version 1.00 or higher • Power source with circuit protection: 12- or 24 -volt DC • Power drain: 200 milliamps • Humidity range: 5% to 95% noncondensing • Operating temperature range: -40 °C to +70 °C ( -40 °F to +158 °F) • Storage temperature range: -40 °C to +85 °C ( -40 °F to +185 °F) • Standards: o CE Directive o NFPA 99 o NFPA 110, Level 1 o UL 508 o ASTM B117 (salt spray test) • Panel dimensions —W x H, 229 x 160 mm (9.0 x 6.3 in.) Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler® generator set distributor for availability. Decision - Maker® 3000 Available Options ❑ Common Fault Relay provides a relay output to trip a circuit breaker or to signal the common fault shutdowns. El 2 input/5 Output Module provides a generator set mounted panel with two inputs and five relay outputs. la Float/Equalize Battery Charger available with 6 or 10 amp DC volt output. The 10 amp models are available with and without NFPA alarm to signal a battery charger fault. ❑ Prime Power Switch prevents battery drain during generator set non - operation periods and when the generator set battery cannot be maintained by an AC battery charger. ❑ Remote Emergency Stop Switch available as a wall mounted panel to remotely shut down the generator set. ❑ Remote Monitoring Panel. The Kohler® Remote Serial Annunciator (RSA II) enables the operator to monitor the status of the generator set from a remote location, which may be required for NFPA 99 and NFPA 110 installations. ig) Run Relay provides a relay indicating that the generator set is running. DISTRIBUTED BY: ® 2009 by Kohler Co., All rights reserved. G6 -100 10/09 Page 4 • • KOMI POWER SYSTEMS TECHNICAL INFORMATION BULLETIN TI B -102 Alternator Data Sheet Alternator Model: 4P8 Frequency: 60 Hz Speed: 1800 RPM Leads: 12 (6 Lead, 600 Volt) Voltage L -N /L -L Phase Power Factor Connection kW* (kVA) Class B Class F Class H 80 °C Continuous 90 °C Lloyds 95 °C ABS 105 °C Continuous 130 °C Standby 125 °C Continuous 150 °C Standby 139/240 48.2 52.0 53.7 56.7 62.2 61.3 64.4 277/480 3 0.8 Wye (60.3) (65.0) (67.1) (70.9) (77.8) (76.6) (80.5) 127/220 46.2 50.1 52.0 55.2 61.3 60.3 64.0 254/440 3 0.8 Wye (57.8) (62.7) (64.9) (69.0) (76.6) (75.4) (80.0) • 120/208 45.0 49.0 50.9 54.3 60.7 59.7 63.7 010/116 3 0.8 Wye (56.3) (61.3) (63.6) (67.9) (75.9) (74.6) (79.6) 110/190 45.0 47.0 48.0 50.0 55.0 54.0 55.0 220/380 3 0.8 Wye (56.3) (58.8) (60.0) (62.5) (68.8) (67.5) (68.8) 120/240 3 0.8 Delta 45.0 (56.3) 49.0 (61.3) 50.9 (63.6) 54.3 (67.9) 60.7 (75.9) 59.7 (74.6) 63.7 (79.6) 120/240 1 1.0 Dogleg 41.0 (41.0) 42.5 (42.5) 43.0 (43.0) 45.0 (45.0) 49.0 (49.0) 48.0 (48.0) 49.0 (49.0) 120/240 1 0.8 Dogleg 25.0 (31.3) ' 26.0 (32.5) 26.5 (33.1) 28.0 (35.0) 32.0 (40.0) 31.0 (38.8) 32.0 (40.0) 347/600 3 0.8 Wye 48.2 (60.3) 52.0 (65.0) 53.7 (67.1) 56.7 (70.9) 62.2 (77.8) 61.3 (76.6) 64.4 (80.5) * All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Submittal Data: 139/240 Volts, 0.8 PF, 1800 RPM, 60 Hz, 3- Phase, 130 °C Rise Symbol Per Unit Ohms Typical Resistances Phase Resistance Rotor Resistance Typical Reactances Synchronous 0.032 0.024 4.792 3.550 Direct Xd 2.928 2.169 Quadrature Xq 1.420 1.052 Transient Unsaturated X'd„ Saturated X'd Subtransient Direct Quadrature Negative Sequence Zero Sequence X "d X "q X2 X0 0.315 0.233 0.277 0.205 0.127 0.117 0.122 0.009 0.094 0.087 0.090 0.007 Typical Time Constants Armature Short Circuit Transient Short Circuit Transient Open Circuit Typical Field Current Full Load No Load Typical Short Circuit Ratio Harmonic Distortion RMS Total Harmonic Distortion Max. Single Harmonic Deviation Factor (No Load, L -L) Telephone Influence Factor Insulation Material Class per NEMA MG1 -1.66 Phase Rotation Symbol Value Ta 0.009 sec. Td 0.084 sec. T'do 0.893 sec. IfFL 20.5 amps IfNL 6.00 amps 0.545 2.7% 5th 4.9% <50 H ABC TIB -102 4P8 60 Hz 12/08j 1 • • • % Efficiency Voltage Dip 100 95 90 85 80 75 70 45 40 35 30 25 20 15 10 5 0 0 4P8, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL ALTERNATOR EFFICIENCY* Output (kW) 4P8, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 50 100 150 Locked Rotor kVA 200 250 * 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 4P8 60 Hz 12/08j TIB -102 ._ 1.0 PF 0.8 PF r....,....______. 0 5 10 15 20 25 30 35 40 45 50 55 60 6! Output (kW) 4P8, 60 Hz, 139/240, 277/480 Volts, Wye TYPICAL MOTOR STARTING CHARACTERISTICS* 50 100 150 Locked Rotor kVA 200 250 * 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 4P8 60 Hz 12/08j TIB -102 • • • Time, Seconds 1000 100 10 1 0.1 0.01 4P8, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 10 100 tl 0 I la a 1000 Armature Current, Amps Alternator Damage Curve ma os Line -to -Line 1 Phase TIB -102 4P8 60 Hz 12/O8j 3 Phase Symmetrical 10000 • m Line -to- Neutral 1 Phase 3 Industrial Generator Set Accessories • KOHLERPOWER SYSTEMS • • 20 -3250 kW Industrial Generator Set Voltage Regulators 9p p� 0 01 affff� FcWVER SYSTEMS NATIONALLY REGISTERED u ' 0 ........ .e ® ®O o �o -_- _o ,Do so 1 n O©0® 0000 000© ----4 to gagnffi 000 ,„, U Declslon- Maker® 550 Controller with Menu - Driven Integral Voltage Regulator Decision- Maker®•3000 Controller with Integral Voltage Regulator 'worn ow or. Gad 13. 10133. 11 Ow* 31331 gun* Ma 01313 11/311 bowl Mt 3 • l Digital DVR® 2000E Voltage Regulator -..- !� o Q I l o -I owning 1 = mm fk3 y� - mum., EiluE.E 1,9,.:1,c;......„1 l � po o o 0 o � I ! ! . I40 .. - . Q I o lW 6♦Nas 0116 020oa 00 !1 34i3 9 R. Fast - Response"' II PMG /RMS Voltage Regulator (RMS Voltage Regulator Circuit Board Shown) Voltage Regulators The following information provides general features, specifications, and functions of available voltage regulators. This information generally applies to a single generator set and multi- ple generator sets with paralleling applications. Refer to the respec- tive generator set specification sheet and see your authorized distribu- tor for information regarding specific voltage regulator applications and availability. Integral Voltage Regulator with Kohler® Decision- Maker ®550 Controller and Menu - Driven Selections (20 -3250 kW Generator Set Models) The voltage regulator is integral to the controller and uses micropro- cessor 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 Kohler® Decision - Maker ®3000 Controller (20 -300 kW Generator Set Models) The voltage regulator is integral to the controller and uses micropro- cessor logic providing ±0.5% no -load to full -load regulation using root - mean- square (RMS) voltage sensing. The voltage regulator features three -phase sensing and is available for 12- or 24 -volt engine electrical systems. Digital DVR® 2000E Voltage Regulator (350 -2250 kW Generator Set Models) The digital voltage regulator has ±0.25% no -load to full -load regulation using RMS voltage sensing. The voltage regulator features three -phase sensing and is available for 12- or 24 -volt engine electrical systems. Fast Response' II PMG with Average Voltage Sensing Voltage Regulator (20 -300 kW Generator Set Models) The solid -state voltage regulator has ±2% no -load to full -load regula- tion using average voltage sensing. The voltage regulator features single- or three -phase sensing options and is available for 12- or 24 -volt engine electrical systems. Available with optional ±1% no -load to full -load regulation using aver- age single -phase voltage sensing. Fast Response"' II PMG with RMS Sensing Voltage Regulator (20 -300 kW Generator Set Models) The solid -state voltage regulator has ±0.5% no -load to full -load regula- tion using RMS voltage sensing. The voltage regulator features single- or three -phase sensing options and is available for 12- or 24 -volt engine electrical systems. Not available on all models. DVR® Is a registered trademark of Marathon Electric Mfg. Corp. G6-58 11/08c ' 0 Q n ----4 to 000 ,„, o °Qa Decision- Maker®•3000 Controller with Integral Voltage Regulator 'worn ow or. Gad 13. 10133. 11 Ow* 31331 gun* Ma 01313 11/311 bowl Mt 3 • l Digital DVR® 2000E Voltage Regulator -..- !� o Q I l o -I owning 1 = mm fk3 y� - mum., EiluE.E 1,9,.:1,c;......„1 l � po o o 0 o � I ! ! . I40 .. - . Q I o lW 6♦Nas 0116 020oa 00 !1 34i3 9 R. Fast - Response"' II PMG /RMS Voltage Regulator (RMS Voltage Regulator Circuit Board Shown) Voltage Regulators The following information provides general features, specifications, and functions of available voltage regulators. This information generally applies to a single generator set and multi- ple generator sets with paralleling applications. Refer to the respec- tive generator set specification sheet and see your authorized distribu- tor for information regarding specific voltage regulator applications and availability. Integral Voltage Regulator with Kohler® Decision- Maker ®550 Controller and Menu - Driven Selections (20 -3250 kW Generator Set Models) The voltage regulator is integral to the controller and uses micropro- cessor 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 Kohler® Decision - Maker ®3000 Controller (20 -300 kW Generator Set Models) The voltage regulator is integral to the controller and uses micropro- cessor logic providing ±0.5% no -load to full -load regulation using root - mean- square (RMS) voltage sensing. The voltage regulator features three -phase sensing and is available for 12- or 24 -volt engine electrical systems. Digital DVR® 2000E Voltage Regulator (350 -2250 kW Generator Set Models) The digital voltage regulator has ±0.25% no -load to full -load regulation using RMS voltage sensing. The voltage regulator features three -phase sensing and is available for 12- or 24 -volt engine electrical systems. Fast Response' II PMG with Average Voltage Sensing Voltage Regulator (20 -300 kW Generator Set Models) The solid -state voltage regulator has ±2% no -load to full -load regula- tion using average voltage sensing. The voltage regulator features single- or three -phase sensing options and is available for 12- or 24 -volt engine electrical systems. Available with optional ±1% no -load to full -load regulation using aver- age single -phase voltage sensing. Fast Response"' II PMG with RMS Sensing Voltage Regulator (20 -300 kW Generator Set Models) The solid -state voltage regulator has ±0.5% no -load to full -load regula- tion using RMS voltage sensing. The voltage regulator features single- or three -phase sensing options and is available for 12- or 24 -volt engine electrical systems. Not available on all models. DVR® Is a registered trademark of Marathon Electric Mfg. Corp. G6-58 11/08c • • Specifications and Features Specification /Feature Voltage Regulator Type Integral 550 Controller Integral with DEC 3000 Controller Digital DVR® 2000E Fast Response'" ll Fast Response°'lI w /RMS Sensing Generator Set Availability 20 -3250 kW Models 20 -300 kW Models 350 -2000 kW Models 20 od0 kW Models Selected 20 -300 kW Models Type Microprocessor based Analog/Discrete Status and Shutdown Indicators LEDs and Digital Display LEDs — DC Power LED 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 MIL-STD-750, Method 7111 -11 -1 Compliant Complianht NA Circuit Protection Solid- State, Redundant Software and Fuses 5 Amp Fuse 15 Amp Fuse Sensing, Nominal 100 240 Volts (L -N), 50 -60 Hz 95 -600 Volts (L -L), 25 -420 Hz 190 -277 Volts, (L -L) 50 -60 Hz 100 -160 Volts (L -N), 50 -60 Hz Sensing Mode RMS, Single- or 3 -Phase Average, Single- or Three -Phase RMS, Single- or 3 -Phase Input Requirements 8 -36 VDC -3 VAC, H 200 0-3660 0 H z (PMG) 8 -32 VDC 9 -18 or 18 -36 VDC Continuous Output 100 mA at 12 VDC 3 Amps at 75 VDC 100 mA at 2 VDC Maximum Output 100 mA at 12 VDC 7.5 Amps at 150 VDC (1 minute) 100 mA at 2 VDC Transition Frequency 50 -70 Hz 50 -70 Hz 40 -70 Hz 50 -70 Hz Exciter Field Resistance NA 18 -25 Ohms NA No -Load to Full -Load Voltage Regulation =0.25% x0.5% 10.25% x2'%° * Linear Loads 10.5% Linear Loads Thermal Drift <0.5% ( -40 °C to 70 °C) [ -40 °F to 158 °F] Range Less than 0.5% for 40 °C (72 °F) Ambient Temperature Change (15 °C to 70 °C) [59 °F to 158 °F] Range <1.0% 40 °C (72 °F) Change ( -40 °C to 70 °C) I -40 °F to 158 °F] Range <0.5% 40 °C (72 °F) Change ( -40 °C to 70 °C) [ -40 °F to 158 °F] Range Response Time Less Than 54 Less Than 74 Voltage Adjustment (of system voltage) x10% 150 -300 (low volt connection) 300 -600 (high volt connection) Voltage Adjustment Controller Keypad Controller Menu Knob Pushbutton Switches Potentiometer Remote Voltage Adjustment Digital Input Standard/ Analog 0 -5 VDC Input Optional N/A Remote - Mounted Digital or Analog Input Optional, 46 m (150 ft.) Max. Remote - Mounted Potentiometer Optional Remote - Mounted Potentiometer or Analog Input Optional Paralleling Capability Reactive Droop Standard N/A Optional Reactive Droop Kt Required Optional Reactive Droop Kt Required VAR /PF Control Input Standard N/A Optional — Op i VAR/PF Contrton ol IG t Reequirquir ed *A ±1% (linear loads) voltage regulator with single -phase voltage sensing is available on selected models. DVR® is a registered trademark of Marathon Electric Mtg. Corp. NA Data not available at time of print. Integral Voltage Regulator with Decision - Maker® 550 Controller • Digital Display Range Setting Default Selection Voltage Adjustme Volt Adj. x10% of System Voltage System Voltage Amplifier Gain . ator Gain Adj. 1 -10000 100% Underfrequency Unload or Frequency Setpoint Frequency Setp • 30 to 70 Hz 1 Hz Below System Frequency (ECM) 2 Hz Below System Frequency (non -ECM) Underfrequency Unload Slope Slope 0 -10% of Ra e (Volts per Cycle) 15 Volts per Cycle at 480 Volts (3.1 %) Reactive Droop Voltage Droop 0 -10% of System 4% of System Voltage VAR Control kVAR Adj. to Rated kVAR Generating •0 Absorbing 0 kVAR PF Adjust Control PF Adj. 0.7 to 1.0 Leading, 0.6 To 1.0 Lagging 0.8 La.. VAR/PF Gain Adjustment VAR/PF Gain Adj. 1 -10000 100% Integral Voltage Regulator with Decision - Maker® 3000 Controller Adjustment Digital Display Range Setting Default Selection Voltage Adjustment Volt Adj. x10% of System Voltage System Voltage Underfrequency Unload or Frequency Setpoint Frequency Setpoint 42 to 62 Hz 2.5 Hz Below System Frequency Underfrequency Unload Slope Slope 0 -10% of System Voltage (Volts per Cycle) 5 Volts per Cycle 06.59 11/09c ntegral Voltage Regulator with Integral Voltage Regulator with ecision - Maker® 550 Controller Decision - Maker® 3000 Controller • • digital display and keypad provide access to data. A two - ne vacuum fluorescent display provides complete and ncise information. • T : controller provides an interface between the generator set : nd switchgear for paralleling applications incorporating mu •le generator set and /or utility feeds. • The •ntroller can communicate with a personal computer direct) or on a network. See spec sheets G6 -76, Monitor III Softwa :, and G6 -50, Decision - Maker ®550 Controller Commu cations, for more information. • Using opt anal menu - driven, Windows ® -based PC software, an operate can monitor engine and alternator parameters and also pr, vide control capability. • The controll: supports Modbus® RTU (Remote Terminal Unit), an indu try standard open communication protocol. • The controller • ovides ISO 8528 -5, Class G3, compliance for transient res onse on some 20 -300 kW generator set models. See th : espective generator set spec sheet for specific applicati• s. Voltage Regulato Menu 11 Displays AVG L -L V Volt Adjustment • L1 -L2 Volts • L2 -L3 Volts (3- phase) • L3 -L1 Volts (3- phase) Under Freq. Unload Enabled N/Y • Frequency Setpoint (cut -in point) • Slope Volts- Per -Cycle Reactive Droop Enabled N/Y • Voltage Droop at 0.8 PF Rated Lo VAR Control Enabled N/Y (active only when the dl . tal Input Is active) • Total kVAR (running) kVAR Adjustment • Generating/Absorbing Y/N PF Control Enabled N/Y (droop at rated load, 0.8 PF) • Average PF (running) PF Adjustment • Lagging/Leading Y/N Regulator Gain Adjustment Utility Gain Adjustment Reset Regulator Defaults DVR® is a registered trademark of Marathon Electric Mtg. Corp. Modbus® is a registered trademark of Schneider Electric. Windows® is a registered trademark of Microsoft Corporation. • A digital display and pushbutton /rotary dial provide access to data. A two -line LCD display provides complete and concise information. • The controller provides ISO 8528 -5, Class G3, compliance for transient response on some 20 -300 kW generator set models. See the respective generator set spec sheet for specific applications. • See G6 -100 Decision - Maker® 3000 for more information. Generator Set Calibration Menu • L1 -L2 Volts • L2 -L3 Volts (3- phase) • L3 -L1 Volts (3- phase) • L1 -N Volts • L2 -N Volts • L3 -N Volts (3- phase) Voltage Regulation Menu • Adjust voltage, ±10% igital DVR® 2000E Voltage Regulator he sealed electronic, solid -state microprocessor -based 'tal voltage regulator controls the generator set output by re lating the current flow into the exciter field. • The • • ital voltage regulator is equipped with single- and /or three -. ase sensing. Single -phase sensing is achieved by conne g terminal E2 and E3 to the same generator set terminal. • Provisions - e included in the regulator to allow the paralleling o o or more generator sets using either reactive droop r reactive differential (cross current) compensation h the addition of an external 5 -amp 5VA current transform (paralleling capability with optional DVR® 2000EC moo :I only). • The underfrequency nction allows the generator set to operate with a constan volts- per -hertz characteristic. • The over - excitation funct n monitors the voltage regulator output voltage and causes e voltage regulator to shut down when the output volta• : exceeds the preset trip level of 80 volts for 15 seconds. • The overvoltage function monit• the voltage regulator sensed voltage and causes the v age regulator to shut down when the sensed voltage ex eds the preset trip levels of 120% for 0.75 seconds. • The voltage regulator is equipped with • sensor that monitors the ambient temperature and I turn itself off when the temperature exceeds 70 °C (15 ' F). • The loss of the sensing function causes the oltage regulator to shut down if an open circuit occu in one or more of the sensing leads. • The field current limit function monitors voltage r: 'ulator output current and limits current should a heavy lo- • or short circuit occur across the field output terminals. • The manual mode of field current controls aid in setup n troubleshooting. • The alarm output contacts provide remote indication of fau condition. G6 -58 11/09c Industrial Generator Set Accessories • KOHLERPOWER SYSTEMS System Batteries 9001 NATIONALLY REGISTERED Typical Overall Dimensions W • Battery Specifications • Kohler Co. selects batteries to meet the engine manufacturer's specifications and to comply with NFPA requirements for engine - cranking cycles. • Heavy -duty starting batteries are the most cost - effective means of engine cranking and provide excellent reliability in generator set applications. • Batteries are rated according to SAE standard J -537. All batteries are 12 -volt and have lead- calcium or lead- antimony plates with sulfuric acid electrolyte. • Most generator set battery kits offer dry- charged or wet - charged batteries. • Tough polypropylene cases protect against life- shortening vibration and impact damage. • Removable cell covers allow checking of electrolyte specific gravity. A B C 4D 8D o e 31 0 24F e 0 Battery Post Layouts A—C and Styles 1 -2 1 2 Post Y Positive, 17.48 dia. Negative, 15.88 dia. 15.88 height 1:9 taper r-16___T__ 12.7 -19.1 height 3/8 -16 UNC -2A thread Notes: Dimensions are in mm; 25.4 mm equals 1 inch. BCI group numbers shown in italics. Order stud kit 254427 to convert from Style 2 to Style 1. 06-16 12/09z Use the tables to find the Battery Kit Number and Charge Type for your model and then go to the System Batteries Specifications •table on the last page for battery specifications. Batteries are for applications below and above 0 °C (32 °F). Gas Models with 12 -Volt Engine Electrical Systems Diesel Models with 12 -Volt Engine Electrical Systems • • Models Charge Type Battery Kit Number 25RZGB Wet PA- 256985 30RZG Wet PA- 256985 30RZGB Wet PA- 256985 35RZG Wet PA- 256985 40REZG Wet PA- 256985 45REZG Wet PA- 256985 45RZG Wet PA- 256985 50REZG Wet PA- 256985 5ORZGB Wet PA- 256985 60REZG Wet - PA- 256985 60HL(9 wet I'A- 2bti96b 80REZG Wet PA- 256985 80RZG Wet PA- 256985 100REZG Wet PA- 256985 100RZG Wet PA- 256985 125REZG Wet PA- 256985 125RZG Wet PA- 256985 150REZG Wet PA- 256985 150RZGB Wet PA- 256985 Gas Models with 24 -Volt Engine Electrical Systems Models Charge Type Battery Kit Number 180REZX Wet PA- 324588 180RZX Wet PA- 324588 200REZX Wet PA- 324588 200RZX Wet PA- 324588 250REZX Wet PA- 324588 250RZX Wet PA- 324588 400REZX Wet PA- 324588 400RZX Wet PA- 324588 Models Charge Type Battery Kit Number 10REOD /REODB* Wet PA- 256985 10REOD /REODB* Dry PA- 225290 10REOZD /REOZDB* Wet PA- 256985 10REOZD /REOZDB* Dry PA- 225290 15REOD /REODB* Wet PA- 256985 15REOD /REODB* Dry PA- 225290 15REOZD /REOZDB* Wet PA- 256985 15REOZD /REOZDB* Dry PA- 225290 20REOD /REODB* Wet PA- 256985 20REOD /REODB* Dry PA- 225290 20REOZD /REOZDB* Wet PA- 256985 20REOZD /REOZDB* Dry PA- 225290 20REOZJB Wet PA- 256985 20REOZJC Wet PA- 256985 30REOZJB Wet PA- 256985 30REOZJC Wet PA- 256985 40REOZJB Wet PA- 256985 40REOZJC Wet PA- 256985 50REOZJB Wet PA- 256985 50REOZJC Wet PA- 256985 60REOZJB Wet PA- 256985 60REOZJC Wet PA- 256985 80REOZJB Wet PA- 256985 BOREOZJD Wet PA- 256985 80REOZJE Wet PA- 256985 100REOZJB Wet PA- 336692 100REOZJD Wet PA- 256985 100REOZJE Wet PA- 256985 125REOZJB Wet PA- 336692 125REOZJD Wet PA- 336692 150REOZJB Wet PA- 336692 150REOZJD Wet PA- 336692 * Service kit GM40633 may be required when the original battery is replaced. See Service Bulletin SB -658. G6-16 12/09z KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 - 459 -1646 For the nearest sales and service outlet in the • US and Canada, phone 1 -800- 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Use the tables to find the Battery Kit Number and Charge Type for your model and then go to the System Batteries Specifications table on the last page for battery specifications. Batteries are for applications below and above 0 °C (32 °F). Diesel Models with 24 -Volt Engine Electrical Systems continued Models Charge Type Battery Kit Number Dual Starter Motors, continued 1500REOZDC Dry GM28546 -KP1 1500REOZDC Wet GM34405 -KP1 1600REOZM Dry GM28546 -KP1 1600REOZM Wet GM34405 -KP1 1600REOZMB Dry GM28546 -KP1 1600REOZMB Wet GM34405 -KP1 1750REOZDC Dry GM28546 -KP1 1750REOZDC Wet GM34405 -KP1 1750REOZMB Dry GM28546 -KP1 1750REOZMB Wet GM34405 -KP1 1820REOZM Dry GM28546 -KP1 1820REOZM Wet GM34405 -KP1 System Batteries Specifications Models I Charge Type I Battery Kit Number Dual Starter Motors, continued 2000REOZDC Dry GM28546 -KP1 2000REOZDC Wet GM34405 -KP1 2000REOZM Dry GM28546 -KP1 2000REOZM Wet GM34405 -KP1 2000REOZMB Dry GM28546 -KP1 2000REOZMB Wet GM34405 -KP1 2250REOZDC Dry GM28546 -KP1 2250REOZDC Wet GM34405 -KP1 2500REOZDB Dry GM28546 -KP1 2500REOZDB Wet GM34405 -KP1 2800REOZDB Dry GM28546 -KP1 2800REOZDB Wet GM34405 -KP1 3000REOZD Dry GM28546 -KP1 3250REOZD Wet GM34405 -KP1 Battery Kit Number Charge Type* Battery Part Number Battery Qty. per Kit BC! Group Size Battery SAE Dimensions, mm (In.) L W H Cold Cranking Amps at -18 °C (0 °F) Minimum Reserve Capacity Minutes at 27 °C (80 °F) Minimum Battery Post Layout and Style GM22297 -KP1 Dry GM22349 2 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 N1 GM28546 -KP1 Dry GM22349 4 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 NI GM34404 -KP1 Wet GM34399 2 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 Ni GM34405 -KP1 Wet GM34399 4 8D 527.1 (20.8) 282.4 (11.1) 276.4 (10.9) 1150 400 N1 PA- 225290 Dry 225289 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 130 C/1 PA- 256985 Wet 256984 1 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 120 C/1 PA- 324588 Wet 324586 2 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 185 B/2 PA- 324589 Dry 324587 2 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 200 B/2 PA- 336071 Wet 256984 2 24 273.0 (10.8) 173.0 (6.8) 228.6 (9.0) 650 120 C/1 PA- 336692 Wet 324586 1 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 950 185 B/2 PA- 354065 Wet 354147 4 31 330.2 (13.0) 173.0 (6.8) 239.8 (9.4) 700 170 8/2 * Charge type: Dry- charged batteries do not contain electrolyte. Supply and add electrolyte per instructions enclosed with each kit. Wet- charged batteries contain electrolyte and have removable covers. NOTE: Battery kit numbers on the Price List may appear with PA- (loose kit) and /or without PA- (installed kit) for some generator set models. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler® generator set distributor for availability. DISTRIBUTED BY: ® 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 by Kohler Co. All rights reserved. 66-16 12/09z Industrial Generator Set Accessories • KOHLERPOV'V'ER SYSTEMS Float /Equalize Battery Charger 09001 NATIONALLY REGISTERED • • ® WARNING Woe AC pm Ma anletl , D.G. A.C. OUTPUT INPUT 0 TYPE ABC TYPE ABC 25 A 120 VAC-7A 240 VAC-5A POWER O ON 0 ,sl,,,.I,, 5 \DC AMMETER 0 5 10 15 20 2S VOLTS 0 Specifications Standard Features • Kohler automatic battery chargers feature two charging modes to keep lead -acid and nickel - cadmium batteries fully charged without overcharging. The battery charger automatic float -to- equalize operation maintains battery voltage with no manual intervention. • Temperature compensation feature prevents overcharging or undercharging battery at high /low ambient temperatures. • Current - limiting circuitry prevents battery charger from overload at low battery voltage and during a short circuit. The ten amp DC current limit allows the battery charger to remain connected to the battery during engine cranking. • Battery charger complies with NFPA 110 code requirements when equipped with optional alarm circuit board. Alarm board features low battery voltage, high battery voltage, and battery charger malfunction alarm contacts. Loose Battery Charger Kit No. Installed Battery Charger Kit Nos. NFPA 110 Alarm Outputs Output Number of Cells Voltage Amps Lead Acid NI-Cd PAD - 292862 — No 12 10 6 9 0. PAD - 292863 — Yes PAD - 292864 GM28562 -KA2, -KA4 No 24 12 18 PAD - 292865 GM28562 -KA1, -KA3 Yes AC Input Voltage, Frequency 120/240 VAC, 50/60 Hz DC Voltage Regulation ±1% Weight (battery charger without mounting brackets) 11.8 kg (26 lb.) Dimensions, L x D x H (battery charger without mounting brackets) 271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.) Note: Installed battery charger kits are available on selected generator set models. See your authorized distributor for availab lity. G6-15 5/051 • • • 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. E!Equalize Voltage � Float Voltage 50% of High Rate Float Current Time —� ® High Rate Constant Current Mode Equalize Mode ❑ Float Mode Temperature Compensation The battery charger compensates for battery temperature using a negative temperature coefficient. The battery charger provides temperature compensation of - 2mv / °C per cell over the ambient temperature range of -40 °C up to 60 °C. The temperature compensation automatically adjusts the float and equalize voltage settings to prevent the battery from overcharging at high ambient temperatures and undercharging at low ambient temperatures. Figure 1 60 40 0) E 20 0 m -20 92 94 96 98 100 102 104 106 % of Nominal Charging Voltage G13-15 5/05i Figure 2 • • • Standard Features • Ammeter and voltmeter indicate battery charging rate with 5% full -scale accuracy. POWER ON lamp indicates battery charger is operating. • AC input and DC output fuses prevent battery charger damage from abnormal overload and short- circuit conditions. • Operational temperature range is from -40 °C ( -40 °F) to 60 °C (140 °F). Battery charger float and equalize voltage automatically adjust throughout the temperature range. • Reverse polarity protection circuitry prevents battery charger from energizing if improperly connected. • Internal terminal blocks for AC input and DC output/ sensing lead connections. • DC voltage regulation of ±1% from no load to full load and AC input line voltage variations of ±10 %. • UL listed /CSA certified. • Wall- mount, slotted enclosure with knockouts for customer conduit installation. • Reconnection blocks allow operation at 120 or 240 volts AC, single phase, 50 or 60 hertz. • Battery charger circuitry protected from AC line and DC load voltage spikes and transients. • Terminal block for remote battery sensing leads. • Automatic float -to- equalize operation with individual potentiometer adjustments. Charge up to 12 lead -acid or 18 nickel- cadmium battery cells. • No adjustments are necessary for lead -acid or nickel- cadmium batteries. • Oversized transformer and SCR heatsink allow constant current charging at 10 amps up to the equalize voltage setting for fastest battery charging. Note: The battery charger will discharge the engine starting battery(ies) when the battery charger is connected to the battery(ies) and is not connected to an AC power supply. To prevent engine starting battery(ies) discharge, install battery charger relay kit GM39659. 06 -15 5 /05i KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 - 459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 -544 -2444 Kohl erPowerSystems .com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 10.67 [271 ] 7.00 [178] C C7 ai m WARNING D.C. AC. OUTPUT INPUT TYPE ABC TYPE ABC 25 A 120 VAC-7A 240 VAC-6A POWER \0 1( ,)os 5 0 \DC AMMETER N A 45 A .25 [6] DIA. (2 HOLES) 7.00 [178] .500 DIA. X .219 DIA. [12.7 X 5.6] KEYHOLE 2 PLACES AC TERMINAL BLOCK DC TERMINAL BLOCK i 0 c1� 1�� 1�11�1►�II1�II1 1 2 3 4 6 6 O SENSE OUTPUT VIEW B -B CUSTOMER CONNECTIONS 5.63 [143] 1 i i 0 0 LV - N.O. CONTACTS, CLOSE ON LOW BATTERY VOLTAGE HV - N.O. CONTACTS, CLOSE ON HIGH BATTERY VOLTAGE CM - N.O. CONTACTS, CLOSE ON LOSS OF AC INPUT OR LOSS OF DC OUTPUT VIEW A -A OPTIONAL ALARM BOARD HV ADJ. LO AEU. LE03 LED1 Q ® ® Q ADV -5871 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 Kohl ere generator set distributor for availability. DISTRIBUTED BY: © 1992, 1993, 1994, 1895, 1999, 2003, 2005 by Kohler Co. All rights reserved. G6 -15 5/051 CUSTOMER INPUT CONNECTIONS CUSTOMER OUTPUT CONNECTIONS AC TERMINAL BLOCK 120 VOLT INPUT 240 VOLT INPUT DC TERMINAL BLOCK BATTERY SENSING CONNECTIONS IF CHARGER OUTPUT LEADS A THAN OO pp p 0 A ID GRD V � qy �¢0I PGA p JUMPERS SENSE USE MINIMUM �1� ■■ ^111. ,I.1.- 4�;: p ®I� JI�.., 0 RUN SEPARATE LEADS TO BATTERY. 18 GA. WIRE. BATTERY CONNECTIONS C1 0'S 4 I I I I I I NOTE: BATTERY CHARGER IS CONNECTED FOR 120 VOLT INPUT AS STANDARD. WIRES MUST BE REPOSITIONED T TO 240 AS SHOWN TO CONNECT TO 240 VOLT INPUT. AC INPUT FUSE MUST BE CHANGED TO AGREE AS SHOWN BELOW. FUSE SUPPLIED. INPUT FUSE 120 VAC 7A TYPE ABC 240 VAC 5A. TYPE ABC POS. 6 NEG. USE MIN. IO GA WIRE. y .dill NOTE. FOR DC CONNECTIONS. USE STRANDED COPPER WIRE. (GOV, ATIO 1270 Whin. PLASTIC INSULATION. LA. STYLE 1015, CSA TYPE TEW. 233860 AC TERMINAL BLOCK DC TERMINAL BLOCK i 0 c1� 1�� 1�11�1►�II1�II1 1 2 3 4 6 6 O SENSE OUTPUT VIEW B -B CUSTOMER CONNECTIONS 5.63 [143] 1 i i 0 0 LV - N.O. CONTACTS, CLOSE ON LOW BATTERY VOLTAGE HV - N.O. CONTACTS, CLOSE ON HIGH BATTERY VOLTAGE CM - N.O. CONTACTS, CLOSE ON LOSS OF AC INPUT OR LOSS OF DC OUTPUT VIEW A -A OPTIONAL ALARM BOARD HV ADJ. LO AEU. LE03 LED1 Q ® ® Q ADV -5871 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 Kohl ere generator set distributor for availability. DISTRIBUTED BY: © 1992, 1993, 1994, 1895, 1999, 2003, 2005 by Kohler Co. All rights reserved. G6 -15 5/051 Industrial Generator Set Accessories • KOHLERPOWER SYSTEMS Weather andl Sound Enclosures • • 09001 -, SFR TEnas NATIONALLY REGISTERED 25 -60 kW Enclosure r :i O 80 -150 kW Enclosure NOT APPLICABLE Applicable to the following: 25- 150REZG Weather Enclosure Standard Features • Internal- mounted critical silencer and flexible exhaust connector. • Skid - mounted, steel construction with hinged doors. • Fade -, scratch -, and corrosion - resistant Kohler® cream beige powder -baked finish. • Lockable, flush- mounted door latches. • Vertical air inlet and outlet hoods with 90 degree angles to redirect air and reduce noise. • High wind bracing, 241 kph (150 mph). Sound Enclosure Standard Features • Includes all of the weather enclosure features with the addition of acoustic insulation material. • Skid - mounted, steel or aluminum construction with hinged doors. Aluminum enclosures are recommended for high humidity and /or high salt/coastal regions. • Acoustic insulation that meets UL 94 HF1 flammability classification and repels moisture absorption. • Sound attenuated enclosure that uses up to 25 mm (1 in.) of acoustic insulation, acoustic -lined air inlet hoods, and acoustic -lined air discharge hood. Weather and Sound Enclosure Specifications Model Max. Dimensions, mm (In.) Weight, kg (lb.) t Sound Enclosure, Sound Pressure at 7 m (23 ft.), dB(A) Length Width Height Steel Weather Enclosure Steel Sound Enclosure Aluminum Sound Enclosure 25REZG 2585(101.8) 1078 (42.4) 1509 (59.4) 855 (1880) 860 (1891) 768 (1689) 74 30REZG 919 (2021) 924 (2032) 832 (1830) 74 40REZG 977 (2149) 982 (2160) 890 (1958) 69 45REZG 1040 (2288) 1045 (2299) 953 (2096) 69 50REZG 1142 (2513) 1147 (2524) 1055 (2321) 68 o' 60REZG 1253 (2757) 1258 (2768) 1166 (2566) 69 80REZG - 3500(137.8) 1156 (45.5) 1697 (66.8) 1581 (2650) 1591 (3500) 1405 (2650) 70 100REZG 1715 (2945) 1725 (3795) 1539 (2945) 71 125REZG 1826 (3190) 1836 (4040) 1650 (3190) 71 150REZG 1954 (3470) 1964 (4320) 1777 (3470) 74 Note: Refer to the respective ADV drawings for details. 1- Weight includes the generator set (wet), enclosure, and silencer. The generator set weight represents using the largest alternator option. G6 -106 1/10c KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 -459 -1646 For the nearest sales and service outlet In the US and Canada, phone 1- 800 -544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Weather and Sound Enclosure Fade -, scratch -, and corrosion- resistant powder -baked finish Hinged doors for ease of servicing Alternator access panel (40 -60 kW models only) Lockable, flush- mounted door latches prevent tampering Enclosed exhaust silencer for improved safely and noise reduction Vertical air discharge through an air outlet grille �F•+ •,•• •. IT glip}U Ui•i• •4cl 11'01,• 111,,• .•.•••••I•••• •••••'••• 1•1411 Rodent guards and skid Fixed air end caps prevent flow inlet unwanted animal entry grille Enclosure ships assembled on generator set skid when ordered installed. Note: 40 -60 kW shown, other models are similar. Oil drain and radiator drains ADV -7657- Acoustic insulation meeting UL 94 HF1 flammability classification Enclosure Features • Available in steel (14 gauge) formed panel, solid construction. Preassembled package offering corrosion resistant, dent resilient structure mounting directly to skid. • Powder -baked paint. Superior finish, durability, and appearance. • Internal critical 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 oil fill and battery. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler© generator set distributor for availability. • Cooling air discharge. Weather protective design featuring a vertical air discharge outlet grille. Redirects cooling air up and above enclosures to reduce noise ambient. • The enclosure has a UL Listing. Additional Sound Enclosure Features • Available in steel (14 gauge) or aluminum 3.2 mm (0.125 in.) formed panel, solid construction. • Attenuated design. Acoustic insulation UL 94 HF1 listed for flame resistance offering up to 25 mm (1 in.) mechanically restrained acoustic insulation. • Cooling air discharge. The sound enclosures include acoustic insulation with urethane film. DISTRIBUTED BY: ® 2009, 2010 by Kohler Co. All rights reserved. G8 -108 1/10c Industrial Generator Set Accessories � KOHLERPOWER SYSTEMS • R9001 Imo • ssrtMS NATIONALLY REGISTERED 25 -60 kW Enclosure O • K> 80 -150 kW Enclosure NOT APPLICABLE Weather and Sound Enclosures Applicable to the following: 25- 150REZG Weather Enclosure Standard Features • Internal- mounted critical silencer and flexible exhaust connector. • Skid - mounted, steel construction with hinged doors. • Fade -, scratch -, and corrosion- resistant Kohler® cream beige powder -baked finish. • Lockable, flush- mounted door latches. • Vertical air inlet and outlet hoods with 90 degree angles to redirect air and reduce noise. • High wind bracing, 241 kph (150 mph). Sound Enclosure Standard Features • Includes all of the weather enclosure features with the addition of acoustic insulation material. • Skid - mounted, steel or aluminum construction with hinged doors. Aluminum enclosures are recommended for high humidity and /or high salt/coastal regions. • Acoustic insulation that meets UL 94 HF1 flammability classification and repels moisture absorption. • Sound attenuated enclosure that uses up to 25 mm (1 in.) of acoustic insulation, acoustic -lined air inlet hoods, and acoustic -lined air discharge hood. Weather and Sound Enclosure Specifications Model Max. Dimensions, mm (in.) Weight, kg (lb.) t Sound Enclosure, Sound Pressure at 7 m (23 ft.), dB(A) Length Width Height Steel Weather Enclosure Steel Sound Enclosure Aluminum Sound Enclosure 25REZG 2585(101.8) 1078 (42.4) 1509 (59.4) 855 (1880) 860 (1891) 768 (1689) 74 30REZG 919 (2021) 924 (2032) 832 (1830) 74 40REZG 977 (2149) 982 (2160) 890 (1958) 69 45REZG 1040 (2288) 1045 (2299) 953 (2096) 69 50REZG 1142 (2513) 1147 (2524) 1055 (2321) 68 0* 60REZG 1253 (2757) 1258 (2768) 1166 (2566) 69 80REZG 3500(137.8) 1156 (45.5) 1697 (66.8) 1581 (2650) 1591 (3500) 1405 (2650) 70 100REZG 1715 (2945) 1725 (3795) 1539 (2945) 71 125REZG 1826 (3190) 1836 (4040) 1650 (3190) 71 150REZG 1954 (3470) 1964 (4320) 1777 (3470) 74 Note: Refer to the respective ADV drawings for details. t Weight includes the generator set (wet), enclosure, and silencer. The generator set weight represents using the largest alternator option. 56 -108 1 /10c KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 -459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Weather and Sound Enclosure Fade -, scratch -, and corrosion- resistant powder -baked finish Alternator access panel (40 -60 kW models only) Hinged doors for ease of servicing Lockable, flush- mounted door latches prevent tampering Enclosed exhaust silencer for improved safety and noise reduction Vertical air discharge through an air outlet grille i...e.f...J.... �M. ii.iuM.i■ •tii'i.• •iM Mi• • il.MMM.M,..l•MM,.MM ,MM: ■.U.l... _ii.i II 0 Rodent guards and skid end caps prevent unwanted animal entry Fixed air flow inlet grille Enclosure ships assembled on generator set skid when ordered installed. Note: 40 -60 kW shown, other models are similar. Oil drain and radiator drains ADV -7657- Acoustic insulation meeting UL 94 HF1 flammability classification Enclosure Features • Available in steel (14 gauge) formed panel, solid construction. Preassembled package offering corrosion resistant, dent resilient structure mounting directly to skid. • Powder -baked paint. Superior finish, durability, and appearance. • Internal critical 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 oil fill and battery. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler© generator set distributor for availability. • Cooling air discharge. Weather protective design featuring a vertical air discharge outlet grille. Redirects cooling air up and above enclosures to reduce noise ambient. • The enclosure has a UL Listing. Additional Sound Enclosure Features • Available in steel (14 gauge) or aluminum 3.2 mm (0.125 in.) formed panel, solid construction. • Attenuated design. Acoustic insulation UL 94 HF1 listed for flame resistance offering up to 25 mm (1 in.) mechanically restrained acoustic insulation. • Cooling air discharge. The sound enclosures include acoustic insulation with urethane film. DISTRIBUTED BY: @ 2009, 2010 by Kohler Co. All rights reserved. G6 -108 1/10c • • • B J 8 7 6 5 4 [ 3 2 OUTLET. HOSE BARB .625 I.D. 79 4.6 --- 3.0 ---i INLET. HOSEBARB .625 I.D. 6.7 1.8 HEATER WITH / SENSING UNIT- 16-3 HPN X 10 LG. INV rm DAT oac4.c.■ mr2m WA; 5'510 ra2sos 2 $5]7 IM,. -BOS UPO.Alta AS PER VI. APPROVAL Ea ER R R 4 EACH —16-3 HPN X 54 LG. Notes: tj & Labeled with PIN. watts. volts. dole code. CSA & U.L. markings. 2. Dimensions are for reference only. 3. Mounting kit shipped loose in plastic bog. 1 L1- STAT..5 NPT W/ SENSING UNIT A TPS051GT10-018 Htr earn TPS SCOW 120V vd 1-stat 1012 CSA Y cord 1/2NPT w! t -stat 810 TPStOtG710018 HIr asm WS 1000W 120V vA I-stat 1012 CSA'Y cord 112NPT sYl I-slat 810 TPS102GT10-018 Htr asm TPS 1000W 240V vA I-stat 1012 CSA Y cord 1/2NPTWI I-stat 810 TPS151GT10-018 Htr asm TPS 1500W 1201/ vA I -51a1 1012 CSA Y cord 1/2NPT vA I-stat 810 • TPS181Gt1O-0i8 Htr asm TPS 1800W 120V vd tctat 1012 CSA Y cord II2NPTwI t -staf 810 TPS202GT10-018 Htr asm TPS 2000W 240V wl t-slat 1012 CSA Y card 1/2NPTwI fatal 810 PIN Description 8 6 -/- ` 16-3 HPN X 54 LG. 1500W/1 20VAC MOUNTING KIT SCALE I : 2 OR OR 120V 1SA NEMA 5-I5P 240V 15A NEMA 6-15P 120V 20A NEMA 5-20P KIM HOTSTART MFG. SPOKANE. WA. PROPR¢1ARY NIFORMA iION PN bh∎A•vm-.a0a6e bwY3 xaro.4P1� +whb+ebwa ekssa.0 T Htr osm TPS w/ f -stat CSA Y cord 1 /2NPT w/ t -stat .,n07.61. D.:r F .ter ER .rr`ct"ER 0310-03 0310 -03 aOaagi 4 CNF3 A- 4021 -20S F:O:S:•ICV - N/A IA`r `rs s N/A ! , N/A. 50 ACV $:sts DRAPRAO B MEl O 13 r' I OF 2 1 "62 2 I 0 C B A • • • 3.3 Vibration Isolation Use one of the vibration isolation types detailed in the following paragraphs. Also, connections between the generator set or its skid and any conduits, fuel lines, or exhaust piping must include flexible sections to prevent breakage and to isolate vibration. These connections are detailed in subsequent sections. Isolator types. The two primary types of isolators are neoprene and spring -type. Figure 3 -5 shows neoprene isolators between the engine - generator and the skid, referred to as integral vibration isolation mounting. Integral vibration isolation units come from the factory with neoprene vibration isolation. Neoprene isolators provide 90% vibration isolation efficiency and are sufficient for installations at or below grade. 3 1. To engine - generator 2. Skid crossmember 3. Neoprene vibration isolator Figure 3 -5 Neoprene -Type Integral Vibration Isolators Figure 3 -6 shows the spring -type isolator kit installed with direct-mRunted units. Direct- mounted units have no factory vibration isolation. Spring -type isolators provide 98% vibration efficiency, are suitable for any installation, and are required for above grade installations. r' D C B 8 7 6 5 • 4 3 2 • SUGGESTED BATTERY HEATER / CHARGER CONDUIT LOCATION (OPTIONAL) SUGGESTED BLOCK HEATER CONDUIT LOCATION (OPTIONAL) CONDUIT ENTRY AREA FOR GENERATOR — LOAD LEADS (BOTTOM ENTRY) CIRCUIT BREAKER OPTION, REMOTE CONNECTION TO TRANSFER SWITCH AND REMOTE ANNUNCIATOR. 325 112.8] vPO 4- 15 [3.0] 15 3.0 SUGGESTED LOCATION FOR FUEL INLET FLEXIBLE FUEL LINE: I IN NPT (MALE) m BATTERY RACK LOCATION 75 [3 Oj_ 305 [12.01 705 [27.8] 960 [37.81 0 FACE OF CONTROLLER CENT350NANNCE FUEL(INLET 2200 [86.61 yo 0 Pm n. 298 [11.71 FUEL INLET 1' NPT (MALE) (NAT. GAS OR LP. GAS) 0EC3000 CONTROLLER LOCATION RADIATOR2O'ENING . ; Ei :fl FUEL INLET MODEL ALTERNATOR WEIGHT (WET) SO 4P7 835 KG [1841 LEIS] 50 4P8 855 KG [1881 LBS1 50 4010 898 KG [1980 1851 60 4P8 855 KG [1881 LBS] 60 4S/ 956 KG 1 10b LBS] 60 4010 898 KG [1980 LOS] 60 4V9 1009 KG 12224 LEIS] 0 NOTES: 48g 19 0 I. IF fBC CERTIFICATION IS APPLICABLE •395 115.5? OR REOUIRED SEE SEISMC ADV FOR ) INSTALLATION INSTRUCTIONS. •437 1[201,8] 2. DIMENSIONS IN [] ARE ENGLISH STANDARD EOUIVALENTS. 8.0 p 6■ ( [ 31 A •8.01 A 3. a - ASTERISK DENOTES 864 [34.01 SKID WIDTH. D C 4)— B 50 MODEL, 4P7/4P8/4010 60 MODEL 4S7/4P8/4010 RECONNECTABLE I. 600V ALTERNATOR 5.0 0 5.7 LITER GM 2009 EMISSIONS 8 7 6 5 4 RE V DATE Oa COOOSI IE OMR. S[1 POI 00. EOM 1[015100 LEVEL IT Mxr ow 0100110 • ��{H��1�/A/� L*ETMC I PRGE • 2•25•05 MEN DRAWING 16 {100•1] —WI ii, '°' m: H►N✓HH�WiA FAR A 4 -07 -00 11EWS CORRECTED 1004161 RN r:. P. s PORN 1055105. OIH[R.: I 13w 0.3.5. POOE[: °u0 KISTSNOT5It AND 00 000 II [I CO IS 6 4 -27 -I0 1[•21 DENSE) WEIGHTS UPDATED 1601021 SAM ]..511 i' Iu 001)0000 �11N IAI AI [ aONM. cRS 00 C 4-21-10 IA •41 4P0 ADDED TO 50 MODEL IC•21 50I4P6 H W RNIa W 1 Ralla u[ 61114 ADDED TO CHART 1096131 SAM T(^.a:37 -8 ' ^' DIMENSION PEE D 5•15.10 ID -21 DEC3000 CONTROLLER VIEW ADDED 1618011 RRN APPROVALS DAVE 50 /80 GM ••••• ERN 2 21 00 0.11]"'` 1"' AI 3 ^— °f1 CR 2rn 2165 4.... 'D ' 2AS -o5 ADV -7671 3 2 8 7 6 5 • 4 3 2 • 50 MODEL, 4P7/4P8/4010 6D MODEL 407/4P8 /4010 RECONNECTABIE & 600V ALTERNATOR 5.0 d 5.7 LITER GM 2009 EMISSIONS t REV DATE CCWPOSITE POS. SEE EMS IC. 700 et1111a LEVEL 3.3.01 000 DRAWING 166112.11 BT 1011 A A-01-01 VIEN5 CORRECTED 1678061 [RH 1.20.10 SEE SHEET 1 1811021 SAM A -27 -10 ODE SHEET 1 1096131 SAM 6 -16 -ID STE SHEET 1 1518091 0 lL Apr 1. P [0H 3 3 II KONLER CO I NEEwc I Wi0 E ',ono 021555. WIO[l. WI $5084 O.S.A. ISIS 1555155 5[51110 700 DETAIL IS RORIE CO. 000/1/21 010 ll t 501 11 550 0. AOL 1• LEa3 51 0a 101[1(1000 TEE 00(0(0100. LL lI11lTS M DIMENSION PRINT 50/80 GM CPO 3 3 0/ 6.1t]+— Iy ^t or e wA JAS 3 -3.09 INA SA ADV -7871 I D 8 7 6 5 4 3 2 D C B A P C B • B 7 6 5 • 4 3 2 • MAXIMUM SEISMIC DESIGN RATING APPUES AS A SYSTEM TO GENSET, TANKS, ENCLOSURES AND ACCESSORIES GENSET MODELS FUEL TANK ENCLOSURE CAPACITY RATING LITERS GAL MAXIMUM IBC SEIMIC DESIGN ACCELERATION FOR ACHORING SYSTEM ANCHORING SYSTEM ANCHORING PLACEMENT LOCATIONS DOC 7 -10 pa) wo-see wavers woo rasa) 1 -0C-,0 (D-7) 4.43 C o3 4y 1.10 e WS LM, RUM COIN, mom 0-0 w oID04 wrt WI (W) 3-10-10 4ZDW 4(W10) A ANCHOR BRAND OTY C D F MIN. ANCHOR MODEL SHANK DIA EMBEDMENT ANCHOR SPACING G MIN. H MIN. 20 -60 REOZJC 25 -150 REZG 230 -275 REOZJE OPEN OR ENCLOSED UNITS UP THROUGH 908 1 240 MIX OF 3.2 4.43 G SEE GENSET & TANK ADVS FOR MTG. HOLES SEE NOTE 4 4 DUC- 34 -500L 19.05 [ 75] 127 [5.0] 127 [5.0] 215.9 [8.5] 254.0 [10.0] AFLX OF 3.2 4.43 G SEE GENSET ADV FOR MTG. HOLES HILTI 6 TZ 15.88 [ 62] 101.6 [40] 203.2 [8.0] 203.2 [8.0] SET ONLY NO TANK AFLX OF 3.2 4.43 G SEE GENSET ADV FOR MTG. HOLES HILTI 12 TZ 19.05 [ 75] 120.7 [4 75] 203.2 [8.0] 203.2 [8.0] 1786 472 AFLX OF 3.2 3.26 G 4.43 G SEE TANK ADV'S FOR MTG. HOLES HILTI HILTI 14 14 TZ HDA -P 19.05 [ 75] 120.7 [4 75] 203.2 [8.0] 203.2 [8.0] 20.0 [.79] 254 [100] 1016 [40.0] 1016 [40.0] 3573 944 1.50 G 1.50 G SEE TANK ADVS FOR MTG. HOLES HILTI 14 TZ 19.05 [ 75] 120.7 [4 75] 203.2 [8.0] 203.2 [8.0] 180 -200 REZX/ RZX OPEN UNITS ONLY ENCLOSED UNITS ONLY AFLX OF 3.2 1.83 G SEE GENSET ADV FOR MTG. HOLES HILTI 6 TZ 19.05 [. 75] 120.7 [4 75] 457.2 [18.0] 304.8 [12.0] 4.43 G SEE GENSET ADV FOR MTG. HOLES HILTI 6 HOA -P M20X250/50 20.0 [.79] 254 [10,0] 762.0 [30.0] 609.6 [24.0] AFLX OF 3.2 2.92 G SEE ENCLOSURE ADV FOR MTG. HOLES HILTI 8 TZ 19.05 [ 75] 120.7 [4.75] 203.2 [8.0] 203.2 (8.0) 4.43 G SEE ENCLOSURE ADV FOR MTG. HOLES HILTI 8 HDA -P M20X250/50 20.0 [.79] 254 [10,0] 635.0 [25.0] 635.0 [25.0] ONCRETE PAD • G MIN EDGE DISTANCE *ANCHOR PLATE A - ANCHOR BRAND B - PT( C - ANCHOR MODEL D - SHANK DIA. E - EMBEDMENT F - MIN ANCHOR SPACING SEE DETAIL A • G MIN EDGE DISTANCE ( TANK OR SKID ANCHOR BOLT ANCHOR NUT ANCHOR PLATE CONCRETE DETAIL A NOTE: 1) SPECIAL INSPECTION PER IBC SECTION 1704 IS REQUIRED ON ALL INSTALLATIONS. ALL ANCHORS MUST BE INSTALLED TO MEET COMPLIANCE 2) NO OTHER ANCHORS ARE ALLOWED WITHIN MINIMUN SPACING DISTANCE WITHOUT ADVANCED APPROVAL OF THE STRUCTURAL PROJECT ENGINEER Or RECORD. 3) •SEE NOTES ON SHEET 4 4) UNITED STRUCTURAL CONNECTORS. METRIC CAD FILE D C B A A 1 • H MIN CONCRETE THICKNESS 60 REOZJC SHOWN 8 ] 7 6 [ 5 4 3 DIMENSIONS IN ] ARE INCH EQUIVALENT moos wad sass - i30° m`e "a"®° KOHLERCQ '; �� smm am a awl aa�:e, °° sue" �, 2000/2003/2006 •..,.® e.„• w DIMENSION PRINT SEISMIC INSTRUCTION *- o-,,..s ,�, SEISMIC INSTRUCTION SERIES 60, VOLVO m u o-,we r" 1'° JOHN DEERE AND OM "°° ow o-1 ADV -7595 I D 2 1 • 8 7 6 5 • 4 3 2 • oar 0 nom, •03 MOM na oar 3 (A-U C n MO ICI MOM I•WI Sul n -13-011 ox Oar 2 O 4. IeO 1) CRI oz SCI ( ®p yr 1 -a-w ox o<v I ICC (0-4) IC n A me wwua mom IsuO) D D C B A SEISMIC INSTALLATION REQUIREMENTS: The following are requirements for seismic installation: 1. The design of post — installed anchors in concrete used for the component anchorage is pre — qualified for seismic applications in accordance with ADI 355.2 and documented in a report by a reputable testing agency. (ex. The Evaluation Service Report issued by the International code Council) 2. Anchors must be installed to an embedment depth as recommended in the pre — qualification test report as defined in Note 1. 3. Anchors must be installed in minimum 4000 psi compressive strength normal weight concrete. Concrete aggregate must comply with ASTM C33. Installation in structural lightweight concrete is not permitted unless otherwise approved by the structural engineer of record. 4. Anchors must be installed to the torque specification as recommended by the anchor manufacturer to obtain maximum loading 5. Anchors must be installed in the locations specified the Kohler ADV dimension print. 6. Anchor bolt design loads or specific anchors are specified on seismic Kohler ADV. 7. Anchor plates from Kohler must be installed at each anchor location between anchor head and equipment to tension load distribution. 8. Concrete floor slab and concrete housekeeping pads must be designed and rebor reinforced for seismic applications in accordance with ACI 318. 9. All housekeeping pad thickness must be designed in accordance with pre — qualification test report as defined in Note 1 or a minimum of 1.5x the anchor embedment depth, whichever is largest 10. All housekeeping pads must be doweled or cost into the building structural floor slab and designed for seismic application per ACI 318 and as approved by the structural engineer of record 11. Wall mounted equipment must be installed to a rebar reinforced structural concrete wall that is seismically designed and approved by the engineer of record to resist the added seismic loads from the components being anchored to the wall. 12. Floor mounted equipment (with or without housekeeping pad) must be installed to a rebor reinforced structural concrete floor that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the floor. 13. When installing to a floor or wall, rebar interference must be considered. 14. Attaching seismic certified equipment to any floor or wall other than those constructed of structural concrete and designed to accept the seismic loads form said equipment is not permitted by this specification and beyond the scope of this certification. 16. Attaching seismic certified equipment to any concrete block walls or cinder block walls is not permitted by this specification and beyond the scope of this certification. 17. For installations upon rooftop, steel dunnage shall be coordinated with the Structural Engineer of Record. 18. Installation upon only rooftop curb shall be coordinated with the curb manufacturer and the Structural Engineer of Record. Any curb or concrete pad that supports the RTU unit is beyond the scope of this certification. 19. Anchor locations, size, type and load requirements are specified on the installation drawing. Mounting requirements details such as brand, type, embedment depth, edge spacing, anchor spacing, concrete strength, wall bracing, and special inspection must be outlined and approved by the project Structural Engineer of Record to withstand the seismic anchor loads as defined on the seismic installation drawing. The installing contractor is responsible for the proper installation of oll anchors and mounting hardware, observing the mounting requirement details outlined by the Engineer of Record. Contact Kohler if a detail Seismic Installation Calculation Package is required. 20. Electrical wiring, piping, duct and other connections to the equipment is the responsibility of the installing contractor. It is necessary that these remain in tact, functional and do not inhibit the functionality of the generator set after a seismic event. Adequate slack shall be allowed cable and piping to allow for motions of set during a seismic event. *21. Concrete pad dimensions are minimum values to satisfy only the anchor bolt requirements. The pad must be designed by the project structural engineer of record. *22 Anchor bolt and concrete recommendations are for the maximum seismic design levels shown. If the specific application has a lower level, thinner concrete or alternate anchors may be acceptable. Consult Kohler. 2000/2003/2006 SEISMIC INSTRUCTION SERIES 60. VOLVO JOHN DEERE AND GM 8 7 6 5 4 3 METRIC CAD FILE DIMENSIONS IN 3 ARE INCH EQUIVALENT 'ZINO2O "` ICCMLER CQ OnoOmt 11D C s L-15-0/1 2 l I DIMENSION PRINT SEISMIC INSTRUCTION ADV -7595 I D C 8 A 8 i ii In4NU G:ANN0 Ifni I MI1 DI II IIII.II11111i111 1111 • TO TO A EXHAUST RAIN CAP 6 • 5 4 3 2 • 860 (33.871 TYP DOOR OPENING .PO ER SYSIFMS � V er 0 a,c AIR INTAKE - 2200 (8 .611 2565 [100.991 NOTE: IF IBC CERTIFICATION IS REQUIRED. SEE SEISMIC ADV FOR INSTALLATION INSTRUCTIONS 8 7 0 0 0 MODEL GENSET WEIGHT (WET) WITH ENCLOSURE ENCLOSURE ONLY MODEL GENSET WEIGHT (WET) WITH ENCLOSURE ENCLOSURE ONLY 25kW 4P4/404 STEEL WEATHER 855 Kg [1885 LEIS] 239 Kg 152 S1 60kW 4P8/1608 STEEL WEATHER 1099 Kg (2423 LOS] 239 Kg (527 LBS) STEEL SOUND ALUMINUM SOUND 30kW 4P5/405 STEEL WEATHER STEEL SOUND 860 Kg [1896 768 K9 [1693 878 89 [1936 883 Kg [1947 LOS] LOS] LOS] LOS) 244 152 Kg [33 BS] 239 Kg (527 LBSI 244 Kg (538 LBSI STEEL SOUND 1104 KO (2434 LBSI ALUMINUM SOUND 30kW 4P7/407 STEEL WEATHER STEEL SOUND ALUMINUM SOUND 40kW 4P5/405 STEEL WEATHER STEEL SOUND ALUMINUM SOUND 40kW 407 45kW 4P7 STEEL WEATHER :893126 Kg 9 Kg 4 Kg Kg Kg 941 Kg 849 Kg 971 Kg [1744 [2026 [2037 (1834 (2064 [2075 11872 (2154 LBSI LBS) LOS] LBSI LBSI LOS) LBS) LOS) 152 Kg [335 LOS) 60kW 457/4V7 ALUMINUM SOUND 1012 Kg 12231 LAS) STEEL WEATHER 1200 Kul 12646 LBS] 1205 Kg 12657 LOS] STEEL SOUND 244 Kg 1538 LBSI 152 Kg 1335 LOS] 239 Kg [527 LBS) 244 Kg [538 LBSI ALUMINUM SOUND 1113 Kg [2454 LBS] 152 Kg [335 LBS) 239 Kg [527 LBSI 244 Kg (538 LBSI 152 Kg [335 LBSI 239 Kg [527 LBSI 244 Kg [538 LBS) 152 Kg (335 LBS/ 239 Kg [527 LBS) 60kW 4P10/4010 60kW 4S9/4V9 STEEL WEATHER 1142 Kg [2518 LOS] 239 Kg [527 LOS/ STEEL SOUND 1141 Kg 12529 LBS] 244 Kg (538 LOS] ALUMINUM SOUND STEEL WEATHER STEEL SOUND 1055 Kg [2326 LBS] 1253 Kg [2762 LBS] 1258 Kg [2773 LOS] 152 Kg (335 LBSI 239 Kg (527 LBSI 244 Kg [538 LOS) ALUMINUM SOUND 1166 Kg [2571 LBS) 152 Kg (335 LB51 STEEL SOUND 982 Kg [2165 LOS] 244 Kg [538 LBSI ALUMINUM SOUND 890 Kg [1962 LOS] 152 Kg (335 LBSI 45kW 4P8/400 STEEL WEATHER 997 Kg [2198 LBS] 239 Kg [527 LEIS] STEEL SOUND 1002 Kg [2209 LOS] 244 Kg (538 LBS) ALUMINUM SOUND 910 Kg [2006 LBS] 152 Kg (335 LBSI 45kW 4P10/4010 STEEL WEATHER 1040 Kg [2293 LOS] 239 Kg (527 LBS) STEEL SOUND 1045 Kg [2304 LBS] 244 Kg (538 LBSI ALUMINUM SOUND 953 Kg [2101 LBS] 152 Kg (335 LOS) 50 4P7/407 STEEL WEATHER 1079 Kg [23T9 LOS] 239 Kg 1527 LBSI STEEL SOUND 1084 Kg 72390 LBS) 244 Kg 1538 LBSI 50 4P1O/4010 ALUMINUM SOUND 992 Kg [2187 LBSI STEEL WEATHER 1142 Kg (2518 LOS) STEEL SOUND 1147 Kg (2529 LOS] 152 Kg 1335 LBS] 239 Kg (527 LBS) 244 Kg (538 LOS) ALUMINUM SOUND 1055 Kg 12326 LOS) 152 Kg [335 LBS] 321 1078 (42.421 r 400 112.621 ALTERNATOR ACCESS PANEL 37 m`. ( 1 . 4 7 1 4% 017.5 1.691 715.751 a 965 [37.991 1040 [40.94] 25-60 KW GM 2009 EMISSIONS MODELS 3PH RECONNECTABLE, (PI-1 AND 600V ALTERNATORS to 2585 [101.17] QEi CIOXIIMFONER SYSTEMS 340 -0 1555 AIR INTAKE [13.39] 161.22 DIMENSIONS IN f 1 ARE INCH EQUIVALENTS REV DATE ON COMM Ii[ MRS. Vu7 10. iCa AE VISKA LEVEL 12 -9 -08 MEN DRAWING 1868131 B1 PLO 2.3 -09 SKID VIEWS UPDATED A IC-4, D -21 CHART REVISED TO REELECT 2000 EMISSIONS MODELS 1870401 PLD 6 -I -09 18-8) 1509 WAS 1386 ID -81 395 WAS 391 1072121 1 -1 -10 IC-5) MODEL 50 4P8 RODEO 70 TABLE 1888851 SAM PRO LI11% 11 , KOHLER CO 'METRIC! PRD-E POWE1 5891006. ORE En. 1 I 93041 0,1.0 11f PA!W AID IA I(f111 R U DEDAII If •O11E1 CO. POGPEIR AID 111(5 OT OF USED R. ALL I1 /11101700 111rv010101AIR P0101011. '10x71 Cl wamg 2-8 -10 10. C-5.21 SENSED SEISM% UPDATED 1891021 SAN AP11 Vas PATE PLD 129 OR " "' DIMENSION PRINT, 25 -60 KW GM ENCLOSURE 3 '�°'• PLD 12 9 OB "4" RJD 12 -9 -08 TTNT O.101'•Ir. 'Ill Al I OS WI ADV -7657 2 D C B A D C B A • 8 7 6 1 5 • 4 3 1 2 1 • JUNCTION BOX rr rr rr NOTE ORR Hi TRANSFORMER DOT OR 'H1' TOWARD GENERATOR CT1 CT2 CT3 TO SLB (P6) [FRII] { SEE DWG. GM35943 OCON28 V7 (STAT) —V/ (185 -1/7) TV.. 4� —O�C-O-Nn�2-9��� V8 (st* } 08 (765-116) OCON30 V9 (STAT)-E=0=0- 119 (785 119) OCON31 VO (STAT)-1===1— VO (CONT VO) SEE DWG. 0 .135943 TO f STAT [FRII] TO { SEE DWG. 01435943 0 0 0 0 0 0 0 0 0 TB10 1 2 3 4 5 6 P 70 7N 0 0 0 0 0 0(1/ o t k tUft TB5 P9A CONNECTIONS PSI /1 P (7810 -P) 2 N/C 3 32A (182 -N3) 4 Nil (7810 -7N) 5 N/C 6 N/C P9A i�e)O1 502 P21 Col El RE El 1:1 ❑P23 TB1 MEm DEC -3000 CONTROLLER N P1 35A 58 38 141' 63 31 CRNYEL 705 146 P2 13 12 n O R OA 16 V7 V7A (1B5 -V7)J YB V8A (785 -V8) —•"' V9 V9A (1135 -W)-- VO 10 VO (000631) —� T82 °t1 OCON32C=:- —56 (P4A -20)� 32A (P9A -3) 2 (W1) A (055 -2) 1 (MS 1) ESS OEN nee a. Nano Mme) (A-0 084 • 1¢ 9013 s 3 • • (11827 -1 0-4 • • 0-044 111• • 304113i n . 111 -441.4 O®1•M.4• 69m• 1¢ 94II3(111111-4) .s .4a • 144131-71 If P1 CONNECTIONS PIN /I 71 (P4A -3) 2 N/C . 1 3 70 (7810 -70) 4 N/C 5 1431 (WI) 6 N/C . 7 708 (P4A -2) 8 N/C . 9 N/C . 10 31A (P4A -5) 11 N/C . 12 14P (OCON1) OCON1 14P (P1 -12) — 14P2 (P4A -14) 13 Y01. YELIOW (P4A -1S) 14 N/C 15 N/C . 16 38 (P6-2) 17 CAN GREEN (P4A -16) 18 N/C . 19 N/C 20 58 (P6-1) 21 N/C . 22 N/C . 23 63 (P44-7) 24 35A (P4A -6) P2 CONNECTIONS PIN /1 11 (C71 -01) 2 1111 (C01 -X2) 3 12 (C72 -01) 4 125 (C12 -02) 5 13 (C73 -01) 6 I3R (CT3 -12) P4A 0 TO OPTIONAL - SHUNT TRIP/ FAILURE RELAY IFrFNO CLS - COOLANT LEVEL SENDER CT(j) - CURRENT TRANSFORMER CWCS - CITY WATER COOLING SOLENOID MG - ENGINE BLOC% GROUND ECM - ELECTRONIC CONTROL MODULE ESS - EMERGENCY STOP SWITCH FV(j) - FUEL VALVE GND - CONTROLLER BOX GROUND J(j) - CONNECTOR LCT - LOW COOLANT TEMPERATURE SWITCH LINO - LOW FUEL PRESSURE SWITCH LIPS - LOW FUEL PRESSURE AUTO SHUTDOWN SWITCH P(j) - CONNECTOR POND - CONTROLLER PANEL GROUND PL(j) - PANEL LAMP OCON(I) - ONCK CONNECT SLB - STATIONARY LED BOARD SM - STARTER MOTOR SS - STARTER SOLENOID STAT - STATOR TB1 - INTERCONNECTION BOARD TERMINAL • - TERMINAL BLOCK T83 - OUTPUT TERMINAL BLOCK TB4 - DIGITAL INPUT TERMINAL BLOCK TB5 - CONTROLLER AC. FUSE BLOCK TB10 - ACCESSORY TERMINAL BLOCK TB12 - JUNCTION BOX TERMINAL BLOCK 731 (1810 -731) yd. 14N (P1 -5 1014 (P4A -22 2 (182 -COM) P4A CONNECTIONS PIN /1 N/C 2 708 (P1 -7) 3 71 (PI -1) 4 N/C 5 31A (PI -10) B 354 (PI -24) 7 63 (P1 -23) e N/C 9 N/C 10 N/C 1I N/C 12 N/C 13 14P1 (1810 -P) 14 1472 (OCON1) 15 YLI. YELLOW (P1 -13) 16 CNN GREEN (P1 -17) 17 N/C 18 N/C 19 N/C 20 56 1131 6AIIA1ED (000432) 21 N/C 22 ION (WI) DEC 3000 W/ ECM 5.0 - B.(L ENGINES GM GAS 50 -150 KW SPUT ACTIVATOR 10. 30 AND 600V 1 7 �p 09'0000 10 10 22 0 o, FOR SCHEMATIC SEE ADV -7861 ANYVaLig L uy 1140 e-u a1�n_y_uy 170 R 4i61.% .AA 33.3111.. JEW DIAGRAM, WIRING GM 50 -150 KW 8 7 6 5 4 3 ) 2 ( X11 GM72401 I D D C B A D C 8 • 8 _I_ 7 I 6 ENGINE I RED (W41 TO SHEET 1 P4 CONNECTIONS PT) /1 N/C . 2 708 (85) 3 71 (P5 -F) 4 N/C 5 31A (P9-A) O 354 (W12) 7 53 (CCON7) a N/C 9 N/C 10 N/C N/C 12 N/C 13 14P1 (WA) 14 I4P2 (W4) 15 TEL (P5 -N) 16 GRN (P5 -P) 17 N/C IB N/C 19 N/C 20 S6 (PS) 21 N/C . 22 ION (COG) P5 CONNECTIONS PIN /A 7091 (85) B 734 (P8 -2) C 73B (P7 -2) D N/C E N/C F 71 (P4-3) O MIL (COONS) H 65 (OCON10) J N/C . K N/C . L N/C . Y N/C N TEL (P4 -15) P CON (PA -I6) R N/C . S N/C • 14PI (P4 -13 4P2 (P4 -14 W4 41/45/. BA RED : T A PI (OCON6) W5 70F (Pb -I) 708 (P4 -2) L 70E (Pa -1) 7091 (P5-6) 700 (P7 -I) 35A1 (000144) —� W 2--, �— 3512 (1272) LT/J. J 35A (P4-6) W6 NO (P6 -2) 9 fQ3) 10142 L _ 86 P7 3 149 (DGDN9) W3 N1 (P9 B) MN' L --W3 N3 (=ONO 144 (OGON3) t ■ 145 (P9 -3) ESC ▪ ION (P4 -22) NOT USED -[ N4 (M3) ./ 06093 3541 (W6) -i' J -NOT USED P5 35A2 No) i LCT2 (NFPA -1I0 ONLY) P9 CONNECTIONS PIN IA 31A (P4 -5) B NI (03) (TO ECM) P9 (CLS) 1)/ e A O© ®00 7100 X00000 ®005 YM1 (P5 -G) -Kg=1 1 FOR MIL OCON6 usw i P1 (W4)— l TO SHEET I .- -70 (1810 -70) [KS (OPTIONAL) TO FUEL TSYSTEM SHEET & SHEETS 3 6 4 5 • • 4 �_ 3 I 2 TO ENGINE THIS SHEET TO ENGINE SHEET NATURAL GAS FUEL SYSTEMS P8 a�1 p8 CONNECTIONS O3 PIN /I 70E (W5) 2 734 (P5-8) 3 145 (W3) IV STANDARD FUEL VALVE P6 • 63 (P4 -7 IFP1 (OPTIONAL PRE- ALARM) OCON9 N9 (W6 OCONIO 65 (PS -H) �47 01111 P7. VAPOR BLACK P7 •ZT CONNECTIONS PIN 11 -, (AS) 2 73: P5-C) 3 Na 63 (P4-7) O3 OCONIO OCON9 65 (P5 -H) N3 (a3)- 0001111 LFP1 (OPO0NAL PRE -ALARM) Para BLACK tr FV1 STANDARD FUEL VALVE FV2 EEO ADOfi liNAL FUEL VALVE (OVAL RE 1IOII FOR ALA. 10 P6 CONNECTIONS PR 11 70F (W5) 2 N6 (W6) 3 N7 (W6) NOT P6 .161E FV2 ADCIRONAL FUEL VALVE (OPTION) RE0URED FOR U.L. APPWAL P6 CONNECTIONS PIN /I 70F (05) 2 146 (WS) 3 N7 (W6) DEC 3000 W/ ECM 5.0 — 8.11 ENGINES GM GAS 50 -150 KW SPLIT ACTIVATOR 10, 30 AND 600V M aomb NA aims. IR COI IIIORLER . CCU m stWOn Iu4RL °.• DIAGRAM. WIRING GM 50 -150 KW NAa r- GM724O1 I D 8 7 6 I 5 4 I 3 i 2 1� 1 - 11-0-01 v - (1ms1 a c A 1- - (A-00050..a9e1 -40.L CN aaat m ®1. 1, WA CC= a (•w) NSW 1W n rear /® W I W IN It 0710.19109 R W N. COMM. woo a 0Q mas 0 a 4 (a0N7 -1) m • -N-10 st R6E12 1 • 2 (017•-■] Pe 0 4-1.}ta >a 005 • (tl174-7) as P6 • 63 (P4 -7 IFP1 (OPTIONAL PRE- ALARM) OCON9 N9 (W6 OCONIO 65 (PS -H) �47 01111 P7. VAPOR BLACK P7 •ZT CONNECTIONS PIN 11 -, (AS) 2 73: P5-C) 3 Na 63 (P4-7) O3 OCONIO OCON9 65 (P5 -H) N3 (a3)- 0001111 LFP1 (OPO0NAL PRE -ALARM) Para BLACK tr FV1 STANDARD FUEL VALVE FV2 EEO ADOfi liNAL FUEL VALVE (OVAL RE 1IOII FOR ALA. 10 P6 CONNECTIONS PR 11 70F (W5) 2 N6 (W6) 3 N7 (W6) NOT P6 .161E FV2 ADCIRONAL FUEL VALVE (OPTION) RE0URED FOR U.L. APPWAL P6 CONNECTIONS PIN /I 70F (05) 2 146 (WS) 3 N7 (W6) DEC 3000 W/ ECM 5.0 — 8.11 ENGINES GM GAS 50 -150 KW SPLIT ACTIVATOR 10, 30 AND 600V M aomb NA aims. IR COI IIIORLER . CCU m stWOn Iu4RL °.• DIAGRAM. WIRING GM 50 -150 KW NAa r- GM724O1 I D 8 7 6 I 5 4 I 3 i 2 Q I 11@ 8 4 RNA A ti g it a k8 I 4444 L �4 3 1 IF § I 1 I0I . Si n d e 1 a S' C s 2 S 8 8 ill 2k I LT L is 1- S- a� eN I1 g Q rn D U 4 m D C A • • • B ) 7 I 6 5 4 I 3 I 2 I I POI • (0-7 a as -a -71 OUT oc000 W too n Dole .® TO too 14 (.-s) 0901 MCP 10 100 M. 0020 ALCM XI 180 M (40.0 -1 104 -4) PM IIR IMO COMM OC aP.1Dm ADND (0417 -11) Drs 0.-1) 100 3-3 Ca I-2 310 C0®131 11e11DeAA. 0e 0131333 MOZO v 00833 Oa 1E03 1 • 3 031n -0 0.-0 SW 2-3 • 6-3 Wen) CPS NO OW 3 (0173-71 FUEL SYSTEMS NATURAL GAS F81 (30018410) �' °ONn L.P. VAPOR (31331311.0 f P7-I 109 430/11,3 LP. UOU D �1 , OCON7 I °COMA 63 , - '�N3Ci6 -!Ll ILb -"JI 0C0NB� (OPio1L- PRE-YAR11) 5NFSi� { /-'� P7� SNEET11 . o- -70E "A �.2 I® o-73B P7-3 0-- P8-3 _- ND l� NS O 63 OCOM7 Prien -I G N9 /a OCON/0 N9 0— uPl oto+7 I \� L MOND TO Luv 0—=111 SNEE) I{ ]OF P6-' USED Nl ( 3mmiwt) C. O COY I I OcoNe la 1 1.111.- J (OPTIONAL- PRE -NARY) 2- 63 mi DCON6 la I L - J (0 PO L- -'e ) N9 N9-+ 9 <31-70F P6 -2 849 1 OCON10 N9 /OS�- N6 116 - • P6-3 O- 65 •••- -000N9 DDON11 65A---c �6 / V- N7 . TOE a 65- 0C 1ON10 ©2-75* �-70E - 2 �- 65 L QCOr11 65A P7 -1 7oc -- © -7OE P8-2 Nm USED -N5 Ns P7-+ M 4 -A 2-7°5 -S • 738 -• 2 -73A 73A J 7. o-/'�- P7 -2 738 O 1VIIT P1 ID-- 738 NB P7 -3 �- NS P6-1 r NM11710NDL a VALVE (REQUIRED • U.L APPROVAL)) 261/1II o- NB r : (REWIRED FOR U.L APPROVAL) I N2 P6-1 C,,,,,, V -a7381 P!-. 10 a OCON1 +7 NOi 738 --• USED OCONI6 ' 40010,YL 1 vN.YE (OPI1N) REIM 1O• 1 AL M 7,,... OLQ119 /1 •.. 19 I3B2- 2-75F P6-2 00 • ��;7� 7 P8-2 C0 1 -70E �'( \LPG.) V.: HO P11-3 6 I P6-3 .. o- N) Q- N7 DEC 3000 W/ ECM 5.0 -8.11 ENGINES GM GAS 50 -150KW I I I Q 4 1 SPLIT ACTIVATOR 10, 30 & 60 Z 8 7 6 5 3 7— 110111xL7 m nmsoi a u. Vi.^° DIAGRAM. SCHEMATIC GM 50 -150KW F- Pm ADV -7661 ID I I WOE • • 2 • - - - •I7 OR ° ; BATTERY A (12 VDC) R2 (PM) F4 (GN ) ♦ RED PNK GRII NK IS __ P GiD1 ECM GROUND 42 8 MEUT GRQIND 28 32 SPAICLCOIL IA 6 RELAY 14 MAT 51 AUILPIM 5 "CAN 1- 48 CAN 1f BUT C FA10110 18431 A[M D1iP2AAam ON 0 6 -l3-CO DR NCO i 1m170-11 641 I g BC,A 3 DNCNOSTC ON GN C01 PNK/DN GRN RED F–.. I.L° B_ B4 PNK/OK GRN 6U(1 B1X 4 5 (GROUND) (CAN 14) 7 (CAN 1 ) B RED/TAN B Bm MAIIP Bm RW /PNK -Ming-, GN .211. A D CONNECTOR 2 (NO CONNECTOR) ../` RW/NHT FR (SiMTER)� RI (START) j &1( C B TEL RED 2200 A, Q MIT/1,1 BW I Y Fur ) RED 10 AYP RED AN IM/Li BUJ Rucli RED/TMI TO ECU INTERFACE (PPS) — SHEET 1 RIO ECM INTERFACE (ANT PIM 52 R (C/), -) P (CA1N C N (START COY4Vm) F (VSO) A (AUK ANA P004) M (OCR I) L (AUK ANA P003) K (AUX MA PU02) 3 (NEC sn(ML) H' MW G (AUX P811 4) E (RELAY POWER) D (SECONDARY) LOCKOFF C (PRRMR1) Ld.Aw1 B S (��) BRN/MR MARC' 5ILLEER BW /PNK OW /M BW /PNK LT BWE /PNt Rt PINVERX "MA" 13 STIRIER 19 I/SWITCH 34 AVK.,APLPUD 4 39 AUX_DIG 1 Fl (VS_) —IAN PNK/TNi 5 A., PN< Am PNK/TN! BK BW/m DK "AIL GRAY/D. BW GRAY/D11 BW DK BW /080 DK BW /ORG 35 AVAJJLLPUD 3 35 AUX_AHA_.WD 2 3e AlOLD10 2 5 MIL 52 AUILPIM 4 11 LOCI(OPT 2 12 LCCKOFF 1 DR BLU/RED DK BW /RED TAN/BRN TAN/BRN GRN/YEL GRN/lEL BRN/PNK BBNAINR PMI/PK GM LT BL11/4RT LT BW/NH" WNT/RLX WRIT /BLK LT GRN/RED (SV X61 B (FPPI) ) 0 (TACO) c (SV INN I) E (MID PRO 3) F (AUX PRM 3 RECRC) G (AUX PI M 6 (9M 1)) H (0110 PWM T (1W 2)) LT GRN /RED 1 LT 111 /RED 4 SV_IXT I App 122 2 MILIEG 1 IpILppS TACIT T BWroBB ,.•I �: 1:' :1.1 C. GB"Y +I 50 -60 KW (5.0L & 5.7L ENGINES) 8 1 •••ew : BLX/LT RRN ' RIK/LT GRN AUX_PIFM 3 54 BRB /0RG AUXVIM } REORC 53 3 RL1 1 IS 5E BRN CRASOMI SENR A u C BK BW 3 SV_RIN 1 931 2 L5 55 33 CMI I LT 0/41/14111 ��ALM1 GRAY/BRN BIN/LT GM S3+SOR A B IT GRN/RFD 23 OIL PRESSURE MAP 24 41 31 AU%_ANLRID 1 20 ) 10 COW a 21 TPS 2 9 OEM - 26 (Cl 41 EGO I 49 ECON 1 BUILT GRN C C LT BLUE LT GRN /PFD LT GREEN LT GRN/RED B VW 1 BUT/LT GM (3 2 TIP 4 13, ELEC 1 MJGR'Y IHT/I T GRN LT GRN /RED R1I/LT CRN PURP/LT BUJ RETEELE LT GTO/ /RED 2 } 4 PNKlNT /1Y LT BW/OK OU RU(/LT GM 6 5 TAN/ORG I ECT & CT &K/LT GAN "I B TAN/11117 DK GRN /0RG KEC01 B BUILT GRN PNK/pI GAN " BLX/NNf T- " ° amt. v7 :.. _ KOHLER CO. VIA. ° ®io.s ° s l.ms ° miu d c I MEG02 4o (CD 2 S0 EGON I BIX/LT GRN D 011 GRN/M1/f DEC 3000 W/ ECM rnwse4<s m_ �� DIAGRAM SCHEMATIC GM 50 -150KW PNK/GI ONN BLK1 51 5.0 -6.1L ENGINES r csa 22-10 C D GM GAS 50- 150KW"'� 1Q� I` 4.4 F _ SPLIT ACTIVATOR 10, 30 & 600V °° « ADV -7861 I D 8 7 6 i • • • 6.1.2 Input/Output (I /O) Module Board The I/O module board provides a generator set mounted panel with two analog or digital inputs and five digital outputs. See Figure 6 -3 for circuit board components and electrical connections to the controller. See Figure 6 -4 for connections of analog inputs. Refer to Figure 6 -24 for accessory connections. See Section 6.2, Accessory Connections, for terminal identification. 7 6 5 2 RARCl1DF I,. VI 1 1. TV. ., I 1. P29/P30/P31 K1 /K2 /K3 2 -amp relay outputs 2. P32 K4 /K5 10 -amp relay outputs 3. SW1 switch 4. P28 In1 /In2 analog or digital inputs 4 5. P25 RJ45 In (DEC 3000 P23) 6. P26 RJ45 Out 7. P27 CAN terminator 3 GM64493 Figure 6 -3 Input/Output (I /O) Module Board Kit P28 Optional 5 V P28 Optional 5 V P28 power _ (50 mA Unaz.j — +5 power (50 mA maz.j — — M� +5 (J VPx + Analog Device Device VPx Output U VPx VNx ill • VNx GND VNx O Q GND GND a GND A V 0 -5 Volt Analog Device 100 ohm min. or 50 mA max. current 0 -5 Volt Ratiometric Sensor GND TP- 6894 -8 +/- 3 Volt Analog Device Figure 6-4 Analog Input Connections P28 76 Section 6 Accessories TP -6694 1/10 Industrial Generator Set Accessories • KOHLERPOWER SYSTEMS Line Circuit Breakers 20 -2250 kW (99001 NATIONALLY REGISTERED "---".3 Single Circuit Breaker Kit with Neutral Bus Bar 20 -300 kW Model Shown • • Dual Circuit Breaker Kit with Neutral Bus Bar 20 -300 kW Model Shown NOT APPLICABLE Standard Features • The line circuit breaker interrupts the generator set output during a short circuit and protects the wiring when an overload occurs. Use the circuit breaker to manually disconnect the generator set from the load during generator set service. • Circuit breaker kits are mounted to the generator set and are available standard with load -side lugs or bus bars and neutral bus bar. • Kohler Co. offers a wide selection of molded -case line circuit breaker kits including single and dual configurations for each generator set. • Four types of line circuit breakers are available: o Magnetic trip o Thermal magnetic trip o Electronic trip o Electronic with Ground Fault Circuit Interruption (GFCI) trip • In addition, line circuit breakers are offered with 80% and 100% ratings (thermal magnetic available only in 80% rating). • Single line circuit breaker kits allow circuit protection of the entire electrical system load. • Dual line circuit breaker kits allow circuit protection of selected priority loads from the remaining electrical system load. • Line circuit breakers comply with the following codes and standards unless otherwise stated. o UL 489 Molded Case Circuit Breakers o UL 1077 Supplementary Protectors o UL 2200 Stationary Engine Generator Assemblies G &88 4/10c Line Circuit Breaker Types 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. •Magnetic Trip The magnetic trip features an electromagnet in series with the load contacts and a moveable armature to activate the trip mechanism. When a sudden and excessive current such as a short circuit occurs, the electromagnet attracts the armature resulting in an instantaneous trip (UL 1077 circuit breakers). • • Thermal Magnetic Trip -> Thermal magnetic trip contains a thermal portion with a bimetallic strip that reacts to the heat produced from the load current. Excessive current causes it to bend sufficiently to trip the mechanism. The trip delay is dependant on the duration and excess of the overload current. Elements are factory- calibrated. A combination of both thermal and magnetic features allows a delayed trip on an overload and an instantaneous trip on a short circuit condition. Electronic Trip These line circuit breakers use electronic controls and miniature current transformers to monitor electrical currents and trip when preset limits are exceeded. Electronic with Ground Fault Trip The ground fault trip feature is commonly referred to as Ground Fault Circuit Interruption (GFCI). Models with GFCI compare current flow in phase and neutral lines, and trip when current unbalance exists. 80% Rated Circuit Breaker Most molded -case circuit breakers are 80% rated devices. An 80% rated circuit breaker can only be applied at 80% of its rating for continuous loads as defined by NFPA 70. Circuit conductors used with 80% rated circuit breakers are required to be rated for 100% of the circuit breaker's rating. The 80% rated circuit breakers are typically at a lower cost than the 100% rated circuit breaker but load growth is limited. 100% Rated Circuit Breaker Applications where all UL and NEC restrictions are met can use 100% rated circuit breakers where 100% rated circuits can carry 100% of the circuit breaker and conductor current rating. The 100% rated circuit breakers are typically at a higher cost than the 80% rated circuit breaker but have load growth possibilities. When applying 100% rated circuit breakers, comply with the various restrictions including UL Standard 489 and NEC Section 210. If any of the 100% rated circuit breaker restrictions are not met, the circuit breaker becomes an 80% rated circuit breaker. Accessories ❑ Neutral Lugs Various neutral lug sizes are available to accommodate multiple cable sizes for connection to the bus bar only. ❑ Alarm Switch The alarm switch indicates that the circuit breaker is in a tripped position caused by an overload, short circuit, ground fault, the operation of the shunt trip, an undervoltage trip, or the push -to- trip pushbutton. The alarm resets when the circuit breaker is reset. ❑ Auxiliary Contacts These switches send a signal indicating whether the main circuit breaker contacts are in the open or closed position. ❑ Bus Bars (units without circuit breakers installed) Bus bar kits are available on alternators with leads for connection to the generator set when circuit breakers are not ordered. Bus bar kits offer a convenient way to connect load leads to the generator set when a circuit breaker is not present. ❑ Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. ❑ Lockout Device (padlock attachment) This field - installable handle padlock attachment is available for manually operated circuit breakers. The attachment can accommodate three padlocks and will lock the circuit breaker in the OFF position only. ❑ Overcurrent Trip Switch The overcurrent trip switch indicates that the circuit breaker has tripped due to overload, ground fault, or short circuit and returns to the deenergized state when the circuit breaker is reset. ❑ Undervoltage Trip, 12 VDC or 24 VDC The undervoltage trips the circuit breaker when the control voltage drops below the preset threshold of 35 % -70% of the rated voltage. ❑ Shunt Trip, 12 VDC or 24 VDC A shunt trip option provides a solenoid within the circuit breaker case that, when momentarily energized from a remote source, activates the trip mechanism. This feature allows the circuit breaker to be tripped by customer - selected faults such as alternator overload or overspeed. The circuit breaker must be reset locally after being tripped. Tripping has priority over manual or motor operator closing. ❑ Shunt Trip Wiring Connects the shunt trip to the generator set controller. 66-88 4/1 Oc Line Circuit Breaker Specifications 41)—> 80% Rating Circuit Breaker 100% Rating Circuit Breaker • Gen. Set kW Alt. Model Ampere Range Trip Type C. B. Frame Style 20- 4P /4Q 30 -100 Magnetic, UL 1077 E (480 V max.) Magnetic, UL 1077 with 12 V shunt trip 60 -180 4P Q Magnetic, UL 1077 with 24 V shunt trip 60 D Electronic GFCI 15 -150 Thermal magnetic H 175 -250 Thermal magnetic 0 150 -400 60 -180 4S /4V 30 -100 Magnetic, UL 1077 E (480 V max.) Magnetic, UL 1077 with 12 V shunt trip Magnetic, UL 1077 with 24 V shunt trip 15 -150 Thermal magnetic H 175 -250 Thermal magnetic J 300 -400 Thermal magnetic L 600 Electronic D Electronic GFCI 700 -800 Thermal magnetic M 800 Electronic P 800 Electronic GFCI 200 -300 4UA 15 -150 Thermal magnetic H 175 -250 Thermal magnetic J 300 -400 Thermal magnetic L 600 Electronic D Electronic GFCI 700 -800 Thermal magnetic M 1000 -1200 Thermal magnetic P 800 -1200 Electronic P 800 -1200 Electronic GFCI 350 -900 (smell ext. box) (no 5M4044) 4M /5M w/leads 300 -400 Thermal magnetic L 600 Electronic D Electronic GFCI 700 -800 Thermal magnetic M 1000 -1200 Thermal magnetic P 800 -1200 Electronic P Electronic GFCI 350 -900 (large ext. box) (no 5M4044) *#- 4M /5M w/leads 1600 -2500 Thermal magnetic R Electronic Electronic GFCI 1000- 2250 and 900 kW with 5M4044 (large ext. box)** 5M/7M w/bus bars 1200 -2500 Thermal magnetic R Electronic Electronic GFCI Ge Set kW Alt. Model Ampere Range Trip Type C. B. Frame Style 20- 4P /4Q 150 -400 Electronic D Electronic GFCI 60 -180 S /4V 150 -400 Electronic D Electronic GFCI 600 -800 Electronic P Electronic GFCI 200 -300 4UA 150 -400 Electronic D Electronic GFCI 608 200 Electronic P Electronic GFCI 350 -900 (small ext. box) (no 5M4044) 4M /5M w/leads 150-400 Electronic D Electronic GFCI 600 -1200 = = ctronic P Ele onic GFCI 350 -900 (large ext. box) (no 5M4044) *t 4M/5M w/leads 1600 -2500 Electr. , is R Electroni FCI 3000 Electronic NW Electronic GFC 1000- 2250 and 900 kW with 5M4044 (large ext. box)** 5M/7M w/bus bars 1200 -2500 Electronic Electronic GFCI R 3000 Electronic Electronic GFCI Circuit Breaker Lugs Per Phase (Al/Cu) Frame Size Ampere Range Wire Range E (480 V max.) 30 -100 Up to two wire terminals fitting 10 -32 or 1/4 -20 stud H 15 -150 One #14 to 3/0 O 175 One 1/0 to 4/0 One 3/0 to 350 kcmil 200 -250 L 300 -400 One #1 to 600 kcmil Al D 150 -400 One #2 to 500 kcmil Al One #2 to 600 kcmil Cu 600 Two 2/0 to 500 kcmil Al Two 2/0 to 350 kcmil Cu M 700 -800 Three 3/0 to 500 kcmil P 600 -800 Three 3/0 to 500 kcmil 1000 -1200 Four 3/0 to 500 kcmil R 1600 -2500 (8) lugs per phase rated for (1) #4 -600 kcmil or (2) 1/0 -250 kcmil NW 3000 * Available as front or rear facing circuit breaker on junction box. Front facing circuit breakers are not available on the 600- 2000REOZM, 600- 2000REOZMB, and 400- 800RZW models t Front facing circuit breakers for 450 /500REOZVB models are available for units with standard air cleaner and not with heavy -duty air cleaner. $ The 5M4044 is a 4 -bus alternator and has bus -type mounting. 06 -88 4/10c • KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 - 459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 Line Circuit Breaker Applications - Single Circuit Breaker Installations 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. • • Line C.B. ATS Distribution Panel Distribution Panel To Remaining To Priority Load(s) Building Loads Single line circuit breaker configuration where circuit breaker trip can trip causing all power to building loads including priority load to be disrupted. Dual Circuit Breaker Combinations NUT Al Al ator Mo I First C. B. Frame Size Second C. B. Frame Size Comments 4P /4Q /4S 4V/4UA H — 4UA j — D available as GFCI 4S/4V/4UA P — 100% rating, no GFCI 4P /4Q /4S/ 4V /4UA D _ 100% rating, standard or GFCI 4S /4V /4UA M 100% , no GFCI 4M /5M/7M P — 100% rating, standard or GFCI 4P /4Q /4S/ 4V /4UA H H J H or J 4S /4V /4UA L H, J, or L 4P /4Q/ 4S /4V D • H, J, L, or D 100% rating, no CI 4UA D H, J, L, or D Primary or sec. availab as 100% rating, std. or GFCI Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler© generator set distributor for availability. Dual Circuit Breaker Installations A generator set with dual circuit breakers installed is used to segregate critical loads. Typically, one circuit breaker will feed a main transfer switch with noncritical loads and the other circuit breaker will feed a second transfer switch that feeds critical loads. First Second Line C.B. Line C.B. To Remaining Building Loads Dual line circuit breaker configuration where first circuit breaker can trip allowing second circuit breaker to continue supplying power to priority load(s). To Priority Load(s) PLICABLE Alte or Mode First C. B. Frame Size Second C. B. Frame Size Comments 4S /4V H, J, L, or D 100% rating, no GFCI 4UA M H, J, L, or D D available as GFCI 4S /4V P , or D 100% rating, no GFCI 4UA P H, J, L, or P and /or D available as CI P P 100% , no GFCI 4M /5M/7M All — Dual circuit b er configurations ava e as Engineered Specials DISTRIBUTED BY: © 2007, 2010 by Kohler Co. All rights reserved. 06 -88 4/10c D C B A • 8 AL/CU MECHANICAL LUGS PER PHASE BREAKER FRAME AMPS WIRE RANGE H 15 -ISO ONE #14 TO 3/0 ONE I/O TO 4/0 O175 200 -250 ONE 3/0 TO 350 KCMIL 0 150-400 ONE #2 TO 500 KCMIL AL ONE #2 TO 600 KCMIL CU 1 - 200 Amp Circuit Breaker NEUTRAL 6 5 • 4 3 2 • STANDARD BREAKER COMBINATIONS BREAKER I BREAKER 2 COMMENT H J 0 STD OR GFI H J H H OR J D H OR J NO GE D D NO GFI 3REAKER I ,-BREAKER 2 (D -FRAME SHOWN) / (J-FRAME SHOWN) 6- II II I II II 1 _J i __I I__J I I) n n : 1_ 1 1 1 - � � I 1 11 II II 1 I' 11. 101 „11 0,,, II 101 4 41J 40 4 0 0 • 014.3 (2) 32 [I 3] 64 12.51 [0.561 LOAD LUGS (SEE CHART) SHOWN WITH COVERS REMOVED ALL VIEWS) NOTE& 11 SEE UNIT DIMENSION PRINT (ADV-XXXX) FOR ADDITIONAL DIMENSIONS. JUNCTION BOX AND STUB -UP LOCATION 2) ADD SKID DEPTH TO WIRE BENDING HEIGHTS ON THIS PRINT TO ARRIVE AT FULL WIRE- BENDING SPACE. 3) CONSULT FACTORY FOR BREAKER COMBINATIONS NOT SHOWN ON THIS PRINT. 41 MECHANICAL LUGS ARE AVAILABLE FOR NEUTRAL SEE ADV -7316. 51 NEUTRALS ARE BONDED TO GROUND AS STANDARD. CONSULT LOCAL CODES OR SYSTEM REQUIREMENTS 6) CIRCUIT BREAKER FRAMES REFER TO STANDARD SQUARE -D PRODUCT. 7) STANDARD NEUTRALS PROVIDED ARE SIZED FOR MAXIMUM UNIT AMPS. GFI NEUTRALS ARE MATCHED TO THEIR CIRCUIT BREAKER AMPS. 8) DIMENSIONS IN 1 I ARE INCHES. BREAKER COORDINATION If the breaker coordination is required, we must be informed during the submittal process so we can requote any breaker changes before the order is placed. iQ LINE CIRCUIT BREAKER (LCB) KITS 4P /4PW /40 /40W ALTERNATOR FRAME STYLES VIEW FROM ENGINE END (HALF VIEW SHOWN) REV DATE DI COMPOSITE DIGS. SEE PARK S0. FOR 1141 5101 LEVEL 5-16.01 NEW DRAWING (796711 9.1 -01 ID-67 D WITH D COMBINATION ADDED 1931191 4-22-08 ID-WI 15.150 WA5 40.150 1641611 BY W5D WOO W5D :..14'S %-- KOHLER Co IMETRIO PRO-E POSER SYSTEMS. KOHLER. WI MAK U.S.A. 0009011!11 0 44 OC60! 30S05E0T060CII 10HL[S CO. DE 510Y1 O0 WI TH 110xLil COtEtWORK U, All RIIGHTI 01 APPROVALS WOO WOO AJH DATE 5 16 07 5 16 01 5 -16 -07 DIMENSION PRINT .0.01,200 ADV-7370 D 8 6 5 t 4 3 2 D C B A • 8 7 6 5 • 4 3 2 • 1 SCHEMATIC go Itx 0 rPIr� SIMON • 10-61 r• m ILSE A1m1 I D pI II D C B A a An a a QO a CONTROL BOARD §0 a OPTIONAL ALARM BOARD AC INPUT FUSE 120 VAC -7A 240 VAC -5A POWER ON I11 TRANSFORMER 6 120 V INPUT AC1 C SCR ODULE 2 AC2 C2 co--- POWER RESISTER -a- 03 OI�TPUT FUSE DC TI 25A 0 0 0 0 0 0 5otst Taloa, DOOR 240 VAC -5A 120 VAC -74 25A TRANSFORMER BACK PANEL DC VOLTS c061 (0241 D>w BLACK N & RED DG 0000 BLMOCK AC2 OUTPUT SCR MODULE MI I- z III= III L. - 02 —61 a POWER • RESISTER r AC2 'Cl a 90 a §0 a CONTROL BOARD CUSTOMER INPUT CONNECTIONS 120 VOLT INPUT AC TERMINAL BLOCK GROUND LUG 240 VOLT INPUT GROUND LUG RIGHT SIDE a a OPTIONAL ALARM BOARD NOTE: WHEN CHANCING AC INPUT VOLTAGE. THE AC INPUT FUSE MUST BE CHANGED TO AGREE AS SHOWN. INPUT FUSE 129 VAC 7A. TYPE ABC 240 VAC 502. TYPE ABC AUTO -FLOAT 12 VOLT BATTERY CHARGER KOHLER CQ AreVera oat nb.1 2 11-02 DIAGRAM, WIRING 7 6 5 3 2 22s07000 I 1 233967 I D4 C B A • • • 6.1.8 Run Relay Kit The run relay kit energizes only when the generator set runs. Use the run relay kit to control air intake and radiator louvers, alarms, and /or other signalling devices. See Figure 6 -20 and Figure 6 -21. See Section 6.2, Accessory Connections, for terminal identifications. 1 2 3 1 J I 4 5 6 i 1 t 1 r 7 8 9 1 1 Figure 6 -20 Run Relay Kit RELAY CONTACTS ,r 28 3a NC 4:fj sal 8e NO 7 8.-i9 - C RED 1 0 0110 TB10 o z r n 0 BLACK OPTIONAL RUN RELAY KIT CONNECTIONS (70) BATTERY VOLTAGE PRESENT ONLY WHEN GENERATOR IS OPERATING. GM16088A -A Figure 6 -21 Run Relay Connections TP -6694 1/10 6.2 Accessory Connections The controller contains a circuit board equipped with terminal strip(s) for use in connecting external optional accessories including alarms, battery chargers, and remote switches. The optional I/O board provides an additional two analog or digital inputs and five digital outputs. For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the instruction sheet accompanying the kit. See Figure 6 -22, Figure 6 -23, and Figure 6 -25 for controller circuit board connections. 13 12 11 ., •:. , nml ,�1 .:..........ii .. �.I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0` 10 9 1. P6 6 -pin connector 2. P7 6 -pin connector 3. P8 4 -pin connector 4. P3 4 -pin white connector 5. TB2 4- position terminal block 6. TB3 6- position terminal block 7. P2 6 -pin connector 8. P1 24 -pin connector 9. TB1 6- position terminal block 10. P22 3 -pin connector 11. P5 24 -pin connector 12. P23 8 -pin connector (RJ45) 13. P21 6 -pin connector Figure 6 -22 Controller Circuit Board Connections Section 6 Accessories 85 • • • 8 7 I 6 I 5 p29 7 NIP AIM OUPUT (2 II CONNECTIONS P29-NC 21 RELAY NORMALLY C105EO P29-0011 2.1 RELAY COMM P20-NO 2.1 RELAY NOUNILY OPEN P30 2 AMP RELAY OUPUT (221 CONNECTIONS P30-NC 12 RELAY N1R1/0LY CLOSED P3D -COM 2.2 RELAY COMMON P30-NO 2.2 MAT INRUA LY CPO pm, AMP RELAY OUPUT (211 CONNETTONS P31-NC 2.3 MAT 100101T 0150) P31 -COM 2.3 RELAY 0010101 P31-IC 2.3 RELAY NONWLY OPAL P32-NO s R ELAY NORMNLI OPEN P32 -0011 2.4 RELAY COMMON P32-IC 2.4 RELAY NORMALLY CLOSED P32-NO 2.5 RELAY NORMALLY (PEN P72 -WM 23 RELAY COMMON P32-NC 23 RELAY NORMALLY CLOSED PI/CE 1110 P27 JUMPER NAl THE PINS P27 254 EEO EEO EEO P29 P30 P31 TOR ❑ P26 REMOTE VO P25 OUT ROCS 5 E VO AGA° 1714110 RETURN INPUT CONNECTIONS P26 -VM2 NO 050001 ON P20 -VP2 A012 SC((NN. P221-45V SUPPLY P20 -GOD we ANALOG RATAN P28-N11 NO CONNECTION P20 -VPI A0H1 SIGNAL P25 --450 SUPPLY (0.05 ALP WY) p26 10107 MPL (f / -3V1 X1020 INPUT CONIECTIONS P213-011) ARA ANALOG SPERM( P25 -VN2 ACH2 IEMME 06TEA0OPL ANAL P29 -VP2 ACH2 MANE P021800510041141004.41 P26 -050 SUPPLY (0.05 ARP MV) ANALOG ROMA • N711 NEGATIVE NEGATIVE OFF(0081IL 5CNAL P32-WI • -RSV APPLY 011 POSITIVE ORTE ITAL 5CR& AMP MAX) NOTE CONTACT NRICRIZEO 06TR000R TO NINE P20 A/0 100010. I4Ic0I.4b103I K1 CAN REMOTE I/O BOARD (OPTIONAL) P32 P28 P21 P23 VO P22 DEC 3000 CONTROLLER ALO 50 (CUSTOMER 01 04 � SIWER PROODFD) BATTERY CHARGER CONNECTIONS (OPTIONAL) BATTERY - 61-4 CHARGER FART 1 RS465 NON-MATED COMPCR 10 P2I- CID P21 -2 • P24 -3 - P21 -N CNN P21 -5 P21 -6 - 50 V8 O V9 0 110 T82 RELAY CONTACTS 3 6■1,G 7B10 -8 (70): BATTERY VOLTAGE PRESENT ONLY WHEN R GENERATOR IS OPERATING II©EU©IIIMIII ICI ROTE F SHUNT 100P OR FNLMRE RELAY IS NOT USED. DISCONNECT • TAPE LEADS 2 & 32A. 32A RUN (OPTIONAL) TB(0 4 3 1 'Aux SHUTDOWN I — (SIYM GE MMER PROVIDED) TB3 13 4 -.3% EWiIE 3 \ (CUSTOMER FROJO)02) SWITCH 1A LOCAL STOP P2 I 1 STOP TWITCH (STANDAN)) R 11 SR GR 110 LOCAL REMO1 EMERGENCY EMERGENCY S10P swarm STOP SWITCH TB3 (STANDARD) (OPTIONAL) IA REMOTE SWITCH C@IIECIIONS 181 1 XCIII NO TUNCOON 811 -012 0012 PLO *407010 161 -043 000 54215A CHARGER FALRE sumac 181111 1011 10 FUNCTION 1B1-02 IOU NO FUNCTION 1B1 -010 PANS ANALOG/DIGITAL RETURN NOTE 181 go AEI7T5 MAY BE REDEFINED - FACTORY IRFIOL15 USTBD. CONTACT M11ECMIFB osmium FOR DETAILS. ocoN1 TO DIANE HARNESS 1AP POE 1M- ir1tP�1 yTy001 morn ENGINE HARNESS (REF.) 32A1 M1 I LJ 32A P 10 2A 2 DCB2 (COMMO( gU N � /FAAILU LEE RELAY) SEE 102 =M UT NOTE J2A2 1(I I p 1 28 2 @ F I }{ A PF1 42A 1 1`1. I-p im `� AP NM 2-0-61 10 MOM �I) Tu (0-41 A-; M 1m6 00RmJ°T0_ lIN 0-0 s q-H PA P0 0.4 Fn ANN 9-1ti) 'ANNA F1/FI6 N WAYM (Cy; -]) R WC limo= VALID 1 • n is -044Th m AZ 0-5. p =XI Amy NANA Im Y 1M 4 0Th Pv7MI lu LINE CIRCUIT WEAKER (OPTIONAL) SHUNT TRP COIL 1 DCB1 P6y6yF2 FUS (") FUSE2 (YAWN) (OPTIONAL) 1 AMP TO AI)V P1 P2 W3 I�I r� Lf11J ST N2 M 1131 W21 F31 NOTE: TRANSFER 41001 BARRA& DEsesA0045 MAT VARY FROM 11105E 910M1 HERE. VERIFY 1110 COWE.CT OMIGNATICNS USING ME APPROPRIATE TRANSFER 50110E ACM DIAGRAM. 3 IND 4: REMOTE ART "ALSSWITOI OR DIANE START CONTACTS ON TRANSFER SWITCH) 162 -OOM (RELAY MOWN FAULT 182 -EOM RELIT 00104) COMM 2-IC MAMA ) 00A11 4 FAULT FO Tat -NC r NORMALLY ) [OINON (ALIT NOTE TB2 RELAY CA PUT WT BE REDBNED - FACTORY DEFAULT 161E13. CONTACT AUBNR® 061PB0TOR FOR DETMS CUSTOMER TO CONNECT 10 182 arum STINT TRIP 6 USED. F AVM TRP 6 USED. CUSTOMER TO CONNECT TO 0092 FOR C01MON FAULT. 8 I 7 I 6 —I- 5 INSTALLATION NOTE: FOR FIELD INSTALLATION A MAXIMUM OF TWO WIRE TERMINALS PER TERMINAL STRIP SCREW IS RECOMMENDED UNLESS OTHERWISE NOTED ON THE WIRING DIAGRAM. DO NOT EXTEND ABOVE THE TERMINAL STRIP BARRIER. DEC 3000 ACCESSORIES I 2 LEGEND P( /) - PLUG OCON( /) - QUICK CONNECT TB ) - TERMINAL BLOCK w( - SONIC WELD 7— KM ION. NIA 1° MS Mr= AAA UA nN DIAGRAM DEC 3000 ACCY INTERCONNECTION -011-011 GM67191 II D � I • KOHLER.POWER SYSTEMS • • Model KSS /KSP Specific- Breaker Rated ATS 9001 NATIONAlLY REGISTERED Ratings Voltage: Current: 208 -480 VAC 50/60 Hz 40 -1000 Amps (standard transition) 100 -600 Amps (programmed transition) Transfer Switch Standard Features • UL 1008 listed at 208 -480 VAC file #E58962 (automatic), #E86894 (nonautomatic) • CSA certification available • Available with either automatic or non- automatic control • Available in 2, 3, or 4 pole configurations • High withstand /closing ratings, for use with specific breakers only • Electrically operated, mechanically held mechanism • Double- throw, mechanically interlocked design (break- before -make power contacts) • Enclosed arc chambers with arc chutes • Standard - transition model KSS and programmed- transition KSP model available • Silver tungsten alloy contacts on 400 -600 amp models (Model KSS) • Silver alloy main contacts (Model KSP) • Front - accessible contacts for easy inspection • Programmed- transition operation provides a center OFF position that allows residual voltages in the load circuits to decay (Model KSP) • Main shaft auxiliary position- indicating contacts, one set Normal and one set Emergency 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 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 the door using the keypad and display o Program and monitor using a PC with Monitor III integrated generator set and ATS monitoring software o Transfer files through the USB port System voltage and frequency Voltage unbalance Over /undervoltage and over /underfrequency for all phases of the normal and emergency sources Time delays Load /no load /auto -load test and load /no -load exercise functions Programmable inputs and outputs Load control outputs (load stepping) Selectable operating modes: utility - generator, generator - generator, or utility - utility Load bank control for exercise or test Pre /post - transfer, nine individual time delays for selected loads ABC /BAC /none phase rotation selection with error detection Resettable historical data In -phase monitor Password protection, three security levels G11 -108 (Model KSS /KSP Transfer Switch) 12/08f Page 1 • • • MPAC TM 1500 Controller Features User Interface LED Indicators • 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 (requires optional current transformers) • 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 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 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. Communications • 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 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 • 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) • External test: loaded /unloaded • Automatic override on generator failure (loaded test and exercise) • Peak shave delay enable /disable • Current monitoring (requires optional current transformers) • Pre /post- transfer, nine individual time delays for selected loads • Resettable historical data • System parameters factory -set per order Modbus® is a registered trademark of Schneider Electric. G11 -108 (Model KSS /KSP Transfer Switch) 12/091 Page 2 • MPAC'm 1500 Controller Features, 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 optional load shed kit) • Peak shave /area protection input • External test • Three - source system disable • Bypass 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 (four 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 Sens ng Default Parameter Default 3 sec. Adjustment Range Undervoltage dropout 90% of pickup 0 -6 sec. # 75 % -98% Undervoltage pickup 90% of nominal Normal source engine cooldown (gen /gen mode) 85% -100% Overvoltage dropout* 115% of nominal* Preferred to standby 106 % - 135% Overvoltage pickup 95% of dropout Pretransfer to preferred signal 95% -100% Unbalance enable Disable Enable /Disable Unbalance dropout 20% Failure to synchronize 5 % -20% Unbalance pickup 10% Off (standby to preferred, programmed- transition only) 3 % -18% Voltage dropout time 0.5 sec. 1 -60 min. # 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 Delay Default Adjustment Range Emergency source engine start 3 sec. 0 -6 sec.t Normal source engine start (gen /gen mode) 3 sec. 0 -6 sec. # Emergency source engine cooldown 5 sec. 0 -60 min. t Normal source engine cooldown (gen /gen mode) 2 sec. Failure to acquire standby source 1 min. Preferred to standby 3 sec. Standby to preferred 15 min. Pretransfer to preferred signal 0 sec. Post - transfer to preferred signal - 0 sec. Pretransfer to standby signal 0 sec. Post- transfer to standby signal 0 sec. Failure to synchronize 30 sec. Off (preferred to standby, programmed- transition only) 1 sec. Off (standby to preferred, programmed- transition only) 1 sec. Auto load test duration 30 min. 1 -60 min. # t Adjustable in 1 second increments. Engine start can be extended to 60 minutes with an External Battery Supply Module Kit. $ 1 minute increments. 011 -108 (Model KSS /KSP Transfer Switch) 12/091 Page 3 • • Application Data Codes and Standards UL- Listed Solderless Screw -Type Terminals for External Power Connections Normal, Emergency, and Load Terminals Model Switch Rating, amps Cables per Pole Range of Wire Sizes, Copper or Aluminum* 5% to 95% noncondensing 40 -150 1 #8 to 3/0 AWG 200 -225 1 #6 AWG to 250 MCM } ® 260 1 #6 AWG to 350 MCM 400 1 #4 AWG to 600 MCM 2 #1/0 AWG to 250 MCM 600 2 #2 AWG to 600 MCM 800 2 #1/0 AWG to 750 MCM 1000 4 #2 AWG to 600 MCM KSP 100 1 #14 to 1/0 AWG 200 1 #6 AWG to 250 MCM 400 2 1/0 AWG to 250 MCM 1 #4 AWG to 600 MCM 600 2 #2 AWG to 600 MCM * Use 60 °C minimum wire for #14 to #1 AWG. Use 75 °C minimum wire for 1/0 AWG and larger. 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 The ATS meets or exceeds the requirements of the following specifications: • Underwriters Laboratories UL 508, Standard for Industrial Control Equipment • Underwriters Laboratories UL 1008, Standard for Automatic Transfer Switches for Use in Emergency Standby Systems file #E58962 (automatic), #E86894 (nonautomatic) • CSA C22.2 No. 178 certification available, file #LR58301 • NFPA 70, National Electrical Code • NFPA 99, Essential Electrical Systems for Health Care Facilities • NFPA 110, Emergency and Standby Power Systems • IEEE Standard 446, IEEE Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications • NEMA Standard ICS 10 -2005, Electromechanical AC Transfer Switch Equipment • EN61000 -4 -4 Fast Transient Immunity Severity Level 4 • IEC 60947 -6 -1, Low Voltage Switchgear and Control Gear; Multifunction Equipment; Automatic Transfer Switching Equipment • EN61000 -4 -5 Surge Immunity Class 4 (voltage sensing and programmable inputs only) • IEC Specifications 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 • IEEE 472 (ANSI C37.90A) Ring Wave Test Contact Ratings Resistive Load inductive Load Motor Load NC NO Engine Start Contacts 2 A@ 30 VDC N/A N/A N/A Auxiliary Contacts, KSS (40 -600A) 15 A @ 250 VAC N/A N/A N/A Auxiliary Contacts, KSS (800- 1000A) 15 A @ 480 VAC 15 A @ 250 VAC; 6A@ 500 VAC 5 A @ 125 VAC; 3A@ 250 VAC; 1.5A @500 VAC 2.5 A @ 125 VAC; 1.5 A@ 250 VAC; 0.75A @500 VAC Auxiliary Contacts, KSP 15 A @ 480 VAC 15 A @ 250 VAC; 6 A @ 500 VAC 5 A @ 125 VAC; 3 A @ 250 VAC; 1.5A @500 VAC 2.5 A @ 125 VAC; 1.5 A @ 250 VAC; 0.75A @500 VAC G11.108 (Model KSS/KSP Transfer Switch) 12/091 Page 4 Weights and Dimensions Weights and dimensions are shown for transfer switches in NEMA type 1 enclosures, type 3R enclosures, and open units. Consult the factory for NEMA type 12, 4, and 4X enclosures. Note: Weights and dimensions are provided for reference only and should not be used for planning installation. See your local distributor for submittal drawings. Standard - Transition Models Amps NEMA Type Dimensions mm (in.) Dimensions mm (in.) Height Weight kg (lb.) Depth * Height Width Depth * 2 -Pole 3 -Pole 4 -Pole 40 -225 1, 3R 791 (31.1) 450 (17.7) 316 (12.5) 28 (62) 30 (65) 31 (68) 260 -400 1, 3R 1223 (48.1) 560 (22.0) 362 (14.3) 52 (115) 56 (123) 59 (131) 600 1, 3R 1702 (67.0) 610 (24.0) 514 (20.2) 179 (395) 183 (403) 186 ( 410) 800 1, 3R 1932 (76.1) 864 (34.0) 515 (20.3) N/A 226 (498) 236 (520) 1000 1, 3R 1932 (76.1) 864 (34.0) 515 (20.3) N/A 231 (509) 241 ( 531) * Allow enough room to fully open the door for inspection and service per NEC and local codes. The NEMA type 3R enclosures have a security cover on the controller that extends 54 mm (2.1 in.) beyond the door. Programmed- Transition Models Amps NE , - Dimensions mm (in.) Weight kg (lb.) Height Width Depth * 2 -Pole 3 -Pole 4 -Pole 100 -200 1, 3R 122 560 (22.0) 362 (14.3) 52 (115) 56 (123) 59 (131) 400 1, 3R 1223 (48.1) 560 (2 . 62 (14.3) 52 (115) 56 (123) 59 (131) 600 1, 3R 1702 (67.0) 610 (24.0) 514 (20.2) 395) 183 (403) 186 ( 410) * Allow enough room to fully open the door for inspection and service per NEC and local codes. The NEMA type 3R enclos on the controller that extends 54 mm (2.1 in.) beyond the door. r : a security cover G11 -108 (Model KSS /KSP Transfer Switch) 12/091 Page 5 Withstand and Close -On Ratings (WCR), Standard - Transition Models Ratings Summary The transfer switch is rated for use on a circuit capable of delivering not more than the RMS symmetrical amperes listed at the specified maximum voltage below, but no greater than the interrupting capacity of the selected circuit breaker or fuse. Circuit breakers and fuses are supplied by the customer. Certified Withstand Current Ratings in RMS Symmetrical Amperes (480 V maximum) * Switch Rating, amps With Current -Lim ting Fuses Specific Coordinated Breaker Rating, per the following tables Maximum Fuse Size, amps Fuse Class Maximum Circuit Amps at 480 VAC Maximum Voltage Maximum Circuit Amps at 480 VAC 40 50 J 200,000 480 V /60 Hz 30,000 80 100 100 125 150 200 300 200 225 300 260 N/A N/A N/A 480 V /60 Hz 35,000 400 600 J 200,000 480 V /60 Hz 50,000 RK5, RK1 100,000 600 N/A N/A N/A 800 1000 L 200,000 480 V /60 Hz 65,000 1000 1250 * All values are available symmetrical RMS amperes and tested in accordance with the withstand /closing requirements of UL 1008. G11.108 (Model KSS/KSP Transfer Switch) 12/091 Page 8 Ratings with Specific Manufacturers' Circuit Breakers, Standard - Transition Models Withstand and close -on ratings (WCR) in RMS symmetrical amperes for specific manufacturers' circuit breakers. Switch Rating, amps Molded -Case Circuit Breakers WCR, amps RMS Voltage, Max. Manufacturer Type Max. Size, amps 40 80 100 150 30,000 480 Cutler- Hammer FDC, HFD 150 HJD, JDC 250 HKD, KD, KDB, KDC, LA TRI -PAC, LCL 400 Square D FC, Fl 100 KC, KH, KI 250 LA, LC, LE, LH, LI, LX, LXI 400 ITE/Siemens CED6, HED4, HED6 125 CFD6, FD6, FXD6, HFD6 250 • 200 225 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, SHJD6, SJD6 400 GE TB1 100 SEL, SEP, TEL, THLC1 150 TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, TJJ, TJK4, TLB4 400 260 35,000 480 Cutler- Hammer FDC, HFD 150 HJD, JDC 250 HKD, KD, KDB, KDC, LA TRI -PAC, LCL 400 Square D FC, Fl 100 KC, KH, KI 250 LA, LC, LE, LH, LI, LX, LXI 400 ITE /Siemens CED6, HED4, HED6 125 CFD6, FD6, FXD6, HFD6 250 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, SHJD6, SJD6 400 GE TB1 100 SEL, SEP, TEL, THLC1 150 TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, TJJ, TJK4, TLB4 400 G11 -108 (Model KSS /KSP Transfer Switch) 12/091 Page 7 • Accessories Accessories are available either factory- installed or as loose kits, unless otherwise noted. Accessory Modules The mounting kit holds up to five optional modules. The maximum total current draw is 300 mA. If an External Battery Module is installed, there is no current restriction. Module Current Draw Specifications, mA Alarm Module 75 Standard I/O Module 75 High Power I/O Module 100 Standard Input /Output Module Inputs Available Inputs 2 Input Definition Contact closure Current 5 mA Max Connection Type Terminal Strip Wire Size #14 -24 AWG Max Distance 700 feet Outputs Outputs Available 6 Contact Type Form C (SPDT) Contact Voltage Rating 2 A @ 30 VDC 500 mA @ 125 VAC Connection Type Terminal Strip Wire Size #14 -24 AWG ❑ High -Power Input /Output Module Inputs Available Inputs 2 Input Definition Contact closure Current 5 mA Max Connection Type Terminal Strip Wire Size #14 -24 AWG Max Distance 700 feet Outputs Outputs Available 3 Contact Type Form C (SPDT) Contact Voltage Rating 12 A @ 24 VDC 12 A @ 250 VAC 10 A @ 277 VAC 2 A @ 480 VAC Connection Type Terminal Strip Wire Size #14 -24 AWG Environmental Specifications Temperature -40 °C to 85 °C ( -40 °F to 185 °F) Humidity 35% to 85% noncondensing ❑ Alarm Module • 90 dB Audible alarm • Any alarm function can be programmed to trigger the audible alarm • Chicago alarm function • Preferred source selection • Supervised transfer control (supervised transfer control switch required) • Connection for external alarm External Alarm Connection Specifications Wire Size #12 -22 AWG Cu Contact Voltage Rating 500 mA @ 120 VAC 250 mA @ 240 VAC ❑ External Battery Supply Module • Energizes the ATS controls using an external battery when no source power is available • Allows extended engine start time delays • Allows the use of any combination of accessory modules (no current draw restriction, maximum of five modules total) • Connects to one or two batteries, 12 VDC or 24 VDC system • Current draw, 140 mA @ 12 VDC, 86 mA @ 24 VDC • Provides low external battery voltage indication to the transfer switch controller • Reverse - polarity protected ❑ Battery Charger • Three -stage (bulk, absorption, and float) electronic battery charger • Red and green LEDs indicate the charge rate • Designed for 12 or 24 VDC battery electrical systems • Charge lead -acid or gel cell batteries • Sealed and potted design is rainproof, lightweight, silent, and completely automatic • Internal short- circuit protection for the outputs • Fuses for reverse - polarity protection • Available only as a loose kit for field installation Battery Charger Specifications Output Charging 12 VDC (min.) at 6 amps 24 VDC (min.) at 3 amps Maintaining 13.30 VDC at 0.1 amps Circuit Protection (2) 10 amp fuses (AGC -10) Recommended Maximum Battery Size Recharging Maintaining only 150 amp -hours 300 amp -hours Current Draw @ 50/60 Hz, 0.7 amps maximum G11 -108 (Model KSS /KSP Tranater Switch) 12/091 Page 10 Accessories, continued ❑ Monitor Ill Software • Monitor and control the power system's generator sets and transfer switches from a personal computer using a single software package • Monitor and control systems through a Windows® -based graphical user interface • Monitor and control systems over a local area network, remotely via a modem connection, or through an Ethernet connection • Password - protected data access: Guest, User, and Supervisor levels • Ethernet capability • Start or stop a test from a remote PC • View and adjust trip points, time delays, and system parameters • Assign inputs and outputs • Available as loose kits: o Software kit with serial cable o Software kit with device modem and cables Other Accessories ❑ CSA Certification ❑ Current Sensing Kit • Monitor current on all phases with 1% accuracy ❑ Digital Meter • Measure and display for both sources: o Voltage o Current o Frequency o Power • Programmable visual alarms: o High voltage o Low voltage o High current • Serial port for optional network connections • Password - protected programming menus • Available factory- installed • See TT -1506, Digital Power Meters ❑ Line -to- Neutral Voltage Monitoring • Monitors all line -to- neutral voltages ❑ Load Shed Kit • Forced transfer from Emergency to OFF • Available for 600 Amp programmed- transition models only • External hardware is required for the forced transfer to OFF function • Factory- installed ❑ Logic Disconnect Switch • Disconnects power to controller without disconnecting load • Mounts inside the enclosure ❑ Neutral Assembly • Available as loose kit for open units ❑ Padlockable User Interface Cover • With or without window • Cover without window standard on NEMA 3R enclosures ❑ Supervised Transfer Control Switch • Auto, Manual, and Transfer positions • Automatic and non - automatic modes • Alarm module required gi Literature Kits • Production literature kit (one kit is included with each transfer switch) • Overhaul literature kit ❑ Extended Warranties • 2 -year basic • 5 -year basic • 5 -year comprehensive • 10 -year major components ❑ Export Packaging G11 -108 (Model KSS/KSP Transfer Switch) 12/081 Page 11 KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920 - 565 -3381, Fax 920 - 459 -1646 For the nearest sales and service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)6264 -6422, Fax(65)6264 -6455 Model Designation Model Mechanism Transition Controls Voltage Poles Enclosure I Kl ©IIS I_I • p IA1 C Record the transfer switch model designation in the boxes. characteristics and ratings as explained below. Sample Model Designation: KSP- DCTA -0100S del K: Kohler Transfer Switch chanism S: Specific- Breaker Rated Transition Standard Programmed ,GAntrols D: MPAC"' 1500 Microprocessor Controls, Automatic F: MPAC' 1500 Microprocessor Controls, Non - Automatic Voltage /Frequency g C: 208 Volts /60 Hz : 220 Volts /50 Hz F: 240 Volts /60 Hz G: 380 Volts /50 Hz H: 400 Volts /50 Hz J: 416 Volts /50 Hz K: 440 Volts /60 Hz M: 480 Volts /60 Hz P: 380 Volts /60 Hz R: 220 Volts /60 Hz Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler® Power Systems distributor for availability. Current Rating • 0 2 0 0 Miscellaneous Is The transfer switch model designation defines Number of Poles/Wires N: 2 -pole, 3 -wire, solid neutral 3 -pole, 4 -wire, solid neutral 4 -pole, 4 -wire, switched neutral Enclosure NEMA 1 t NEMA 12 C: NEMA 3R D: NEMA 4 F: NEMA 4X G: Open unit t NEMA 1 enclosure is standard. Other types available to order. are Current Rating: Numbers indicate the current rating of the switch in amperes: 0040 # 0080 t 0100 0150 f 1 0200 0225 0260 0400 0600 08001 1000$ t Standard- transition models only. tcellaneous Standard Connections DISTRIBUTED BY: ® 2005, 2006, 2007, 2008, 2009 by Kohler Co. All rights reserved. G11 -108 (Model KSS/KSP Transfer Switch) 12/09f Page 12 • 8 ' 6 SECURITY COVER - OPTIONAL ON NEMA I REQUIRED FOR NEMA 3R ACCESSORY MODULE (OPTIONAL) SECTION A-A 8 5 • 4 PADLOCK HASP (SECURITY OPTION AND MENA OR ONLY) LOGIC DISCONNECT (OPTIONAL) 450 [17,71 B - -J L_5 NOTE: ALLOW FOR MINIMUM DOOR SWING CLEARANCE OF 508 [20.01 IN FRONT OF CABINET. 7 - -- ---r — 6 5 3 HEATER (OPTIONAL) MODEL K1 MPAC LOGIC 4022SA 2, 3 & 4 POLE STANDARD TRANSITION SPECIFIC BREAKER RATED STANDARD CONNECTION NEMA 18 3R SECTION B-B 2 68 [2.01 273 [10.81 • DETAIL D NEUTRAL 12 & 3 POLE UNITS ONLY) EQUIPMENT GROUND HEATER (OPTIONAL) RECOMMENDED ENTRANCE AREA TOP & BOTTOM SURGE PROTECTION (OPTIONAL) D C DETAR- D OF SECTION B-B NOTE: DUE TO THE SPACE LIMITATIONS. SURGE PROTECTION OR HEATER MAY BE ORDERED, BUT NOT BOTH. DIMENSIONS IN 17 ARE INCHES. FINISH. ANSI 49 GRAY REFER TO OPERATOR'S MANUAL PRIOR TO INSTALLATION AND OPERATION OF UNIT. REV A OAT[ 2-13-06 2 -14 -08 2 -10 -10 IS ION NEW DRAWING 1768421 ISO n1:4E1 , n04 18-21 EQUIPMENT GROUND NOTE ADDED: 1830131 18-11 DETAIL D AND NOTE ADDED: IC-21 SURGE PROTECTION )OPTIONAL) ADDED; I13,C-31 NEATEN (OPTIONAL) ADDED; 1890951 Tr 4 3 !TSUI OAK. d w rzuwg U)PNOVALS OATS WSD 2 13 06 °O1 00 2 13 06 '^"" A18 2 -13-06 KOHLER CO I METRIC I PRO-E POOR EESTENS. AMEN. WI 33011 O.E.A. ""1 :1 ONUSIE 01Ne[ USED IKEA! IONLEN CO. WnGCT ION 540 105 AT CO. NOON. . L "6x15 d DE SI e. M INVENTION AN[ AF SE NVF D. L DIMENSION PRINT ..,I NONE �.. ADV -7189 B A • • • 8 L ENGINE START TERMINALS 7 6 241 [9.51 5 l 4 a 4X 012.7 L501 WEIGHTS KG (LBS) 2 POLE 3 POLE 4 POLE 28 (62) 30 (65) 31 (68) i a0 rIvir AUXILIARY CONTACTS ♦ EMERGENCY 1 73 [2.9] SCREW TYPE TERMINALS FOR EXTERNAL POWER CONNECTION A 305 [12.01 SWITCH RATING (AMPS) RANGE OF WIRE SIZES CONTACTOR (PER PRASE) NEUTRAL (2 & 3 POLE) GROUND 40 -I50 200-225 (I) 08 TO 3/0 (I) 06 TO 250 KCMIL (3) 06 -3/0 (31 t6 -3/0 (3) 04 -600 KCMIL OR 16) I/0-250 KCMIL MODEL KI MPAC LOGIC 40 -225A 2, 3 6 4 POLE STANDARD TRANSITION SPECIFIC BREAKER RATED STANDARD CONNECTION NEMA I 3R 2 EIRE I r 0 0 SECTION A -A 1 NEIL REVISION A 2-13-06 2.(4 -08 NE■ CRANING (76642) IA -11 NEUTRAL UPDATED; (A-61 (71 90-7/0 KCMIL RAS III TO I /0; (A -TI 4A 012.7 1.50) RAS 010 (.4) (AI; 1830931 800 BIM nu. 11.11s 2.10-10 SEE SHEET I OF 2 1890951 OW RP ROY 85 850 m. 850 0ETT Z 13 06 2 13 06 DIMENSION PRINT •J 2 -13-06 NT. AOAE ADV -7189 I -, •7 ID 8 i 6 3 U Q 8 8 6 1.. N -o H m A h 1 I 1 11 U Q 2 W 2 a 4 a 3 0 10 N 10 CD C7 o- g • R - E L▪ IE t �I 1 11 Ia h h h h fop'= I I r1 I I M § I V 0 8 8 1 1 1 1 g$4 0 0 L 0 z 0 0 L 0 p. 3 0 it uI gilt 833 11 O � b N n W U Z 1 ha s 2x 2 2ft0 2 frt 2 °y 2 °+1 2 °s' 2 °w = IT -W 2.2 1 ]IZ UI 50— � 20— --I f— — —44-05 o --.-II b 1k aw 5, 2 o- e 0 0 CO a rtt • • • Kohler Standby /Prime Generator Set Test Program Testing is an integral part of quality assurance. In keeping with our uncompromising commitmentto quality, safety, and reliability, every Kohler Standby /Prime power generator set undergoes an extensive series of prototype and production testing. Prototype Testing Prototype testing includes the potentially destructive tests necessary to verify design, proper function of protective devices and safety features, and reliability expectations. Kohler's prototype testing includes the following: • Alternator temperature rise test per NEMA MG1 -32.6. Standby and prime ratings of the alternator are established during this test. • Maximum power test to assure that the prime Production Testing mover and alternator have sufficient capacity to operate within specifications. In production, Kohler Standby /Prime generator sets • Alternator overload test per NEMA MG1 -32.8. are built to the stringent standards established by the prototype program. Every Kohler Generator set is • Steady -state load test to ensure voltage regulation fully tested prior to leaving the factory. Production meets or exceeds ANSI C84.1, NEMA MG1 -32.17 testing includes the following: requirements and to verify compliance with steady •Stator and exciter winding high-potential testonall state speed control specifications. generators. Surge transient tests on stators for • Transient test to verify speed controls meets or generators 180 kW or larger. Continuity and exceeds specifications. balance tests on all rotors. • Transient load tests per NEMA MG1- 32.18, and • One -step, full -load pickup tests to verify that the ISO 8528 to verify specifications of transient performance of each generator set, regulator, and voltage regulation, voltage dip, voltage overshoot, governor meets published specifications. recovery voltage, and recovery time. • Generator set cooling and air flow tests to verify maximum operating ambient temperature. • Reliability tests to demonstrate product durability, followed by root cause analysis of discovered failures and defects. Corrective action is taken to improve the design, workmanship, or components. • Acoustical noise intensity and sound attenuation effects tests. • Motor starting tests per NEMA MG1- 32.18.5 to evaluate capabilities of generator, exciter, and regulator system. • 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. • Voltage, amperage, frequency and power output • Three -phase symmetrical short- circuit test per ratings verified by full -load test. NEMA MG1 -32.13 to demonstrate short circuit performance, mechanical integrity, ability to • The proper operation of controller logic circuitry, sustain short- circuit current. prealarm warnings, and shutdown functions is tested and verified. • Harmonic analysis, voltage waveform deviation per NEMA MG1 -32.10 to confirm that the • Any defect or variation from specification generator set is producing clean voltage within discovered during testing is corrected and retested acceptable limits. prior to approval for shipment to the customer. Torsional analysis data, to verify torsional effects are not detrimental and that the generator set will provide dependable service as specified, is available upon request. Kohler offers other testing at the customer's request at an additional charge. These optional tests include power factor testing, customized load testing for specific application, witness testing, and a broad range of MIL - STD -705c testing. A certified test report is also available at an additional charge. KOHLER. POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920 - 565 -3381, Fax 920- 459 -1646 For the newest sales /service outlet in the US and Canada, phone 1- 800 -544 -2444 KohlerPowerSystemscom G18 -58 12/05a • • • ii"Wd THE VMC GROUP The Power of Together SEISMIC CERTIFICATE OF COMPLIANCE KOHLER. POWER SYSTEMS The following Kohler Power Systems generator sets, sub -base fuel tanks and enclosures are seismically certified' in accordance with the IBC — 2000, IBC — 2003, IBC — 2006, and IBC — 20092 International Building Codes: Gas Generator Sets 1Z Diesel Generator Sets 25REZG, 30REZG, 40REZG, 45REZG, 50REZ� 60REZG 2OREOZJC, 30REOZJC, 4OREOZJC, 50REOZJC, 6OREOZJC 230REOZJE *,250REOZJE`,275REOZJE` 80REZG, 100REZG, 125REZG,150REZG,18OREZX,200REZX • Seismic certification level is limited to Sos of 2.0g at grade level (corresponding to a seismic design acceleration, Fp/Wp, of 1.05g ASD for units installed on the 944 gallon sub -base fuel tank manufac ured and supplied by Kohler Power Systems. Mathematical modeling and shake table testing of representative samples were conducted in accordance with ASCE 7- 98, ASCE 7 -02 and ASCE 7 -05 as referenced in the International Building Codes. Where applicable, tri -axial shake table testing was conducted in accordance with AC156 at nationally recognized Clark Dynamic Test Laboratory and analytically evaluated by the independent approval agency, The VMC Group.3 The above referenced equipment is APPROVED for seismic applications when properly installed, used as intended, and located in the United States. Below grade, grade, and roof -level installations are permitted and included in this approval per the parameters listed below. Installations in essential facilities and as life safety applications - both requiring post event functionality, are also included in this approval. Application boundaries are as follows: Seismic shake table TRS levels enveloped a required response spectrum with a ZPA of 2.40g and acceleration of 3.20g. This RRS level corresponds to an SOS value of 2.0g (300 %g Ss for Soil Class D 1.0 and also envelopes the RRS level for grade and below grade installations that correlate to an (369 %g Ss for Soil Site Class D and lower)5 at z/h = 0. All analysis was conducted per allowable stress design and to a seismic design acceleration of 3.10g. load and resistance factor design acceleration is 4.43g. The above mentioned factors determine acceleration level. an amplified region and lower)5 at z/h = SD5 value of 2.46g The corresponding the seismic design c E C uJ . O 7 N Q TO E 0 z Required Response Spectrum, Tested Equipment 3.50 3.00 - 2.50 2.00 1.50 1.00 - 0.50 0.00 J T J L L - L L r 10 Frequency [Hz] 10 Kohler 60REOZJC Enclosed Genset w/ Sub-base Fuel Tank - Horizontal Capacity, AFLX =3.2g,ARIG =2.4g — - Kohler 60REOZJC Enclosed Genset w/ Sub -base Fuel Tank - Vertical Capacity, AFLX = 1.33g, ARIG = 0.53g The VMC Group -113 Main Street, Bloomingdale, NJ 07403 -Tel: 973 - 838. 1780 -Fax: 973-492-8430- www.thevmcgroup.com G18-172 1/10 THE VMC GROUP The Power of Together CERTIFICATE OF COMPLIANCE NOTES 1. All equipment listed herein successfully passed the seismic acceptance criteria for non - structural components and systems as set forth in the various versions of the International Building Codes. For those components shake table tested in accordance with the International Code Council Evaluation Service Seismic Qualification by Shake -table Testing of Nonstructural Components and Systems (AC156), each unit remained captive and operational after the seismic shake -table event. Components mathematically modeled, successfully passed the design criteria as required by the American Society of Civil Engineers Minimum Design Loads for Building Structures Standard 7. 2. The following building codes are addressed under this certification: IBC 2000 — referencing ASCE 7 -98 and ICC AC -156 IBC 2003 — referencing ASCE 7 -02 and ICC AC -156 IBC 2006 — referencing ASCE 7 -05 and ICC AC -156 IBC 2009 — referencing ASCE 7 -05 and ICC AC -156 3. Seismic structural analysis was performed by finite element methods and calculations using principles from the ASCE/SEI Standard 7 -05, AISC Manual of Steel Construction Allowable Stress Design (Ninth Edition), published design and analysis methods, and experimental data as permitted in the IBC. Seismic qualification testing was conducted on a tri -axis shake table. The test response spectrum exceeded the design response spectrum as defined in the American Society of Civil Engineers documents ASCE 7 -98, ASCE 7 -02 and ASCE 7 -05 as well as acceptable testing references defined in the IBC 2000, 2003, 2006 and 2009. The test response spectrum (TRS) enveloped the design response spectrum (DRS) as shown on previous page. 4. Refer to Kohler Power Systems product drawings for anchor requirements and mounting considerations. Anchor locations, size, type, and load requirement guidelines are specified on the Generator Seismic Installation Drawing provided by Kohler. Mounting requirement details such as brand, type, embedment depth, edge spacing, anchor spacing, concrete strength, wall bracing, and special inspection must be outlined and approved by the installation project Structural Engineer of Record. Structural walls, structural floors, and housekeeping pads must also be seismically designed and approved, by the installation project Structural Engineer of Record, to accommodate the anchor selections as defined on Kohler installation drawings. The installing contractor is responsible for the proper installation of all anchors and mounting hardware, observing the mounting requirement details outlined by the Engineer of Record. Contact your Kohler Representative if a detailed Seismic Installation Calculation Package is required. When seismic vibration isolators are required, this certification is only valid on Kohler specified and approved products. 5. The Sos value is obtained from the Mapped Maximum Considered Earthquake Short Period Spectral Response Acceleration, Ss, for Soil Site Class B with 5% damping. When the site soil properties or final equipment installation location are not known, the soil site coefficient, Fa, defaults to the Soil Site Class D coefficient. Soil Classes A, B, C, D, E, Seismic Use groups I, II, III, IV, and Seismic Design Categories A, B, C, D, E, and F are all covered under this certification, limited by the Sps value stated above. A seismic importance factor, 1p, of 1.5 applies to this certification to include essential facility requirements and life safety applications for post event functionality. John P. Giuliano, PE President, The VMC Group Allan J. Bliemeister Sr. Staff Engineer, Kohler Power Systems Original Issue Date: 9/1/09 Revision Date: 1/22/10 (Revision 1) Renewal Date: 1/31/11 Reference Reports: VMA- 43794 -1, VMA- 45449 -1, VMA- 45450 -1, and VMA- 45451 -1 (by The VMC Group.) The VMC Group •113 Main Street, Bloomingdale, NJ 07403•Tel: 973- 838- 1780•Fax: 973- 492- 8430•www.thevmcgroup.com G18 -172 1/10 Certificate US9510189 The management system of Kohler Power Systems Americas N7650 County Road LS Sheboygan, WI 53083 United States has been assessed and certified as meeting the requirements al ISO 9001:2008 For the tolloving activities Design, manufacture, and distributor support for electrical generators, alternators, automatic transfer switches, and switchgesr. Further clarfaceons regarding the scope ()tibia cenficate and the applicabity of ISO 90012008 requirements may be obtained by crawling the organization This certificate is valid from 17 November 2009 until 16 November 2012 and remains valid subject to satisfactory surveillance audits. Recertification audit due a minimum of 30 days before the expiration date. Issue 8. Certified since February 1995 This is a mufti-site certification. Additional site details are listed on subsequent pages. G15-152 3/10F Authorized by liekeratre-AvZ-' Zachary Pivarnlit Accreditation Manager, Noah America SGS US Testing Drapery, his.. Systems and Services Codification 201 Route 17 NOM, Ruthertord, New Jersey, 07070 USA 1+1 201 5083000 1+1 201 925 4555 wmv us.sus.com This certificate remains the property of SOS and shall be returned upon request Page 1 of 2 %008 SGSI G15-152 3/10F on. 431. antioi 10010 Car .,,SW anal Nask Certificate US9510189, continued Kohler Power Systems Americas ISO 9001:2008 Issue 8 Detafied scope Bother Clarifications regarding the scope of this cer65oats and the ap deity of ISO 90012008 requirements may be obtained by consulting the organisation Addranal fealties 800 N. Dekora Woods Blvd., Saukville, WI 53080, United States G15 -152 3/10F VW. 6.1W ...a...7W Ord wood M o•U wow»o..r ww..em.wo.e..e • • POWER SOLUTIONS, INC. 655 Wheat Lane — Wood dale, IL 60191 630.350.9400 (M) — 630.350.9900 (F) www.psienqines.com — info psiengines.com • PSI 2010 Stationary 60 Hz Emergency Stand -by'" Certified Power Generation Rating Data Generator Model Engine Speed Freq Fuel Duty Cycle Flywheel power 2,3 Engine Family THC +NOx CO bsfc5 Catalyst RPM Hz HP kW (g /KW -hr) (g /kW -hr) (g /kW -hr) 60REZG 5.7L 1800 60 LP Emergency 113.2 84.4 APSIS5.702ED 9.66 29.61 232.1 No 5.7L 1800 60 NG Emergency 104.7 _ 78.1 APSIS5.702ED 7.72 26.73 229.4 No 1 Standby and overload ratings based on IS03046. Continuous ratings based on ISO 8528. 2 All ratings are gross flywheel horsepower corrected to 77 °F at an altitude of 328 feet with no cooling fan or alternator losses using heating value for NG of 1015 BTU /SCF. 3 Production tolerances in engines and installed components can account for power variations of +/- 5 %. Altitude, temperature and excessive exhaust and intake restrictions should be applied to power calculations. a Electrical ratings are an estimated based on assumed fan and generator losses and may vary depending on actual equipment losses. 5 Bsfc is based on 100% gross flywheel power rating and does not include fan or generator losses. Power Solutions, Inc. 655 Wheat Lane — Wood Dale, IL 60191 630.350.9400 (M) — 630.350.9900 (F) www.psienqines.com infopsienqines.com Manufacturer: Engine Family: Certificate Number: Certificate Type: POWER SOLUTIONS, INC. APSIB5.702ED PSI- LSI -10 -07 STATIONARY ONLY Effective Date: 10/30/2009 Date Issued: 10/30/2009 Karl J. Simon, Director Compliance and Innovative Strategies Division Office of Transportation and Air Quality Pursuant to Section 213 of the Clean Air Act (42 U.S.C. section 7547) and 40 CFR 1048, 1065, 1068, and 60 (stationary only and combined stationary and mobile) and subject to the terms and conditions prescribed in those provisions, this certificate of conformity is hereby issued with respect to the test engines which have been found to conform to applicable requirements and which represent the following nonroad engines, by engine family, more fully described in the documentation required by 40 CFR 1048 and produced in the stated model year. This certificate of conformity covers only those new nonroad spark - ignition engines which conform in all material respects to the design specifications that applied to those engines described in the documentation required by 40 CFR 1048 and which are produced during the model year stated on this certificate of the said manufacturer, as defined in 40 CFR 1048. This certificate of conformity does not cover nonroad engines imported prior to the effective date of the certificate. It is a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 1068.20 and authorized in a warrant or court order. Failure to comply with the requirements of such a warrant or court order may lead to revocation or suspension of this certificate for reasons specified in 40 CFR 1048. It is also a term of this certificate that this certificate may be revoked or suspended or rendered void ab initio for other reasons specified in 40 CFR 1048. This certificate does not cover nonroad engines sold, offered for sale, or introduced, or delivered for introduction, into commerce in the U.S. prior to the effective date of the certificate. 5i. p if - c iu '- * X44, pi �" S _ UNITED STATES ENVIRONMENTAL PROTECTION AGENCYq OFFICE OF TRANSPORTATION AND AIR QUALITY WASHINGTON, DC 20460 CERTIFICATE OF CONFORMITY 2010 t oir;' '�7- .F4. Pft( • ) ,65 r t Manufacturer: Engine Family: Certificate Number: Certificate Type: POWER SOLUTIONS, INC. APSIB5.702ED PSI- LSI -10 -07 STATIONARY ONLY Effective Date: 10/30/2009 Date Issued: 10/30/2009 Karl J. Simon, Director Compliance and Innovative Strategies Division Office of Transportation and Air Quality Pursuant to Section 213 of the Clean Air Act (42 U.S.C. section 7547) and 40 CFR 1048, 1065, 1068, and 60 (stationary only and combined stationary and mobile) and subject to the terms and conditions prescribed in those provisions, this certificate of conformity is hereby issued with respect to the test engines which have been found to conform to applicable requirements and which represent the following nonroad engines, by engine family, more fully described in the documentation required by 40 CFR 1048 and produced in the stated model year. This certificate of conformity covers only those new nonroad spark - ignition engines which conform in all material respects to the design specifications that applied to those engines described in the documentation required by 40 CFR 1048 and which are produced during the model year stated on this certificate of the said manufacturer, as defined in 40 CFR 1048. This certificate of conformity does not cover nonroad engines imported prior to the effective date of the certificate. It is a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 1068.20 and authorized in a warrant or court order. Failure to comply with the requirements of such a warrant or court order may lead to revocation or suspension of this certificate for reasons specified in 40 CFR 1048. It is also a term of this certificate that this certificate may be revoked or suspended or rendered void ab initio for other reasons specified in 40 CFR 1048. This certificate does not cover nonroad engines sold, offered for sale, or introduced, or delivered for introduction, into commerce in the U.S. prior to the effective date of the certificate. • • • Stationary Standby and Prime Power One -Year or Two Thousand (2000) -Hour Limited Warranty Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original consumer, Kohler Co. warrants, for the period indicated below, each product to be free from defects in materials and workmanship. Repair, replacement, or appropriate adjustment at Kohler Co.'s option will be furnished if the product, upon Kohler Co.'s inspection, is found to be properly installed, maintained, and operated in accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, repair or service by unauthorized persons, or normal wear and tear. Kohler Product Warranty Coverage* Generator Set & Accessories Prime Power Generator Set 20 kW or Larger One (1) year or 2000 hours (whichever occurs first) from date of initial startupt One (1) year or 2000 hours (whichever occurs first) from date of initial startupt *Some restrictions may apply. Contact your Kohler distributor/dealer for full details. tStartup must occur within 24 months of original shipment by Kohler Co. The following will not be covered by the warranty: 1. Normal engine wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage caused by accidents, improper installation or handling, faulty repairs not performed by an authorized service representative, or improper storage. 3. Damage caused by operation with improper fuel or at speeds, loads, conditions, modifications, or installation contrary to published specifications or recommendations. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficient quantity of lubricating oil. b. Failure to keep the air intake and cooling fin areas clean. c. Failure to service the air cleaner. d. Failure to provide sufficient coolant and /or cooling air. e. Failure to perform scheduled maintenance as prescribed in supplied manuals. f. Failure to regularly exercise the generator set under load (stationary applications only). 5. Original installation charges and startup costs. 6. Starting batteries and the following related expenses: a. Labor charges related to battery service. b. Travel expense related to battery service. 7. Engine coolant heaters, heater controls, and circulating pumps after the first year. 8. Rental of equipment during performance of warranty repairs. 9. Parts purchased from sources other than Kohler Co. Replacement of a failed Kohler part with a non - Kohler part voids warranty on that part. 10. Radiators replaced rather than repaired. 11. Fuel injection pumps not repaired locally by an authorized servicing dealer. 12. Non - Kohler- authorized repair shop labor without prior approval from Kohler Co. Warranty Department. 13. Engine fluids such as fuel, oil, or coolant /antifreeze. 14. Shop supplies such as adhesives, cleaning solvents, and rags. 15. Expenses incurred investigating performance complaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, lamps, filters, spark plugs, loose or leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. ship date as the startup date. To obtain warranty service, call 1- 800 - 544 -2444 for your nearest authorized Kohler service representative or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND including, but not 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® POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920 -565 -3381, Fax 920- 459 -1646 For the nearest sales /service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPowerSystems.com TP -5374 12/99c • • • 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 otherthan 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, ortransportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty nor is anyone authorized to make any on our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state. KOHLER® POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920- 565 -3381, Fax 920 - 459 -1646 For the nearest sales /service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPowerSystems.com TP -5373 12/99d • • Industrial Warranty Program Features Generator Set Warranties Transfer Switch and Bypass Isolation Switch Warranties 2 -Year Extended 5 -Year Extended d xtene Extended, Major Components 1 -Year Basic t Prime Basic Comprehensive t Warranty Form Number TP -5374 TP -5497 TP -5560 TP -5498 TP -5561 TP -5562 Application Stationary Standby and Prime Power Stationary Standby Stationary Prime Liquid - Cooled Diesel, 20 kW and Larger Stationary Standby Stationary Standby Stationary Standby Liquid - Cooled Diesel, 20 kW and Larger Warranty Period from Startup Date One year or 2000 hours Two years or 2000 hours Two years or 6000 hours Five years or 3000 hours Five years or 3000 hours Ten years or 3000 hours Parts Reimbursement Standard Standard Standard Standard Standard Standard major components only in years 6-10 or up to 3000 hours Labor Standard Standard Standard Through second year only Standard Through second year only Travel /Mileage Round Trip (maximum)* 483 km (300 miles) 483 km (300 miles) 483 km (300 miles) 483 km (300 miles) through second year only 483 km (300 miles) 483 km (300 miles) through second year only Deductibles None None None None None None * Applies to US installations only. Contact the warranty administrator for information on international installations. t For additional warranty, see Platinum Warranty Packages. Transfer Switch and Bypass Isolation Switch Warranties TP -5820 3/07g 1 Extended 2 -Year Basic 5-Year Basic 5-Year rehe Comprehensive 10 -Year Major Components 1 -Year Warranty Form Number TP -5373 TP -6085 TP -6086 TP -6087 TP -6088 Application All All All All All Warranty Period One year from Startup Date Two years Five years Five years Ten years Parts Reimbursement Standard Standard Standard Standard Standard major components only in years 6 -10 Labor Standard Standard Through second year only Standard Through second year only Travel/Mileage T Tavel Trip (maximum)* 483 km (300 miles) 483 km (300 miles) 483 km (300 miles) through second year only 483 km (300 miles) 483 km (300 miles) through second year only Deductibles None None None None None * Applies to US installations only. Contact the warranty administrator for information on international installations. TP -5820 3/07g 1 • • Pacific Power Gierinrarticsra Company: Phone Number: Job Name: DELIVERY REQUEST Customer Information Contact: Fax: PO Number PPG Product Information Model to be delivered: Weight: Dimensions: To schedule and facilitate delivery, please complete all pertinent information in this section and return by fax or email to: smarquardt @pacificpowergen.com Job Site Name: Address: City/State /Zip Code: PPG will be delivering by a flatbed or enclosed van: customer need to provide offloading: Offloading by: Forklift n Is a loading dock available? Yesn Cranes Non Are there any limits on truck size or unique offloading requirements Yesn Non If yes, please describe limitations: Note attached Kohler Procedures for lifting a generator. Unit must be lifted by all four (4) forklift pockets when using a crane or forklift. So not use the lifting eye on the generator or engine. Special care must be utilized on weather - housed units and require proper rigging. Desired Delivery Date: Second Choice: Time: Time: Due to travel time from PPG warehouse, we request that deliveries be scheduled after 10:00 AM. If excessive stand by time is incurred by the delivery truck the customer will be charged for the additional cost. • 5808 S. 196th Street, Kent, WA. 98032 (253)395 -9077 Fax: (253) 395 -4145 • • • Section 2 Loading and Transporting The loading and transporting processes expose the generator set to many stresses and the possibility of improper handling. Therefore, after transporting industrial generator sets: • Check the alignment of the radiator and supports to ensure that the radiator is evenly spaced from the generator and that supports are square and of even length. Check the radiator fan for uniform alignment and equal clearance within the radiator shroud. Adjust if necessary. • After confirming the correct alignment, tighten the hardware to its specified torque. Reference Appendix C, General Torque Specifications. 2.1 Generator Set Lifting 2.1.1 General Precautions Follow these general precautions when lifting all generator sets. • Do not lift the generator set using the lifting eyes attached to the engine and /or alternator. These eyes cannot support the generator set's weight. Instead, use the four holes in the mounting skid of each generator set that are intended for attaching lifting hooks. The placement of the holes prevents the lifting cables from damaging the generator set components and maintains balance during lifting. • If the lifting cables contact air cleaners, shrouds, or other protruding components, use spreader bars on the cables as outlined in subsequent sections. If the cables still do not clear the protruding component(s), remove the component(s). • Generator sets above 1000 kW may have reinforcing plates on the skid. See Figure 2 -1. Figure 2 -1 Lifting Hook Placement (above 1000 kW) TP•5700 9/08 Do not attach lifting hooks to the outside reinforcing plate of the skid. Attach lifting hooks as shown in Figure 2 -1 to use the strongest portion of the mounting skid and prevent the lifting hooks from slipping. To raise generator sets not equipped with skid reinforcing plates, attach lifting hooks to either the inside or outside of the skid. 2.1.2 Determining Weights Refer to the respective specification sheet and/or the submittal drawing for the weight of the generator set and accessories. Contact your distributor /dealer if weights are not shown. Specification sheets typically show weights for the following components: • Generator set • Weather housing • Sound shield • Subbase fuel tank When the subbase fuel tank contains fuel, use the following formula to determine the weight of the diesel fuel: Fuel in liters x 0.848 = fuel weight in kilograms Fuel in gallons x 7.08 = fuel weight in pounds 2.1.3 Lifting Methods The distributor /lifting contractor should choose one of the following methods to lift the generator set depending upon the location circumstances and the generator set's weight and size. The hook and cable apparatus method may not be appropriate for heavier or bulkier generator sets; therefore, choose the lifting fixture method if there is any doubt regarding the ability of the hook and cable apparatus method to support the generator set's weight or to accommodate its size. Section 2 Loading and Transporting 17 • • • Hook and Cable Apparatus Method • Lift the generator set by inserting lifting hooks in the skids lifting holes. Use an apparatus of hooks and cables joined at a single rigging point. See Figure 2 -2. If the cables contact any component of the generator set, use spreader bars slightly wider than the generator set skid to avoid damage to the generator set. Apply only vertical force to the skid while lifting. 1. Spreader bars may be necessary to protect generator set Figure 2 -2 Generator Set with Lifting Hooks in Skid • Lift the generator set by inserting bars that extend through the skid's lifting holes and then attaching lifting hooks to the bars. See Figure 2 -3. Choose bars sized to support the weight of the generator set and secure the lifting hooks to prevent them from sliding off the ends of the bars. Use spreader bars if the lifting cables contact the generator set components. Lifting Fixture Method Use a lifting fixture with adjustable cables to adapt to different size generator sets and to compensate for unit imbalance. See Figure 2 -4. Select equipment (cables, chains, and bars) capable of handling the weight of the generator set. 18 Section 2 Loading and Transporting TP.5700.2 1. Spreader bars may be necessary to protect generator set 2. Lifting bars Figure 2 -3 Generator Set with Lifting Bars in Skid Figure 2-4 Generator Set with Lifting Fixture TP -5700 9/08 • 2.1.4 Lifting Subbase Fuel Tank The distributor and /or lifting contractor determines the type of subbase fuel tank lifting device. Lift the subbase fuel tank as one unit if the tank is not installed on the generator set. When lifting the fuel tank, use the subbase fuel tank's lifting eyes, if equipped; otherwise use chains or cables wrapped around the subbase fuel tank. If using lifting straps, protect the straps from the sharp edges of the fuel tank. Generator sets to 400 kW. If the fuel tank is empty and does not extend outside the perimeter of the generator set skid, lift the generator set and the subbase fuel tank together. If the tank is not empty or extends outside the perimeter of the skid, use the next procedure. Generator sets 400 kW and above. Uninstall the subbase fuel tank by removing the mounting hardware and wiring between the generator set and the subbase fuel tank. Lift the generator set and subbase fuel tank separately. It is not necessary to drain the fuel tank when lifting just the fuel tank. 2.1.5 Lifting Weather Housing Lift the weather housing and generator set together as one unit while observing the general precautions in Section 2.1.1. • 2.1.6 Lifting Sound Shield Installed on Mounting Base (Concrete Slab) If the generator set has an installed sound shield and subbase fuel tank, lift the set as one unit only if the subbase fuel tank has lifting eyes installed, the fuel tank is empty, and the tank does not extend outside the perimeter of the generator set skid. In all other cases, remove the sound shield. • Sound Shield Removal Procedure Refer to the sound shield's installation instructions for general considerations and reference figures. 1. Remove the sound shield's attaching bolts. These bolts may be hidden by the sound shield insulation; if so, carefully lift the insulation near the skid to locate the bolts. 2. Lift the sound shield by the eyebolts to remove it from the wood skid. Use the sound shield eyebolts to lift only the sound shield. 3. Reinstall the sound shield after installing the generator set. TP -5700 9/08 2.1.7 Lifting Sound Shield with Integral Structural Steel Mounting to Generator Set Skid If the generator set has an installed sound shield that mounts directly to the generator set skid using structural steel components, the assembly can be lifted as a unit. This type of configuration typically provides a single top - lifting eye for lifting the entire assembly. Remove the generator set from the shipping pallet before lifting the generator set assembly using the single lifting eye. 2.2 Generator Set Transporting Follow these guidelines when transporting the generator set: • Select the transporting vehicle/trailer based on the dimensions and weight of the generator set as specified in the generator set dimension drawing or specification sheet. Ensure that the gross weight and overall height of the generator set and vehicle /trailer in transport does not exceed applicable transportation codes. • Use low boy -type trailers that meet clearance requirements when transporting units larger than 1000 kW. Load large (unboxed) radiator - equipped generator sets with the radiator facing the rear to reduce wind resistance during transit. Secure fans to prevent fan rotation in transit. • Securely fasten the generator set to the vehicle /trailer and cover. Even the heaviest of generator sets can move during shipment unless they are secured. Fasten the generator set to the vehicle/trailer bed with a correctly sized chain routed through the mounting holes of the generator set skid. Use chain tighteners to remove slack from the mounting chain. Cover the entire unit with a heavy -duty canvas or tarpaulin secured to the generator set or trailer. Section 2 Loading and Transporting 19 Pacific Power • Generation • • DATE: 6 /25/09 PAGE 1 of 2 GENERATOR START UP REQUEST TO: FAX: COMPANY PHONE: EMAIL: FROM: This is a pre -start up form to help the Pacific Power Generation Service Department better serve you and your customer with operation instructions and first start up of the new generator system. We will call to schedule start up when we receive your completed request form. A minimum of 2 weeks advance notice is required for scheduling. Payment to be made per our terms and conditions prior to startup being performed. Training will be given same day as start up and testing. unless agreement made otherwise. Please complete both pages and e-mail or fax to: (253) 395 -4145 Attn: Sheryl Marquardt smarquardt @pacificpower gen.com Preferred startup date: Alternate date(s): Owners Name /Job Site: Site Address: Number of people expected to be present at the instruction session - S/N Model Job Contractor Supervisor Cell # PO # Office Phone # Start up request PGEN.DOC form updated 5/14/08 • • Pacific Power Generation PAGE 2 of 2 Job Name /Owner Contractor Site Address Site Contact Site Contact Phone Please complete the following to verify that your generator is ready for startup and testing. Startup and testing cannot be scheduled without a completed and signed form returned to Pacific Power Products. If startup. testing & training are scheduled but the generator and /or transfer switch are not ready and /or additional time or subsequent trips to the site are required. you- will incur additional charges. The warranty period begins when the start up is completed and the Startup Notification form is signed. Please Check the Applicable Boxes Below: > Generator Bolted to Slab > Vibration Isolators (If Required) Properly Installed • AC Power to Block Heater • AC Power to Battery Charger • Battery Charger Wired to Generator Controls > Batteries Installed Exhaust System Properly Installed • Air Inlet Supply Properly Sized and Installed > Air Outlet Properly Sized and Installed • Natural Gas or Propane: 4 to 6 oz Pressure to the Secondary Regulator (Units over 100KW may require more pressure) • Natural Gas or Propane: All Necessary Valves and Regulators Installed • Diesel: All Necessary Fuel Connections Installed > Diesel: Adequate Fuel for the Required Startup and Testing • AC Output From the Generator Wired to the Transfer Switch > ATS wired, auto start leads connected between Generator and ATS. Note: If you have a M -340 ATS, the phase must be A.B.C. (1 -2 -3) only. Switch will not accept any other connection. > Remote annunciator interconnections terminated at generator and annunciator. • Utility power available to ATS YES C 0 • n n n n • n • n u u • a n • PI El 0 n❑❑❑❑❑ ❑n n ri ❑ C n C o Please provide the following information: Distance from the generator to the nearest available parking: Feet Length of cable required to hook load bank trailer to generator, if applicable Feet Location of the generator (basement, roof top, garage, etc.) By signing below, I verify that this system will be ready for startup and testing on the date I request. I also verify that I have read and understand the above statement outlining additional charges for subsequent site visits and the start of the warranty period. I am authorized to obligate the above contractor for these charges. A minimum of 2 weeks advance notice is required for all testing and startups. This form is only a request. Pacific Power Products will call and confirm the actual startup date. Signed Date Company Phone # Start up request PGEN.DOC form updated 5/14/08 KOHL. POWER SYSTEMS low the startup checklist on the back of this form. Then complete the form. form is required for coverage under the Kohler limited warranty and must be completely filled out at the time of Initial startup. Representatives of the distributor /dealer and owner must sign the notification form. Signing this form represents acceptance of the unit and that all information on the startup form is correct. Return a copy of the completed form to the Kohler Co. within 60 days of the startup date. Startup Notification Startup Date mo. day yr. form to: Pacific Power Generation ATTN: Generator Sales Admin. 5808 S. 196th Street Kent, WA. 98032 or FAX: 253 395 -4145 ATTN: Sales Admin. Authorized Kohler Representative Performing Startup Owner Name/Unit Location Telephone Telephone Company Name Company Name /Owner Address Address of Unit Location City City State State ZIP/Postal Code ZIP /Postal Code Country Country Round -trip miles tram nearest authorized Kohler servicing distributor /dealer to the power system equipment: Generator Set and Eng ne Nameplate information Generator Set No. 1 Engine No. 1 Generator Set No. 2 Engine No. 2 Serial No. Model No. Spec No. p . ° �/` #� ati'} ° 'a. '� $' ; 31� vyo t.q- p: f r 2 , ? ae��te� Y;���,'L- �`s�i�.c��at''„� A. gty7ir -st( ,fie -iY 1li ,, L. y e , .�.il`•'t=+ .t:c .... Application information (one Item in each column must be checked) ❑ Industrial ❑ Residential /Commercial ❑ Mobile/Towable/Trailer- Mounted ❑ Stationary ❑ Prime ❑ Rental ❑ Standby Transfer Switch and Switchgear Nameplate Information ATS No. 1 ATS No. 2 ATS No. 3 ATS No. 4 Switchgear Serial No. Spec No. Contactor Serial No. Model No. 5..,.h:Y ij,' o-};3 �ti;,iititid s {y ,�r h. l4Jyd1 ,: Y ,:?f . 5 x ,��(:. Fd, a 1A. Ft `fM l t C, t k kC Fl� i g I i ] K ±:.i t.,!uv�_:.1La.u,..r.�,.a ::.ae— uC. "` <; rCefe ta>„ ;, �.,}Ft�. � a `+ rP,Js m1 9y }4AF�N �1(t a . 1S:y 'Yad :Y , 5 �,.,FS".,. .,3.4.::. .- ._� :`. -!' .k.`tif .�Yastr3vx_vJu;- Kohler Representative's Name (print) Owner Representative's Name (print) Kohler Representative's Signature and Date day Owner Representative's Signature and Date mo. day yr. MO. yr. form to: Pacific Power Generation ATTN: Generator Sales Admin. 5808 S. 196th Street Kent, WA. 98032 or FAX: 253 395 -4145 ATTN: Sales Admin. Generator Set/Transfer Switch Installation Checklist This document has generic content and some items may not apply to some applications. Check only the items that apply to the specific application. Read and understand all of the safety precautions found in the Operation and Installation Manuals. Make the following installation checks before performing the Startup Checklist. Note: Use this form as a general guide, along with any applicable codes or standards. Comply with all applicable codes and standards. Improper installation voids the warranty. Equipment Room or Weather Housing Does Not Yes Apply ❑ ❑ 1. Is the equipment installed in a fire - resistant room (made of non - combustible material) or in an outdoor weather housing? ❑ ❑ 2. Is there adequate clearance between the engine and floor for service maintenance? ❑ ❑ 3. ❑ ❑ 4. ❑ ❑ 5. ❑ ❑ Is there emergency lighting available at the equipment room or weather housing? Is there adequate heating for the equipment room or outdoor weather housing? Is the equipment room clean with all materials not related to the emergency power supply system removed? 6. Is the equipment room protected with a fire protection system? Engine and Mounting ❑ ❑ 7. Is the mounting surface(s) properly constructed and leveled? ❑ ❑ 8. Is the mounting surface made from non - combustible material? ❑ ❑ 9. Was the generator -to- engine alignment performed after attaching the skid to the mounting base? Generator sets with two- bearing generators require alignment. Lubrication ❑ ❑ 10. Is the engine crankcase filled with the specified oil? Cooling and Ventilation ❑ ❑ 11. Is the cooling system filled with the manufacturer's specified coolant/antifreeze and purged of air? 12. Is there adequate inlet and outlet air flow (electric louvers adjusted and ventilation fan motor(s) connected to the corresponding voltage)? ❑ ❑ 13. Is the radiator duct properly sized and connected to the air vent or louver? 14. Are flexible sections installed in the cooling water lines? ❑ ❑ ❑ ❑ Fuel ❑ ❑ 15. Is there an adequate /dedicated fuel supply? ❑, ❑ 16. Are the fuel filters installed? ❑ ❑ 17. Are the fuel tanks and piping installed in accordance with applicable codes and standards? ❑ ❑ 18. Is there adequate fuel transfer tank pump lift capacity and is the pump motor connected to the corresponding voltage? 19. Is the fuel transfer tank pump connected to the emergency power source? 20. Are flexible fuel lines installed between the engine fuel inlet and fuel piping? 21. Is the specified gas pressure available at the fuel regulator inlet? 22. Does the gas solenoid valve function? 23. Are the manually operated fuel and cooling water valves installed allowing manual operation or bypass of the solenoid valves? Exhaust ❑ ❑ 24. Is the exhaust line sized per guidelines and does it have flexible connector(s)? Is the flexible connector(s) straight? Does Not Yes Apply ❑ ❑ 25. Is there an exhaust line condensate trap with a drain installed? ❑ ❑ 26. Is the specified silencer installed and are the hanger and mounting hardware tightened? ❑ ❑ 27. Is a heat - isolating thimble(s) installed at points where exhaust lines pass through combustible wall(s) or partition(s)? ❑ ❑ 28. Is the exhaust line free of excessive bends and restrictions? Is the backpressure within specifications? ❑ ❑ 29. Is the exhaust line installed with a downward pitch toward the outside of the building? ❑ ❑ 30. Is the exhaust line protected from entry by rain, snow, and animals? ❑ ❑ 31. Does the exhaust system outlet location prevent entry of exhaust gases into buildings or structures? ❑ ❑ 32. Are individuals protected from exposure to high temperature exhaust parts and are hot parts safety decals present? AC Electrical System ❑ ❑ 33. Does the nameplate voltage/frequency of the generator set and transfer switch match normal /utility source ratings? ❑ ❑ 34. Do the generator set load conductors have adequate ampacity and are they correctly connected to the circuit breakers and /or the emergency side of the transfer switch? ❑ ❑ 35. Are the load conductors, engine starting cables, battery charger cables, and remote annunciator leads installed in separate conduits? ❑ ❑ 36. Is the battery charger AC circuit connected to the corresponding voltage? Transfer Switch, Remote Control System, Accessories ❑ ❑ ❑ D ❑ ❑ 37. Is the transfer switch mechanism free of binding? Note: Disconnect all AC sources and operate the transfer switch manually. 38. Are the transfer switch AC conductors correctly connected? Verify lead designations using the appropriate wiring diagrams. 39. Is all other wiring connected, as required? Batteries and DC Electrical System ❑ ❑ 40. Does the battery(ies) have the specified CCA rating and voltage? ❑ ❑ 41. Is the battery(ies) filled with electrolyte and connected to the battery charger? ❑ ❑ 42. Are the engine starting cables connected to the battery(ies)? ❑ ❑ 43. Do the engine starting cables have adequate length and gauge? ❑ ❑ 44. Is the battery(ies) installed with adequate air ventilation? ❑ ❑ 45. Are the ends of all spark plug wires properly seated onto the coil /distributor and the spark plug? Special Requirements ❑ ❑ 46. Is the earthquake protection adequate for the equipment and support systems? ❑ ❑ 47. Is the equipment protected from lightning damage? Generator Set/Transfer Switch Startup Checklist This document has generic content and some items may not apply to some applications. Check only the items that apply to the specific application. Read and understand all of the safety precautions found in the Operation and Installation Manuals. Complete the Installation Checklist before performing the initial startup checks. Refer to Service Bulletin 616 for Warranty Startup Procedure Requirements regarding generator set models with ECM - controlled engines. Does Not Yes Apply ❑ ❑ 1. Verify that the engine is filled with oil and the cooling system is filled with coolant/antifreeze. ❑ ❑ 2. Prime the fuel system. ❑ ❑ 3. ❑ ❑ 4. Open all water and fuel valves. Temporarily remove the radiator cap to eliminate air in the cooling system. Replace radiator cap in step 21. Place the generator set master switch in the OFF /RESET position. Observe Not -in -Auto lamp and alarm, if equipped, on the controller. ❑ ❑ 5. Press the lamp test, if equipped on controller. Do all the alarm lamps on the panel illuminate? ❑ ❑ 6. Open the main line circuit breakers, open the safeguard breaker, and /or remove fuses connected to the generator set output leads. ❑ ❑ 7. Turn down the speed control (electronic governor) or speed screw (mechanical governor).* ❑ ❑ 8. Verify the presence of lube oil in the turbocharger, if equipped. See the engine and /or generator set operation manual. ❑ ❑ 9. Place the generator set master switch in the RUN position. Allow the engine to start and run for several seconds. ❑ ❑ 10. Verify that the day tank, if equipped, is energized. ❑ ❑ 11. Place the generator set master switch in the OFF /RESET position. Check for oil, coolant, and exhaust leaks. ❑ ❑ 12. Turn on the water /oil heaters and fuel lift pumps. ❑ ❑ 13. Check the battery charger ammeter for battery charging indication. ❑ ❑ 14. Place the generator set master switch in the RUN position. Verify whether there is sufficient oil pressure. Check for oil, coolant, and exhaust leaks. ❑ ❑ 15. Close the safeguard circuit breaker. Adjust the engine speed to 50/60 Hz if equipped with an electronic governor or to 52.8/63 Hz if equipped with a mechanical governor.* ❑ ❑ 16. If the speed is unstable, adjust according to the appropriate engine and /or governor manual.* ❑ ❑ 17. Adjust the AC output voltage to match the load voltage using the voltage adjusting control. See the generator set/controller operation manual. ❑ ❑ 18. Allow the engine to reach normal operating coolant temperature. ❑ ❑ 19. Check the operating temperature on city water - cooled models and adjust the thermostatic valve as necessary. ❑ ❑ 20. Manually overspeed the engine to cause an engine shutdown (68 -70 Hz on 60 Hz models and 58 -60 Hz on 50 Hz models). Place the generator set master switch in the OFF /RESET position.* ❑ ❑ 21. Check the coolant level, add coolant as necessary, and replace the radiator cap. Verify that all hose clamps are tight and secure. ❑ ❑ 22. Place the generator set master switch in the RUN position. ❑ ❑ 23. Verify the engine low oll pressure and high coolant temperature shutdowns.* ❑ ❑ 24. Check the overcrank shutdown.* ❑ ❑ 25. ❑ ❑ 26. ❑ ❑ 27. ❑ ❑ 28. Manually transfer the load to the emergency source. * Some models with an Engine Electronic Control Module (ECM) may limit or prohibit adjusting the engine speed or testing shutdowns. Refer to appropriate documentation available from the manufacturer. Place the generator set master switch in the OFF /RESET position. Open the normal source circuit breaker or remove fuses to the transfer switch. Disconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch. Does Not Yes Apply ❑ ❑ 29. Close the normal source circuit breaker or replace fuses to the transfer switch. ❑ ❑ 30. ❑ ❑ 31. D 32. 0 33. ❑ 0 34. ❑ ❑ 35. ❑ ❑ 36. 0 37. ❑ ❑ 38. ❑ ❑ 39. 0 40. ❑ ❑ 41. ❑ ❑ 42. ❑ ❑ 43. 0 44. ❑ ❑ 45. ❑ ❑ 46. ❑ ❑ 47. ❑ ❑ 48. ❑ ❑ 49. ❑ ❑ 50. ❑ ❑ 51. Check the normal source voltage, frequency, and phase sequence on three -phase models. The normal source must match the load. Open the normal source circuit breaker or remove fuses to the transfer switch. Manually transfer the load to the normal source. Close the generator set main line circuit breakers, close the safeguard breaker, and /or replace the fuses connected to the transfer switch. Place the generator set master switch in the RUN position. Check the generator set voltage, frequency, and phase sequence on three -phase models. The generator set must match normal source and load. Place the generator set master switch in the OFF /RESET position. Open the generator set main line circuit breakers, open the safeguard breaker, and /or remove the fuses connected to the transfer switch. Reconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch. Close the normal source circuit breaker or replace fuses to the transfer switch. Place the generator set master switch to the AUTO position. Close the generator set main line circuit breakers, close the safeguard breaker, and /or replace the fuses connected to the transfer switch. Place the transfer switch in the TEST position (load test or open normal source circuit breaker). NOTE: Obtain permission from the building authority before proceeding. This procedure tests transfer switch operation and connects building load to generator set power. Readjust frequency to 50 or 60 Hz with total building loads.* Verify that the current phase is balanced for three phase systems. Release the transfer switch test switch or close the normal circuit breaker. The transfer switch should retransfer to the normal source after appropriate time delay(s). Allow the generator set to run and shut down automatically after the appropriate cool down time delay(s). Set the plant exerciser to the customer's required exercise period, if equipped. Verify that all options on the transfer switch are adjusted and functional for the customer's requirements. If possible, run the building loads on the generator set for several hours or perform the load bank test if required. Verify that all the wire connections from the generator set to the transfer switch and optional accessories are tight and secure. Verify that the.customer has the appropriate engine /generator set and transfer switch literature. Instruct the customer in the operation and maintenance of the power system. Fill out the startup notification at this time and send the white copy to the Generator Warranty Dept. Include the warranty form if applicable. • Pacific Power issismiammiffigilmimmaimimithEr Generation PREVENTATIVE MAINTENANCE LIST SCHEDULE A —SEMI- ANNUAL SERVICE ONCE PER YEAR ✓ Lube oil and filters change; parts included. ✓ Replace fuel filter (diesel engines), parts included Oil samples, lab testing fee is included. Coolant sample test for proper inhibiting level, combustion leaks, etc Fuel sample, lab testing fee is included. Cetane Test Only. ✓ All spark plugs to be inspected, cleaned. (Non - diesel engines) ✓ Ignition system including points, condenser, cap rotor, coil, and wiring. (Inspection only) Confidence test. Load bank test/Optional but highly recommended EVERY SIX MONTHS ✓ Verify fuel supply. ✓ Service or replace air filter, parts not included. ✓ Visual check for oil, water, or fuel leaks. ✓ Inspect hoses. ✓ Test antifreeze and adjust, parts not included. ✓ Pressure test cooling system, tighten hose connections as required. ✓ Inspect and tighten belts. ✓ Check engine heater operation. ✓ Check for oil moisture, dirt; clean as necessary. ✓ Check battery charger operation and charge rate. ✓ Load test batteries, check specific gravity, and clean connections. ✓ Check emergency system operation without load. ✓ Check frequency and governor operation; adjust as necessary. ✓ Check engine alternator and charge rate. ✓ Check gauges and meters for proper operation and reading levels. ✓ Check generator set auto shutdown system and alarms. ✓ Check automatic transfer switch and accessory operation. ✓ Emergency system operation with load transfer during normal business hours. (With owner's permission only) ✓ Check generator output voltage and adjust as necessary. ✓ Inspect for rodent infestation. ✓ Indicates services to be performed • Scheduling will be done according to current service agreements in your area as close to proper service interval as possible. • Pacific Power • • ammiwitimitifforisamis Generation PREVENTATIVE MAINTENANCE LIST SCHEDULE A - ANNUAL SERVICE ONCE PER YEAR ✓ Lube oil and filters change; parts included. ✓ Replace fuel filter (diesel engines), parts included Oil samples, lab testing fee is included. Coolant sample test for proper inhibiting level, combustion leaks, etc. Fuel sample, lab testing fee is included. Cetane Test Only. All spark plugs to be inspected, cleaned, or replaced, if required (Non - diesel engines), parts not included. Ignition system including points, condenser, cap rotor, coil, and wiring - Inspection only. Confidence test. Load bank test two hours. Optional, but highly recommended. ✓ Verify fuel supply. ✓ Service or replace air filter, parts not included. ✓ Visual check for oil, water, or fuel leaks. ✓ Inspect hoses. ✓ Test antifreeze and adjust, parts not included. ✓ Pressure test cooling system, tighten hose connections as required. ✓ Inspect and tighten belts. ✓ Check engine heater operation. ✓ Check for oil moisture, dirt; clean as necessary. ✓ Check battery charger operation and charge rate. ✓ Load test batteries, check specific gravity, and clean connections. ✓ Check emergency system operation without load. ✓ Check frequency and governor operation; adjust as necessary. ✓ Check engine altemator and charge rate. ✓ Check gauges and meters for proper operation and reading levels. ✓ Check generator set auto shutdown system and alarms. ✓ Check automatic transfer switch and accessory operation. ✓ Emergency system operation with load transfer during normal business hours. (With owner's permission only) ✓ Check generator output voltage and adjust as necessary. ✓ Inspect for rodent infestation. ✓ Indicates services to be performed Scheduling will be done according to current service agreements in your area as close to proper service interval as possible. • Pacific Power Generation • • Dear Kohler Power System Owner: We would Iike to stress the importance of routine maintenance to help keep your generator operating at top performance. Enclosed is a letter outlining the importance of generator maintenance, a sample schedule "A" for services performed and an agreement form. In addition to routine maintenance, we can provide loadbank testing, engine tune -up and repair, generator and transfer switch troubleshooting and certified confidence testing. Pacific Power Generation is the authorized distributor in Washington, Oregon, Alaska, Hawaii and Northern Idaho for Kohler Power Systems products. We have serviced this marketing area for over 30 years with quality products on heavy duty industrial engines and generator sets. The service department works on a 24 hour emergency call out basis and our service contract customers receive top priorty. If you would like more information or are interested in a maintenance proposal for your specific equipment, please feel free to contact your Kohler sales representative or call me directly in the service department I would be happy to put together a quote for you. If you have any questions, or if I can be of further assistance, please give me a call. We look forward to meeting your generator service needs. Thank you. Sincerely, Mike Bourn General Manager (253) 395-9077 5808 S. 196th Street, Kent, WA. 98032 Fax: (253) 395 -4145 � Pacific Power Generation • • Why should I purchase a maintenance agreement? 1. Installation Review /Start-Up and preventative Maintenance all performed by a trained professional. Kohler distributors are trained by Kohler factory personnel and are experienced with Kohler equipment, procedures and policies. Put your generator system in the hands of an expert. 2. Generators require periodic maintenance to help long -term, trouble —free operation. Batteries, engine oil, anti -freeze and belts are all subject to deterioration, not only from generator operation, but also from time itself. Oxidation, corrosion, separation and fatigue all jeopardize your power system operation. Oil changes, fuel and oil filter replacement, air cleaner inspection and anti -freeze checks are very important for the proper operation and longevity of your generator set. 3. Periodic preventative maintenance saves you money. Early detection can help you identify small problems before they become major repair costs. Spark plugs, Hoses, ignition systems, batteries, belt adjustments and exhaust checks all require maintenance performed by experienced service technicians. 4. Electrical power when you need it. In an emergency, the cost savings when powering your emergency loads can be lost if your generator system is not properly maintained. While no maintenance program can guarantee operation, help remove doubt or wony when your generator is maintained by a factory trained and authorized Kohler distributor. 5. Warranty Coverage. The warranty on any generator system depends on proper installation and maintenance. Count on your Kohler distributor to ensure your warranty provisions are always met. They use quality parts, and keep a permanent record of all service repairs performed. 2 and 5 year extended warranties are available through your Kohler distributor. This is a great value and may be purchased anytime prior to the expiration of your original warranty. When you purchase a Kohler generator system from your Kohler distributor, you have more than an investment, you have peace of mind • • Paciflc Power Generation CUSTOMER FREIGHT DAMAGE CLAIMS POLICY In the event the product is damaged in transit to the customer's site, the customer must take the following steps: 1. If there is physical damage to the carton, the customer must note it on the waybill or delivery document, sign & date it. If this is not done, the claim may be denied. 2. Retain the original shipping carton. Failure to do so may void claim. 3. Hold damaged product at the destination point. Moving the damaged product to a different site will void the freight claim. 4. Contact Pacific Power Generation (either your sales rep or Ruth Wyatt) at 1-877 - POWRGEN (1 -877- 769 -7436) within 24 hours to notify us of the damage. There is usually a time limit involved with notifying a freight company of damage. If we don't notify the freight company within the required time frame the claim can be denied. 5. Take pictures of the damage. 6. Provide any additional information requested by Pacific Power Generation. Pacific Power Generation will arrange for a technician to go out to the site to make the necessary repairs. Pacific Power Generation is not liable for damages sustained while the product is in transit. We will be happy to file a claim on the customer's behalf, but only if all the steps above have been followed. In the event the claim is denied, all charges may be back charged to the customer. • Installation Industrial Generator Sets Models: 20-3250 kW RECOMMENDED PRACTICE ONLY NOT PROJECT SPECIFIC KOHLER. • POWER SYSTEMS 99001 ilms POWER SYSTEMS NATIONALLY REGISTERED TP -5700 9/08k California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field- installed kit numbers after installing the kits. Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate(s). Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Controller Description Engine Identification Record the product identification information from the engine nameplate. Manufacturer Model Designation Serial Number • • • • • Table of Contents Product Identification Information 2 Safety Precautions and Instructions 7 Introduction 13 Service Assistance 13 Section 1 General 15 Section 2 Loading and Transporting 17 2.1 Generator Set Lifting 17 2.1.1 General Precautions 17 2.1.2 Determining Weights 17 2.1.3 Lifting Methods 17 2.1.4 Lifting Subbase Fuel Tank 19 2.1.5 Lifting Weather Housing 19 2.1.6 Lifting Sound Shield Installed on Mounting Base (Concrete Slab) 19 2.1.7 Lifting Sound Shield with Integral Structural Steel Mounting to Generator Set Skid 19 2.2 Generator Set Transporting 19 Section 3 Location 21 3.1 Location Factors 21 3.2 Mounting Surface 21 3.2.1 Single -Pad Mounting 22 3.2.2 Dual -Pad Mounting 22 3.2.3 Four -Pad Mounting 22 3.2.4 Mounting Pad Specifications 22 3.3 IBC Seismic Installation 22 3.4 Vibration Isolation 23 3.5 Dual- Bearing Alternator Alignment 24 Section 4 Air and Cooling 25 4.1 General 25 4.2 Air - Cooled Engines 25 4.3 Liquid - Cooled Engines 25 4.3.1 System Features 25 4.3.2 Installation Considerations 25 4.3.3 Recommended Coolant 26 4.4 Unit - Mounted Radiator Cooling 27 4.4.1 System Features 27 4.4.2 Installation Considerations 27 4.5 Remote Radiator Cooling 28 4.5.1 General 28 4.5.2 Vent Lines 30 4.5.3 Fill Lines (Balance or Static) 32 4.5.4 Location Considerations 32 4.5.5 Installation Considerations 32 4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator 33 4.5.7 Procedure to Fill with Deaeration 34 4.5.8 Procedure to Fill without Deaeration 34 4.5.9 Checks after Initial Startup 34 4.6 City Water Cooling 35 4.6.1 System Features 35 4.6.2 Installation Considerations 35 4.7 Cooling Tower 36 4.8 Block Heaters 36 TP -5700 9/08 Table of Contents 3 Table of Contents, continued Section 5 Exhaust System 37 5.1 Flexible Exhaust Line 37 5.2 Condensation Trap 37 5.3 Piping 38 5.4 Double- Sleeved Thimbles 38 5.5 Exhaust Outlet 39 5.6 Exhaust System Backpressure 39 Section 6 Fuel Systems 47 6.1 Diesel Fuel Systems 47 6.1.1 Main Tank 47 6.1.2 Day Tanks 49 6.1.3 Fuel Lines 50 6.1.4 Auxiliary Fuel Pumps 50 6.2 Gasoline Fuel Systems 51 6.2.1 Fuel Storage Tank 51 6.2.2 Fuel Lines 51 6.2.3 Fuel Pumps 51 6.3 Gas Fuel Systems, Common Components 51 6.3.1 Gas Lines 51 6.3.2 Gas Regulators 52 6.4 LP Fuel Systems 52 6.4.1 LP Gas Vapor - Withdrawal Systems 53 6.4.2 LP Gas Liquid - Withdrawal Systems 53 6.5 Natural Gas Systems 54 6.6 Combination Systems 54 6.6.1 Combination Natural Gas and LP Gas 54 6.6.2 Combination LP Gas or Natural Gas and Gasoline 55 6.7 Pipe Size Requirements for Gas Fuel Systems 56 Section 7 Electrical System 59 7.1 Generator Set Voltage Reconnection 59 7.2 Electrical Connections 64 7.3 Load Lead Connections 64 7.4 Grounding and Grounded Conductor (Neutral) Connections 65 7.5 Terminal Connector Torque 66 7.6 Batteries 67 7.7 Battery Chargers 67 7.8 Optional Accessories 68 7.8.1 Audiovisual Alarm 68 7.8.2 Bus Bar Kits /Bus Lugs 68 7.8.3 Common Failure Relay Kit 69 7.8.4 Controller (Customer) Connection Kit 69 7.8.5 Float/Equalize Battery Charger Kit with Alarm Option 69 7.8.6 Ground Fault Annunciation 69 7.8.7 Line Circuit Breaker 69 7.8.8 Low Fuel (Level or Pressure) Switch 69 7.8.9 Remote Annunciator Kit 70 7.8.10 Remote Serial Annunciator (RSA) 70 7.8.11 Remote Emergency Stop Kit 75 7.8.12 Run Relay Kit 75 7.8.13 Safeguard Breaker 75 7.8.14 Single -Relay Dry Contact Kit 75 7.8.15 Ten -Relay Dry Contact Kit 76 7.9 Wiring Connections 76 4 Table of Contents TP -5700 9/08 • • • Table of Contents, continued Section 8 Paralleling and Remote Start/Control Systems 77 8.1 Automatic Transfer Switches 77 8.2 550 Controller, Menu 15 Paralleling Relays 78 8.3 550 Controller, Menu 11 Voltage Regulator 78 8.4 Reactive Droop Compensator 78 8.5 Remote Speed Adjustment 80 8.6 Remote Voltage Adjustment 81 8.7 Remote Wiring 83 8.8 Remote Voltage Regulator Kit 83 8.9 Voltage Regulator DVR 2000EC /Remote Voltage Regulator Kit, 350 kW and Above 85 8.10 Voltage Regulator, PMG 87 8.11 Voltage Regulator, Wound Field 88 Appendix A Abbreviations 91 Appendix B Common Hardware Application Guidelines 93 Appendix C General Torque Specifications 94 Appendix D Fuel Physical Properties 95 Appendix E Gas Fuel Vapor Pressures 96 Appendix F Gas Fuel System Installation Planning 97 Appendix G Voltage Regulator Definitions and Adjustments 98 TP -5700 9/08 Table of Contents 5 • Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life- threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice. A DANGER Danger indicates the presence of a hazard that will cause severe personal Injury, death, or substantial property damage. A WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage. A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting A 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. Battery A WARNING Sulfuric acid In batteries. Can cause severe Injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. A WARNING Explosion. Can cause severe injury or death. Relays In the battery charger cause arcs or sparks. Locate the battery in a well - ventilated area. Isolate the battery chargerfrom explosive fumes. Battery electrolyte Is a diluted sulfuric acid. Battery acid can cause severe Injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe Injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 Ib.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. TP -5700 9/08 Safety Precautions and Instructions 7 Battery gases. Explosion can cause severe Injury or death. Battery gases can cause an explosion. Do not smoke or permitflames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and /or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative ( -) lead first when disconnecting the battery. Reconnect the negative ( -) lead last when reconnecting the battery. Never connect the negative ( -) battery cable to the positive ( +) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Engine Backfire /Flash Fire A WARNING Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe Injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the fuel system. A flash fire can cause severe Injury or death. Do not smoke or permit flames or sparks near the fuel injection system, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or fuel system. Servicing the air cleaner. A sudden backfire can cause severe Injury or death. Do not operate the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System A WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: • Light - headedness, dizziness • Physical fatigue, weakness in joints and muscles • Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision • Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. Fuel System A WARNING ®, Explosive fuel vapors. Can cause severe Injury or death. Use extreme care when handling, storing, and using fuels. 8 Safety Precautions and Instructions TP -5700 9/08 • • • A WARNING Avoid high pressure fluids. Can cause severe Injury or death. Do not work on high pressure fuel or hydraulic systems without protective equipment to protect hands, eyes, and body. Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines. Search for leaks using a piece of cardboard. Always protect hands, eyes, and body from high pressure fluids. If an accident occurs, seek medical attention immediately. The fuel system. Explosive fuel vapors can cause severe Injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels; Store fuels in a well - ventilated area away from spark - producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operatethe generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Explosive fuel vapors can cause severe Injury or death. Take additional precautions when using the following fuels: Gasoline —Store gasoline only in approved red containers clearly marked GASOLINE. Propane (LP)— Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer's instructions. Natural Gas — Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer's instructions. TP -5700 9/08 Fuel tanks. Explosive fuel vapors can cause severe Injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks. Draining the fuel system. Explosive fuel vapors can cause severe Injury or death. Spilled fuel can cause an explosion. Use a containerto catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system. Gas fuel leaks. Explosive fuel vapors can cause severe Injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 -8 ounces per square inch (10 -14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. Asuccessful test depends on the ability of the solution to bubble. LP liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. Hazardous Noise A CAUTION Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set. Hazardous Voltage/ Moving Parts A DANGER Hazardous voltage. Will cause severe Injury or death. Disconnect all power sources before opening the enclosure. A WARNING Hazardous voltage. Moving parts. Can cause severe Injury or death. Operate the generator set only when all guards and electrical enclosures are in place. A WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe Injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. Safety Precautions and Instructions 9 A CAUTION Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). Grounding electrical equipment. Hazardous voltage can cause severe Injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative ( -) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery- charging alternator connections. (5) Attach the weld ground connection close to the weld location. Installing the battery charger. Hazardous voltage can cause severe Injury or death. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure tothe ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances. 10 Safety Precautions and Instructions Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Servicing the day tank. Hazardous voltage can cause severe Injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnectthe power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution. Short circuits. Hazardous voltage /current can cause severe Injury or death. Short circuits can cause bodily injury and /or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Engine block heater. Hazardous voltage can cause severe Injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe Injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and followthe instructions ofthe test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under) Servicing the generator set when It Is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. A WARNING Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Heavy Equipment A WARNING Unbalanced weight. Improper lifting can cause severe Injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. TP -5700 9/08 • Hot Parts A WARNING Hot coolant and steam. Can cause severe Injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. A WARNING Hot engine and exhaust system. Can cause severe Injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Servicing the engine heater. Hot parts can cause minor personal Injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts. Notice NOTICE This generator set has been rewired from Its nameplate voltage to 248242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor /dealer. NOTICE Canadian Installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground. TP -5700 9/08 Safety Precautions and Instructions 11 • • • Introduction This manual provides installation instructions for industrial generator sets. Operation manuals and wiring diagram manuals are available separately. Some additional model- specific installation information may be included in the respective generator set controller operation manual. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference. Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. • Consult the Yellow Pages under the heading Generators — Electric. • Visit the Kohler Power Systems website at KohlerPower.com. • Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. • Call toll free in the US and Canada 1- 800 - 544 -2444. • Outside the US and Canada, call the nearest regional office. Headquarters Europe, Middle East, Africa (EM EA) Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone: (33) 1 49 178300 Fax: (33) 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264 -6422 Fax: (65) 6264 -6455 TP -5700 9/08 China North China Regional Office, Beijing Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 Fax: (86) 10 6518 7955 East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550 India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208 (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440 -4515 Fax: (813) 3440 -2727 Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619 -7568 Fax: (863) 701 -7131 Introduction 13 • • Section 1 General Industrial power systems give years of dependable Your authorized generator set distributor /dealer may service if installed using the guidelines provided in this also provide advice about or assistance with your manual and in applicable codes. Incorrect installation installation. can cause continuing problems. Figure 1 -1 illustrates a typical installation. 1. Exhaust thimble (for wall or ceiling) 2. Silencer 3. Supports 4. Flexible sections 5. Duct work for cooling air outlet 6 6. Mounting base 7. Controller 8. Electrical conduit 9. Water trap with drain 10. Fresh air intake Figure 1 -1 Typical Stationary-Duty Generator Set Installation TP -5700 9/08 Section 1 General 15 This manual references several organizations and their codes that provide installation requirements and guidelines such as the National Fire Protection Association (NFPA) and Underwriter's Laboratories Inc. (U L). • NFPA 54 National Fuel Gas Code • NFPA 70 National Electrical Code ®; the National Electrical Code is a registered trademark of the NFPA • NFPA 99 Standard for Health Care Facilities • NFPA 101 Life Safety Code • NFPA 110 Emergency and Standby Power Systems • UL 486A -486B Wire Connectors • UL 486E Equipment Wiring Terminals for Use with Aluminum and /or Copper Conductors • UL 2200 Stationary Engine Generator Assemblies 16 Section 1 General These organizations provide information specifically for US installations. Installers must comply with their respective national and local codes. Before beginning generator set installation, record the following data from the generator set's specification sheet and keep this data accessible for reference during installation: • Dimensions and weight (verify dimensions and weight using the submittal data) • Exhaust outlet size and maximum allowable backpressure • Battery CCA rating and quantity • Fuel supply line size and fuel pressure requirement (gas models) • Air requirements TP -5700 9/08 • • Section 2 Loading and Transporting The loading and transporting processes expose the generator set to many stresses and the possibility of improper handling. Therefore, after transporting industrial generator sets: • Check the alignment of the radiator and supports to ensure that the radiator is evenly spaced from the generator and that supports are square and of even length. Check the radiator fan for uniform alignment and equal clearance within the radiator shroud. Adjust if necessary. • After confirming the correct alignment, tighten the hardware to its specified torque. Reference Appendix C, General Torque Specifications. 2.1 Generator Set Lifting 2.1.1 General Precautions Follow these general precautions when lifting all generator sets. • Do not lift the generator set using the lifting eyes attached to the engine and /or alternator. These eyes cannot support the generator set's weight. Instead, use the four holes in the mounting skid of each generator set that are intended for attaching lifting hooks. The placement of the holes prevents the lifting cables from damaging the generator set components and maintains balance during lifting. • If the lifting cables contact air cleaners, shrouds, or other protruding components, use spreader bars on the cables as outlined in subsequent sections. If the cables still do not clear the protruding component(s), remove the component(s). • Generator sets above 1000 kW may have reinforcing plates on the skid. See Figure 2 -1. • Figure 2 -1 Lifting Hook Placement (above 1000 kW) TP -5700 9/08 Do not attach lifting hooks to the outside reinforcing plate of the skid. Attach lifting hooks as shown in Figure 2 -1 to use the strongest portion of the mounting skid and prevent the lifting hooks from slipping. To raise generator sets not equipped with skid reinforcing plates, attach lifting hooks to either the inside or outside of the skid. 2.1.2 Determining Weights Refer to the respective specification sheet and /or the submittal drawing for the weight of the generator set and accessories. Contact your distributor /dealer if weights are not shown. Specification sheets typically show weights for the following components: • Generator set • Weather housing • Sound shield • Subbase fuel tank When the subbase fuel tank contains fuel, use the following formula to determine the weight of the diesel fuel: Fuel in liters x 0.848 = fuel weight in kilograms Fuel in gallons x 7.08 = fuel weight in pounds 2.1.3 Lifting Methods The distributor /lifting contractor should choose one of the following methods to lift the generator set depending upon the location circumstances and the generator set's weight and size. The hook and cable apparatus method may not be appropriate for heavier or bulkier generator sets; therefore, choose the lifting fixture method if there is any doubt regarding the ability of the hook and cable apparatus method to support the generator set's weight or to accommodate its size. Section 2 Loading and Transporting 17 Hook and Cable Apparatus Method • Lift the generator set by inserting lifting hooks in the skid's lifting holes. Use an apparatus of hooks and cables joined at a single rigging point. See Figure 2 -2. If the cables contact any component of the generator set, use spreader bars slightly wider than the generator set skid to avoid damage to the generator set. Apply only vertical force to the skid while lifting. 1. Spreader bars may be necessary to protect generator set Figure 2 -2 Generator Set with Lifting Hooks in Skid • Lift the generator set by inserting bars that extend through the skid's lifting holes and then attaching lifting hooks to the bars. See Figure 2 -3. Choose bars sized to support the weight of the generator set and secure the lifting hooks to prevent them from sliding off the ends of the bars. Use spreader bars if the lifting cables contact the generator set components. Lifting Fixture Method Use a lifting fixture with adjustable cables to adapt to different size generator sets and to compensate for unit imbalance. See Figure 2 -4. Select equipment (cables, chains, and bars) capable of handling the weight of the generator set. 18 Section 2 Loading and Transporting TP- 5700 -2 1. Spreader bars may be necessary to protect generator set 2. Lifting bars Figure 2 -3 Generator Set with Lifting Bars in Skid 1 1. Lifting fixture Figure 2-4 Generator Set with Lifting Fixture TP- 5700 -2 TP -5700 9/08 • • • 2.1.4 Lifting Subbase Fuel Tank The distributor and /or lifting contractor determines the type of subbase fuel tank lifting device. Lift the subbase fuel tank as one unit if the tank is not installed on the generator set. When lifting the fuel tank, use the subbase fuel tank's lifting eyes, if equipped; otherwise use chains or cables wrapped around the subbase fuel tank. If using lifting straps, protect the straps from the sharp edges of the fuel tank. Generator sets to 400 kW. If the fuel tank is empty and does not extend outside the perimeter of the generator set skid, lift the generator set and the subbase fuel tank together. If the tank is not empty or extends outside the perimeter of the skid, use the next procedure. Generator sets 400 kW and above. Uninstall the subbase fuel tank by removing the mounting hardware and wiring between the generator set and the subbase fuel tank. Lift the generator set and subbase fuel tank separately. It is not necessary to drain the fuel tank when lifting just the fuel tank. 2.1.5 Lifting Weather Housing Lift the weather housing and generator set together as one unit while observing the general precautions in Section 2.1.1. 2.1.6 Lifting Sound Shield Installed on Mounting Base (Concrete Slab) If the generator set has an installed sound shield and subbase fuel tank, lift the set as one unit only if the subbase fuel tank has lifting eyes installed, the fuel tank is empty, and the tank does not extend outside the perimeter of the generator set skid. In all other cases, remove the sound shield. Sound Shield Removal Procedure Refer to the sound shield's installation instructions for general considerations and reference figures. 1. Remove the sound shield's attaching bolts. These bolts may be hidden by the sound shield insulation; if so, carefully lift the insulation near the skid to locate the bolts. 2. Lift the sound shield by the eyebolts to remove it from the wood skid. Use the sound shield eyebolts to lift only the sound shield. 3. Reinstall the sound shield after installing the generator set. TP -5700 9/08 2.1.7 Lifting Sound Shield with Integral Structural Steel Mounting to Generator Set Skid If the generator set has an installed sound shield that mounts directly to the generator set skid using structural steel components, the assembly can be lifted as a unit. This type of configuration typically provides a single top - lifting eye for lifting the entire assembly. Remove the generator set from the shipping pallet before lifting the generator set assembly using the single lifting eye. 2.2 Generator Set Transporting Follow these guidelines when transporting the generator set: • Select the transporting vehicle /trailer based on the dimensions and weight of the generator set as specified in the generator set dimension drawing or specification sheet. Ensure that the gross weight and overall height of the generator set and vehicle /trailer in transport does not exceed applicable transportation codes. • Use low boy -type trailers that meet clearance requirements when transporting units larger than 1000 kW. Load large (unboxed) radiator - equipped generator sets with the radiator facing the rear to reduce wind resistance during transit. Secure fans to prevent fan rotation in transit. • Securely fasten the generator set to the vehicle/trailer and cover. Even the heaviest of generator sets can move during shipment unless they are secured. Fasten the generator set to the vehicle /trailer bed with a correctly sized chain routed through the mounting holes of the generator set skid. Use chain tighteners to remove slack from the mounting chain. Cover the entire unit with a heavy -duty canvas or tarpaulin secured to the generator set or trailer. Section 2 Loading and Transporting 19 • • • Section 3 Location 3.1 Location Factors Ideally, the generator set should be mounted on concrete at ground level. For above - ground installations, including roof installations, weight considerations are especially important. The building engineer determines whether the structure can support the weight of the generator set. The location of the generator set must meet the following criteria. General: • Support the weight of the generator set and related equipment such as fuel storage tanks, batteries, radiators, and mounting pad(s). Keep in mind that the mounting pad weight may exceed the weight of the generator set. • Meet applicable fire rating codes and standards. • Position the generator set over a noncombustible surface. If the mounting surface directly under or near the generator set is porous or deteriorates from exposure to engine fluids, construct a containment pan for spilled fuel, oil, coolant, and battery electrolyte. Do not allow accumulation of combustible materials under the generator set. • Permit vibration isolation and dampening to reduce noise and prevent damage. • Be clean, dry, and not subject to flooding. • Provide easy access for service and repair. Indoor Installations: • AIIow adequate ventilation with a minimum amount of ductwork. • AIIow safe expulsion of exhaust. • AIIow for storage of sufficient fuel to sustain emergency operation. See the generator set specification sheet for fuel consumption. • AIIow for locating the fuel tank within the vertical lift capabilities of the fuel pump and any auxiliary pumps. See Section 6, Fuel Systems. TP -5700 9/08 • Provide adequate protection to prevent injury in the stub -up area. If the stub -up area opening is exposed, provide a cover or fill in the area to avoid the risk of tripping or falling into the stub -up opening. • Minimize the risk of public or unauthorized access. Outdoor Installations: • Select a location that provides adequate air flow. Avoid locations next to tall buildings that block normal air flow and cause air vacuum pockets. Avoid areas that are subject to high winds, excessive dust, or other airborne contaminants. High dust areas may require more frequent air cleaner maintenance. High temperature conditions affect generator set efficiency. Select a shaded area away from direct sunlight and /or other heat - producing equipment when practical. 3.2 Mounting Surface Figure 3 -1 shows typical mounting surface details for sizing the concrete surface beyond the generator set and allowing for clearances during generator set service. Follow the dimensional details provided in Figure 3 -2, Figure 3 -3, or Figure 3 -4 depending upon the mounting method. 1. Engine end 2. Generator set skid 3. Extend the concrete surface a minimum of 152 mm (6 in.) beyond the generator set 4. Battery rack 5. AIIow at least 457 mm (18 in.) between the generator set and adjacent walls or other obstructions on all sides for ease of servicing the generator set 6. Alternator end 7. Mounting pad (concrete surface) Figure 3 -1 Mounting Surface Detail (top view) Section 3 Location 21 3.2.1 Single -Pad Mounting The manufacturer recommends a single, level concrete mounting pad as shown in Figure 3 -2. This method provides maximum stability for the generator set; however, draining the oil and servicing the generator set may require raising the set from the pad. Use an oil drain pump if clearance below the oil drain or extension is insufficient for a pan large enough to hold all the engine's oil. Figure 3 -2 Single -Pad Mounting 3.2.2 Dual -Pad Mounting The two -pad arrangement shown in Figure 3 -3 provides easy access to conveniently drain the oil. Follow the oil draining considerations outlined in Section 3.2.1. Figure 3 -3 Dual -Pad Mounting 3.2.3 Four -Pad Mounting The four -pad arrangement shown in Figure 3 -4 provides more room under the engine for service than the previous two methods. Follow the oil draining considerations outlined in Section 3.2.1. 22 Section 3 Location Figure 3-4 Four -Pad Mounting 3.2.4 Mounting Pad Specifications Mounting pad weight. The weight of the single mounting pad or combined weight of multiple mounting pads should equal or exceed the combined weight of the generator set and attached accessories. To determine the weight of the mounting pad(s), determine the volume (length x width x height) of each pad in cubic meters (cubic feet). Multiply this result by 2400 kg (150 Ib.) to determine a pad's weight. In multiple -pad installations, add the weights of all pads to determine the total mounting pad weight. Mounting pad specifications. Mounting pad composition should follow standard practice for the required loading. Typical specifications call for 17238- 20685 kPa (2500 -3000 psi) concrete reinforced with eight -gauge wire mesh or No. 6 reinforcing bars on 305 mm (12 in.) centers. The recommended concrete mixture by volume is 1:2:3 parts of cement, sand, and aggregate, respectively. Surround the pad with a 200 -250 mm (8 -10 in.) layer of sand or gravel for proper support and isolation of a pad located at or below grade. Note: Refer to the generator set and accessory dimension drawings for conduit and fuel -line placement. The drawings give dimensions for electrical and fuel connection roughins and stubups. 3.3 IBC Seismic Installation International Building Code (IBC) seismic installations involve additional mounting and installation considerations. Refer to seismic installation drawing ADV -7595 for requirements. TP -5700 9/08 • • 3.4 Vibration Isolation Use one of the vibration isolation types detailed in the following paragraphs. Also, connections between the generator set or its skid and any conduits, fuel lines, or exhaust piping must include flexible sections to prevent breakage and to isolate vibration. These connections are detailed in subsequent sections. Isolator types. The two primary types of isolators are neoprene and spring -type. Figure 3 -5 shows neoprene isolators between the engine - generator and the skid, referred to as integral vibration isolation mounting. Integral vibration isolation units come from the factory with neoprene vibration isolation. Neoprene isolators provide 90% vibration isolation efficiency and are often sufficient for installations at or below grade. 1. To engine - generator 2. Skid crossmember a. Neoprene woranon isolator Figure 3 -5 Neoprene -Type Integral Vibration Isolators Figure 3 -6 shows the spring -type isolator kit installed with direct - mounted units. Direct - mounted units have no factory vibration isolation. Spring -type isolators provide 98% vibration efficiency and are recommended for above grade installations and other locations where vibration sensitivity could be an issue. TP -5700 9/08 .62 DIA. MS USS .. 7 0 r.ii ii:. 0 . . .44 DIA. 4 -HOLES GM41122 .44 DIA. 4 -HOLES Note: Dimensions are inches; in. x 25.4 = mm CX- 272000A -C Figure 3-6 Vibration Spring Isolators Generator sets with integral vibration isolation. Skids for generator sets 20 kW and larger use I or C section- fabricated steel with a width of 52 -76 mm (2 -3 in.) per channel. The length varies with the size of the unit, resulting in a static load on the generator set skid of 69 -172 kPa (10 -25 psi) if the total bottom surface of the channel is in contact with the mounting pad. Generator sets with direct mounting. Larger generator sets typically mount directly to a structural steel base. For these units, install the recommended vibration isolators between the base and the mounting pad in the holes provided. Because of the reduced mounting surface area of these individual mounts, the static load on the mounting surface increases to the range of 345 -690 kPa (50 -100 psi). Section 3 Location 23 Dual isolation. For applications involving integral vibration isolators and where the factory does not offer spring -type isolators as a standard accessory, spring - type isolators may be installed under the skid provided they equal the number of neoprene isolators, are inline front -to -back with the existing neoprene isolators, and additional support plates are installed, as required. See Figure 3 -7. 3.5 Dual- Bearing Alternator Alignment Generator sets equipped with dual- bearing alternators require alignment after mounting the generator set skid to a mounting pad. Refer to Service Bulletin SB -566 for details. 1. Generator set skid rail 2. Generator set neoprene integral vibration isolators 3. Skid rail gussets 4. Support plate, 13 mm (1/2 in.) thick steel, of sufficient length to distribute loads directly to skid rail gussets. 5. Locate accessory spring -type vibration isolators axially aligned with neoprene isolators 6. Concrete mounting pad Figure 3 -7 Accessory Vibration Mount Location 24 Section 3 Location TP -5700 9/08 • • • Section 4 Air and Cooling 4.1 General Combustion and heat dissipation require an ample flow of clean, cool air regardless of whether the generator set is air- or liquid - cooled. Approximately 70% of the heat value of fuel consumed by an engine is lost through the cooling and exhaust systems. Battery compartment ventilation. To prevent the accumulation of explosive gases, ventilate compartments containing batteries. 4.2 Air - Cooled Engines Refer to the generator set specification sheet for air requirements. Generally, airflow requirements do not present a problem since air - cooled models are designed for outside installation. When planning outside installation, consider how buildings and landscaping affect airflow. Also consider seasonal changes such as snow or foliage accumulation and potential flooding conditions. Follow a regular maintenance routine to remove snow and foliage accumulations. 4.3 Liquid - Cooled Engines 4.3.1 System Features Generator sets designed for interior installation feature liquid cooling systems. The three most common liquid cooling systems are unit - mounted radiator, remote radiator, and city -water cooling. Observe the common installation considerations outlined below as well as the installation considerations for your generator set's cooling system as detailed in subsequent sections. 4.3.2 Installation Considerations Intake and outlet openings. Provide air intake and air outlet openings for generator sets located in a building or enclosure. Keep air inlets and outlets clean and unobstructed. Position the air inlet into the prevailing wind and the air outlet in the opposite direction. TP -5700 9/08 Ventilating fans. Some buildings tend to restrict airflow and may cause generator set overheating. Use ventilating fans and /or ductwork to increase airflow in the building if the generator set's cooling fan does not provide adequate cooling. See Figure 4 -1. Remote radiator and city -water cooled models require ventilating fans. When using ductwork and ventilating fans, check the exhaust fan capacity in m3 /min. (cfm). If using exhaust fans, install fan - operated louvers with exhaust fans to regulate airflow. See Figure 4 -2. Follow the fan manufacturer's recommendations to determine the size of the inlet and outlet openings. Figure 4 -1 Ventilating Fan Figure 4 -2 Exhaust Fan - Operated Louvers Section 4 Air and Cooling 25 Thermostatically - controlled louvers. Do not allow uncontrolled recirculation of air within an enclosure. The ventilation system must provide a temperature differential sufficient to prevent high engine temperature shutdown on even the hottest days. In areas of great temperature variation, install movable louvers to thermostatically regulate airflow and room temperature. See Figure 4 -3 and Figure 4 -4. Refer to 4.4.2, Installation Considerations, Louver use for further information. Figure 4 -3 Stationary Air Inlet Louvers Figure 4-4 Moveable Air Inlet Louvers In cold climate interior installations using controlled recirculation to recover heat, install thermostatically activated louvers and fans to prevent'the generator set and engine room from overheating. 26 Section 4 Air and Cooling Electric louvers are usually connected to the optional generator set run relay. Typically, the louvers are energized to open when the generator set is operating. However, some louvers are energized to close and when deenergized are spring - actuated to open when the generator set is operating. Filters. Install a furnace -type or similar filter in the inlet opening if the generator set operates in an atmosphere highly contaminated with impurities such as dust and chaff. Air restrictions. When using a filter, screen, or other air restriction, increase the inlet opening size by the following amounts to compensate for diminished airflow: • Louvers: Enlarge the opening 50 %. • Window screening: Enlarge the opening 80 %. • Furnace -type filters: Enlarge the opening 120 %. 4.3.3 Recommended Coolant All applications require antifreeze /coolant protection. Add antifreeze /coolant before starting the generator set or energizing the block heater(s). Most diesel engine manufacturers require the use of an inhibitor additive to the antifreeze /coolant. Use a proper mixture of glycol (ethylene, propylene, or extended life organic acid), water, and supplemental coolant additive (SCA). The antifreeze /coolant and additive mixture reduces corrosion, sludge formation, and cavitation erosion and provides boil and freeze protection. The generator set manufacturer recommends a solution of 50% ethylene glycol and 50% clean, softened water to provide freezing protection to -37 °C ( -34 °F) and boiling protection to 129 °C (256 °F). A 50/50 solution also inhibits corrosion. Refer to the engine manufacturer's operation manual for engine antifreeze /coolant specifications, concentration levels, and inhibitor selection recommendations. TP -5700 9/08 • • 4.4 Unit - Mounted Radiator Cooling The unit - mounted radiator is the most common cooling system for engine- driven generator sets 20 kW and larger. 4.4.1 System Features The system's major components include an engine - driven fan and circulating water pump, a radiator, and a thermostat. The pump circulates water through the engine until it reaches operating temperature. Then the engine thermostat opens, allowing water circulation through the radiator. The thermostat restricts water flow as necessary to prevent overcooling. The fan blows air from the engine side of the radiator across the cooling surface. 4.4.2 Installation Considerations Figure 4 -5 shows a typical unit - mounted radiator installation. Note the direction of airflow and refer to the figure as needed during installation. 1 1. Air inlet opening 2. Ductwork mounting flange 3. Air outlet duct 4. Support legs 5. Flexible section with radiator duct flange 6. Pusher fan Figure 4 -5 Radiator - Cooled Generator Set Installation TP -5700 9/08 Avoid suction fan use. The alternator airflow should move in the same direction as the engine's standard pusher fan. Using a suction fan to reverse airflow is not recommended because it may interfere with the alternator cooling airflow. This in turn reduces the maximum engine power available because higher temperature combustion air is drawn into the air cleaner. Use ductwork to direct airflow. Direct the radiator air outside the room or enclosure using sheet metal ductwork with structural supports. Keep ductwork as short, straight, and unobstructed as possible. Combined static pressure restrictions greater than 0.12 kPa or 13 mm (0.5 in.) water column on the radiator inlet and outlet openings cause reduced airflow and contribute to overheating especially in high ambient air temperatures. Use heavy canvas, silicone rubber, or similar flexible material for the connection between the radiator duct flange and the ductwork to reduce noise and vibration transmission. Outlet and inlet location and sizing. Size the outlet duct area 150% larger than the radiator duct flange area. Size the inlet air opening at least as large but preferably 50% larger than the outlet. If screens, louvers, or filters are used on either the inlet or outlet, increase the inlet or outlet size according to the recommendations given in Section 4.3.2, Installation Considerations. Since the exhaust air of larger units is both high volume and high velocity, direct the exhaust flow away from areas occupied by people or animals. Section 4 Air and Cooling 27 Louver use. Design temperature - controlling louvers to prevent air inlet restrictions and air pressure reductions inside the building. Low building pressure can extinguish pilot lights on gas -fired appliances or cause problems with the building ventilation system. Additionally, bringing large quantities of winter air into a building wastes building heat and risks frozen water pipes in normally heated spaces. Use dampers and controlled air outlet louvers as shown in Figure 4 -6 to eliminate these problems and allow recovery of engine heat to reduce building heat Toss. Close the louvers to the exterior and open the interior louvers when the outdoor temperature is below 18°C-21°C (65 °F- 70 °F). Reverse the louver settings when the outdoor temperature is above 21 °C -24 °C (70 °F- 75 °F). 1 2 3 4 1. Exterior 2. interior 3. Air outlet duct TP- 5700 -4 4. Generator set 5. Dampers 6. Controlled air outlet louvers Figure 4-6 Air Control Louvers 4.5 Remote Radiator Cooling A remote radiator system allows installation of generator sets in locations where it would otherwise be difficult to bring the volume of air required to cool a unit - mounted radiator. In these systems, the engine water pump pushes coolant through a radiator mounted remotely from the generator set and, typically, in an open area. An electric motor - driven fan mounted on the radiator circulates air across the radiator's cooling fins. 28 Section 4 Air and Cooling In order to assess a remote radiator cooling system, the cooling system designer needs the following data. From the respective generator set specification sheet, obtain the: • Engine jacket water flow, Lpm (gpm) • Cooling air required for generator set based on 14 °C (25 °F) rise and an ambient temperature of 29 °C (85 °F), m3 /min. (cfm) • Maximum static (vertical) head allowable above engine, kPa (ft. H2O) From the engine and /or radiator data sheet, obtain the: • Maximum water pump inlet restriction kPa (psi) • Maximum allowable coolant pressure differential external to engine kPa (psi) The following subsections provide general design guidelines for a remote radiator system. 4.5.1 General System limitations. Cooling systems are limited by radiator cap ratings. The maximum radiator operating pressure is 138 kPa (20 psi) and the maximum operating temperature is 121°C (250 °F). Radiators are available for vertical or horizontal discharge. See Figure 4 -7 and Figure 4 -8. Air requirements. Refer to the generator set specification sheet for radiator air and engine /alternator air requirements. Cooling air required for generator sets equipped with a remote radiator is based on a 14 °C (25 °F) rise and an ambient temperature of 29 °C (85 °F). The amount of air required to ventilate the generator set room or enclosure determines the size of the air inlet and outlet. Configure the ventilation air inlet and outlet so that air flows across the generator set. Use aventilating fan, if necessary, to dissipate alternator and engine heat loss. Note: All remote radiators are sized for mounting in an open area with no additional external devices attached. Attached devices, confined installation, louvers, dampers, ductwork, or other inlet or outlet air restriction require resizing the radiator to compensate for reduced airflow. TP -5700 9/08 • 1 14 13 1 1 8 1. Remote vertical radiator 2. Pressure cap 3. Surge tank /expansion tank 4. Radiator inlet 5. Fill line 6. Vent line 7. Shutoff Valve 12 10 TT11883 8. Engine outlet 9. Engine water pump 10. Suction side 11. Fill /drain (lowest point of engine 12. Shutoff valve 13. Radiator outlet 14. Maximum allowable static (vertical) head (varies with engine) • Figure 4 -7 Remote Vertical Radiator System • 1. Radiator inlet 2. Pressure cap 3. Surge tank/expansion tank 4. Horizontal radiator 5. Radiator outlet 6. Vent line(s) 7. Fill line 8. Shutoff valve 9. Engine outlet TT11884 10. Engine inlet 11. Fill /drain (lowest point of engine) 12. Shutoff valve Figure 4-8 Remote Horizontal Radiator System TP -5700 9/08 Section 4 Air and Cooling 29 Static (vertical) head. If the vertical distance from the engine water pump to the radiator (known as static head) is within the engine manufacturer's recommendations, and the pressure drop through the piping and remote radiator does not exceed the engine manufacturer's limits, use the engine water pump to circulate water through the remote radiator. The allowable static head ranges from 5.2 m -15.2 m (17 ft. -50 ft.) and is listed on the generator set specification sheet. Exceeding the allowable static head causes excessive pressure on engine components resulting in problems such as leaking water pump seals. Note: Size the pressure relief valve or cap to remain under the engine pressure limit. Hot well tank/heat exchanger. When the static (vertical) head exceeds the distance stated in the specification sheet, use a hot well tank or heat exchanger and auxiliary circulating pump as shown in Figure 4 -9 or Figure 4 -10. Always wire the circulating pump in parallel with the remote radiator fan so that both operate whenever the generator set operates. A partial baffle divides a hot well tank into two or more compartments. The engine pump forces heated water into the hot side, and the auxiliary pump then draws the water off and forces it into the radiator. After circulating through the radiator, coolant drains back to the cold side of the well where the engine water pump removes it. A hot well or heat exchanger also isolates head pressures from the engine. Note: The water in the hot well tank drains into the radiator when the generator set is not running. Note: Determine the size requirements of the remote radiator and hot well tank/heat exchanger for each application. Do not use a standard remote radiator with a hot well tank /heat exchanger. 4.5.2 Vent Lines Route the vent lines at a continuous upward slope from the engine connection exit to the expansion tank. Port all vent lines individually into the expansion tank above the coolant level. Locate the vent lines in the expansion tank to prevent splash on the coolant level sensor. Thoroughly vent the systems by installing vent lines to all the vent points on the engine and the charge air cooler circuits including the radiator core. Refer to the installation drawings for vent points. Size the vent line the same as the connection point on the engine. The vent lines may be slightly larger; however, vent lines sized too large will increase fill line flow and possibly reduce head pressure applied to the engine water pump inlets. 30 Section 4 Air and Cooling TP -5700 9/08 • • • 4'' C) 1. Vacuum relief check valve 2. Remote radiator 3. Auxiliary water pump 4. Baffles 12 11 10 5. High volume breather 6. Expansion space 7. Vent line(s) 8. Shutoff valve TT11885 9. Generator set 10. Fill /drain (lowest point of engine) 11. Shutoff valve 12. Hot well tank Figure 4 -9 Compound Remote Radiator /Hot Well Tank Cooling System 3 12 1. Expansion /surge tank 2. Remote radiator 3. Vent line 4. Expansion /surge tank J 11 5. Vent line(s) 6. Fill line 7. Shutoff valve 8. Generator set 10 9 5 / 8 0 TT11885 9. Fill /drain (lowest point of engine) 10. Shutoff valve 11. Heat exchanger 12. Auxiliary water pump Figure 4 -10 Compound Remote Radiator /Heat Exchanger Cooling System TP -5700 9/08 Section 4 Air and Cooling 31 4.5.3 Fill Lines (Balance or Static) Connect the fill line(s) to the bottom of the expansion tank. Make the lines as short as possible, continuously descending, and connected directly before the engine water pump(s). To provide a positive head pressure to the engine water pump inlet, properly locate the fill line (or makeup line). See the installation drawings for the fill line connection points. Connect the vent and fill lines to the expansion tank at the greatest possible distance from each other to prevent aeration and preheating of the coolant returning down the fill line. The minimum fill line sizes cannot be smaller than the connection point on the engine. Do not allow fittings on the fill lines to reduce the effective size. If other cooling system components vent too much coolant to the expansion tank, larger diameter fill lines may be needed. 4.5.4 Location Considerations When choosing the radiator's location: • For economical installation and operation, locate the radiator as close as practical to the engine and at the same elevation to reduce piping, coolant, and wiring costs. • Locate the radiator surge tank fill opening and vent line(s) at the highest point in the cooling system. • Position the radiator no closer than one fan diameter from a wall, another radiator, or any other obstruction that would restrict air movement and future service access. • Locate the radiator to prevent recirculation of the heated exhaust air back into the intake stream. • Mount the radiator in an area where prevailing winds do not hamper free airflow. • Locate the radiator where it is not subject to deep snow or ice accumulation, flooding, industrial fallout, leaf accumulation, heavy dust and chaff, or other detrimental seasonal or environmental conditions. • For rooftop installations, do not locate the radiator near critical sound areas, building ventilation, or hood exhausts. 32 Section 4 Air and Cooling 4.5.5 Installation Considerations When installing the remote radiator: • Use a remote radiator setup kit to aid installation. See Figure 4 -11. • Wire the cooling fan motor to the generator set output so that the fan operates whenever the generator set operates. There is no need for a thermostatic control of the fan motor because the engine thermostat prevents overcooling as it does on generator set - mounted radiator systems. Follow all applicable national and local codes when wiring the cooling fan. • Follow the wiring diagram on the remote radiator's fan motor. The motor rotation must match the fan blade design. The manufacturer supplies most units with counterclockwise fan rotation as viewed from motor side. The fan is a blower type, moving air from the fan side of the radiator, through the core, and out the front side. • Preferably, connect no devices to either side of the radiator. Resize the radiator if adding louvers or duct work to the radiator to compensate for reduced airflow. • Ensure that the radiator is level and securely bolted to a firm, solid foundation. • Brace the radiator as needed, especially in areas with strong winds. • Use isolators to keep area vibration from affecting the radiator or to keep vibration produced by the radiator from affecting surrounding areas. • Use hose clamps on all nonthreaded connections. TP -5700 9/08 1. Top mounting bracket 2. Upper radiator hose outlet 3. Drain valve 4. Belt guard bracket 5. Left -hand belt guard 6. Front belt guard 7. Bottom belt guard 8. Lower radiator hose inlet 9. Right -hand belt guard 10. Top belt guard GJ- 273000 -B Figure 4 -11 Remote Radiator Setup Kit, Typical 4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator A horizontal discharge remote radiator requires the use of a surge (expansion) tank as shown in Figure 4 -8. Locate the tank at the highest point in the cooling system. The surge tank provides venting, surge/ expansion protection, and filling /makeup functions. • Equip the surge tank with a sight -glass gauge, overflow tube, and pressure cap. • Size the surge tank to handle at least 6 % -10% of the total cooling system volume. Follow the engine manufacturer's recommendation when available. • Connect the main line from the surge tank to the highest point of the remote radiator. Most vertical core radiators have the surge tank as part of the radiator top tank. The setup illustrated in Figure 4 -8 provides for radiator and engine deaeration and a positive pressure at the pump suction inlet. • Use a strainer to filter dirt, scale, and core sand from the coolant line. Piping. Size water piping between the engine and the remote radiator large enough to eliminate the need for a booster pump. If the cooling system requires a booster pump, contact your distributor /dealer. TP -5700 9/08 Use piping of ample size and with as few short sweep bends or elbows, tees, and couplings as possible. Use long sweep elbows or long bends, if bends are required. Installation. Support piping externally, not from the radiator or engine. On standard remote radiators, connect radiator bottom outlets only to the suction side of the pump. Plumb the lines to prevent air from becoming trapped in the lines. Route piping in one general direction, either upward or downward. A combination of both upward and downward piping creates air pockets in the piping. Route vent lines to the expansion /surge tank without creating low spots in the lines. Flexible connections. Provide flexible connections when connecting piping to the radiator assembly. Use hose clamps at all nonthreaded connections. Shutoff valves. Locate shutoff valves between the engine and cooling system to allow for isolation of both the radiator and the engine. A shutoff valve eliminates the need to drain the entire cooling system during service. Section 4 Air and Cooling 33 4.5.7 Procedure to Fill with Deaeration For radiators designed for full deaeration, fill the radiator according to the following procedure. 1. Fill the cooling system from the bottom when possible. Otherwise, fill the radiator at the filler neck. 2. Next, fill the radiator through one of the top tank or expansion /surge tank inlets located before the final hose connection. 3. Continue filling the system to cover the filler neck bottom until coolant appears in the sight glass located in the radiator top tank. 4. Check and correct any Teaks in the system. 4.5.8 Procedure to Fill without Deaeration For radiators designed without deaeration, fill the radiator according to the following procedure. 1. Initially, fill the radiator through one of the top tank inlets located before the final hose connection for faster and more complete fillup. 2. Fill the cooling system from the bottom when possible. Otherwise, fill the radiator at the filler neck with coolant covering the filler neck bottom until coolant appears in the sight glass located in the radiator top tank. 3. Check for and correct any leaks in the system. 34 Section 4 Air and Cooling 4.5.9 Checks after Initial Startup If any problems arise during startup, immediately shut down the generator set. See Figure 4 -12, Cooling System Checklist. Even after a successful startup, shut down the generator set after 5 -10 minutes and recheck the belt tension to make sure no hardware has loosened during operation. Perform another recheck after 8 -12 hours of operation. Figure 4 -12 Cooling System Checklist TP -5700 9/08 Operation Verify the cooling fan's position in the fan shroud. Check the mounting hardware. Check the fan motor for free rotation. Check V -belts for alignment and tension. Fill the system with coolant and check all connections for tightness and leaks. Verify that all electrical connections are secure and that the power source matches the motor nameplate. Verify that no loose foreign material is in the fan's air stream. With the unit running, check tor: fan clearance excessive vibration excessive noise coolant leaks Figure 4 -12 Cooling System Checklist TP -5700 9/08 • • 4.6 City Water Cooling 4.6.1 System Features City water - cooling systems use city water and a heat exchanger for cooling. They are similar to remote radiator systems because they require less cooling air than unit - mounted radiator systems. Figure 4 -13 shows some of the elements of a typical installation. The heat exchanger limits the adverse effects of city water chemistry to one side of a heat exchanger, which is relatively easy to clean or replace, while engine coolant circulates in a closed system similar to the radiator system. The heat exchanger allows engine temperature control, permits the use of antifreeze and coolant conditioners, and is suited to the use of an engine block heater as a starting aid. 4.6.2 Installation Considerations Vibration isolation requirements. Water inlet and outlet connections are mounted on the generator set skid and isolated from engine vibration by flexible sections. If the generator set is vibration - mounted to the skid and the skid is bolted directly to the mounting base, no additional flexible sections are needed between connection points on the skid and city water lines. If the generator set skid is mounted to the base with vibration isolators, use flexible sections between the connection points on the skid and city water lines. Shutoff valve location. A solenoid valve mounted at the inlet connection point automatically opens when the generator set starts, providing the engine cooling system with pressurized water from city water mains. This valve automatically closes when the unit shuts down. Use an additional customer - supplied valve ahead of the entire system to manually shut off city water for generator set service. Side View 11 1. Coolant expansion tank 2. Coolant expansion tank pressure cap 3. Ventilation fan (for heat rejected from exhaust and engine) 4. Connect heat exchanger inlet to city water supply 5. Flexible section 6. Manual shutoff valve End View 10 9 8 HC- 273000 -E/1P- 57004 7. City water supply 8. Heated city water into floor drain 9. Connect heat exchanger outlet to floor drain 10. Heat exchanger 11. Solenoid valve Figure 4 -13 City -Water Cooling System with Heat Exchanger TP -5700 9/08 Section 4 Air and Cooling 35 4.7 Cooling Tower A cooling tower system is a variation of a city water cooling with heat exchanger system. In warm, dry climates, a cooling tower is a suitable source of generator set cooling water. A cooling tower system consists of the engine cooling system plus a raw -water system. The engine cooling system usually includes the engine water pump, a heat exchanger, a surge tank, and the engine water jacket. The raw -water system consists of the cooling tower, a raw -water pump, and the tube portion of the heat exchanger. A typical system is shown in Figure 4 -14. The engine cooling system circulates coolant through the heat exchanger outer shell. Raw water circulates through the heat exchanger tubes absorbing heat from the engine coolant. The heated raw water flows into a pipe at the top of the cooling tower and sprays down into the tower to cool by evaporation. Because some water is constantly being lost through evaporation, the system must provide makeup water. 1. Engine water pump 2. Surge tank 3. Cooling tower 4. Makeup water connection 5. Cooling tower drain 7. Heat exchanger 6. Heat exchanger drain 8. Auxiliary water pump Figure 4 -14 Cooling Tower System 4.8 Block Heaters Block heaters are available as installed accessories on all generator sets. Generator sets installed in NFPA applications generally require use of a block heater. Equip generator sets with block heaters on all standby applications where the generator set is subject to temperatures below 0 -20 °C (32- 68 °F). See the respective generator set spec sheet for specific temperature recommendations. Connect the block heater to a power source that is energized when the generator set is not running. 36 Section 4 Air and Cooling The block heater thermostat is set to 43 °C (110 °F) on all generator sets models except the 1750 /2000REOZMB. The 1750 /2000REOZMB models have a thermostat setting of 50 °C (122 °F) for optimum operation. This adjustment is made by removing the thermostat cap. Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater. TP -5700 9/08 Section 5 Exhaust System • • • Satisfactory generator set performance requires proper exhaust system installation. Figure 5 -1 and Figure 5 -2 show typical arrangements of recommended exhaust systems. The following sections detail exhaust system components. 5.1 Flexible Exhaust Line Install a section of seamless stainless steel flexible exhaust line at least 305 mm (12 in.) long within 610 mm (2 ft.) of the engine exhaust outlet. See Figure 5 -1 and Figure 5 -2. 8 TP- 5700 -5 1. Supports 5. Drain petcock 2. Pitch line downward 6. Flexible section 3. Silencer 7. Solid section 152 -203 mm (6 -8 in.) 4. Water trap 8. Manifold Figure 5 -1 Exhaust System, End Inlet Silencer 1. Exhaust wall thimble 2. Silencer 3. 45° Y fitting 4. Water trap 5. Drain petcock 2 F=D 1 TP- 5700 -5 6. Outer diameter adapter and clamp 7. Flexible section 8. Manifold 9. 45° elbow Figure 5 -2 Exhaust System, Side Inlet Silencer TP -5700 9/08 The flexible line limits stress on the engine exhaust manifold or turbocharger. Never allow the engine manifold or turbocharger to support the silencer or exhausting piping. Note: Do not bend the flexible section or use it to compensate for misalignment between the engine exhaust and the exhaust piping. When using threaded flexible exhaust connectors, place a 152 -203 mm (6 -8 in.) length of pipe between the flexible exhaust connectors and the exhaust manifold. See Figure 5 -1. The pipe reduces the temperature of the flexible connection, simplifies flexible section removal, and reduces strain on the engine exhaust manifold. 5.2 Condensation Trap Some silencers are equipped with a drain pipe plug for draining condensation; see Figure 5 -3. Otherwise, install a wye- or tee -type condensation trap with a drain plug or petcock between the engine and the exhaust silencer as shown in Figure 5 -4. The trap prevents condensed moisture in the engine exhaust from draining into the engine after shutdown. Periodically drain collected moisture from the trap. 1. Pipe Plug TP- 5700 -5 Figure 5 -3 Silencer Condensation Drain Plug rit 1. Condensation trap TP- 5700 -5 Figure 5-4 Condensation Trap Section 5 Exhaust System 37 5.3 Piping Note: Select piping with a diameter that is the same size as, or larger than, the manifold outlet's inside diameter. • Keep exhaust lines as short and straight as possible. • Use schedule 40 black -iron pipe. • Use sweep elbows with a radius of at least three times the pipe diameter. • Use exhaust piping that conforms to applicable codes. • Support the exhaust piping securely, allowing for thermal expansion. • Insulate the exhaust piping with high- temperature insulation to reduce the heat rejected by exhaust piping and consequently the amount of ventilating air required. In general, exhaust temperatures measured at the engine's exhaust outlet are less than 538 °C (1000 °F), except for infrequent brief periods; therefore, low -heat appliance standards apply. Each generator set specification sheet provides exhaust temperatures. For units with exhaust temperatures below 538 °C (1000 °F), route the exhaust piping a minimum of 457 mm (18 in.) from combustible material, including building materials and natural surroundings. If exhaust temperatures exceed 538 °C (1000 °F), the minimum distance is 914 mm (36 in.). When planning exhaust silencer and piping placement, consider the location of combustible materials. If the proximity of the exhaust system to the combustible materials cannot be avoided, follow a regular maintenance schedule to ensure that combustible materials are kept away from the exhaust pipes after installation. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a safe distance from the exhaust system. 5.4 Double- Sleeved Thimbles If the exhaust pipe passes through a wall or roof, use a double - sleeved exhaust thimble to prevent the transmission of exhaust pipe heat to the combustible material. Figure 5 -5 shows construction details of a typical double - sleeved thimble in which exhaust piping passes through a combustible structure. Sheet metal shops usually fabricate thimbles using installation engineer's specifications and drawings. 38 Section 5 Exhaust System 15 1. Rain cap (or gradual U bend) 2. Rain shield 3. 254 mm (10 in.) minimum 4. 25 mm (1 in.) minimum 5. Exhaust pipe 6. Ventilation holes at both ends 7. 254 mm (10 in.) minimum 8. 25 mm (1 in.) minimum 9. Flashing 10. Inner sleeve 11. Outer sleeve 12. Thimble outer diameter 13. 254 mm (10 in.) minimum outside 14. 254 mm (10 in.) minimum inside 15. Exhaust pipe diameter Figure 5 -5 Double- Sleeved Thimbles and Rain Cap Construct the thimble so it extends at least 254 mm (10 in.) both inside and outside the structure's surface. Openings at both ends of the thimble allow cooling air to circulate through the thimble. If screening is used on the outer end to keep birds and animals from entering the thimble, use a mesh large enough to allow unrestricted air circulation through the thimble. See Section 5.5 for additional exhaust outlet location and protection considerations. TP -5700 9/08 • • • 5.5 Exhaust Outlet Outlet location. Engine performance and efficiency depend on the location of the exhaust outlet. Direct the exhaust outlet away from the air inlet to prevent exhaust gases from entering the air inlet and clogging the dry- type air filter elements. Hot exhaust drawn through the radiator adversely affects engine cooling. Locate the exhaust outlet to prevent exhaust fumes from entering a building or enclosure. Noise reduction. The exhaust outlet configuration affects the apparent noise level for people or animals in the vicinity. An upward- directed outlet seems quieter than one directed downward or horizontally. Additionally, a 30- to 45- degree angled cut at the end of a horizontal exhaust outlet pipe reduces turbulence at the outlet, thereby reducing the noise level. Rain cap. To prevent precipitation from entering the exhaust pipe, install a rain cap on vertical outlets. See Figure 5 -5. In a climate where freezing is common, do not use a rain cap. Instead, extend the exhaust piping at least 610 mm (24 in.) beyond the roof line and create a gradual U bend at the end to direct the exhaust outlet downward. Keep the pipe outlet at least 457 mm (18 in.) from the roof to prevent hot exhaust from igniting the roof material. Note: Do not use a rain cap in areas subject to freezing temperatures. 5.6 Exhaust System Backpressure Exhaust backpressure limits engine power and excessive backpressure causes serious engine damage. Excessive backpressure usually results from one or more of the following reasons: • The exhaust pipe diameter is too small. • The exhaust pipe is too long. • The exhaust system has too many sharp bends. • The exhaust silencer is too small. • The exhaust silencer is not the correct design for the application. Use the following procedure to verify that the installed exhaust system does not exceed the engine's maximum exhaust backpressure limit as specified in the generator set specification sheet. TP -5700 9/08 Exhaust System Backpressure Calculation Procedure Determine the total backpressure by calculating the effects of the individual exhaust system components and adding the results. Make calculations using either English or metric units. Exhaust pipe references are nominal pipe NPT (in.) sizes. The procedure shows an example with italic text. Calculations relate to end inlet silencers. Note: When calculating backpressure drop for side inlet silencers, use the end inlet values shown and add 0.75 kPa (0.25 in. of mercury or 3.4 in. of water) to backpressure calculations. 1. Select the exhaust silencer type for the application — hospital, critical, residential, or industrial. See the silencer specification sheet for definitions for each exhaust silencer type. Confirm silencer type availability for your generator set with your authorized distributor /dealer, as some generator sets do not use all four types. Example: Determine the silencer backpressure for the recommended critical silencer on a 230 kW, 60 Hz diesel generator set. 2. Refer to the generator set specification sheet for: a. Engine exhaust flow at rated kW in m3 /min. (cfm) Example: 57.5 m3 /min. (2030 cfm) b. Maximum allowable backpressure in kPa (in. of Hg) Example: 10.2 kPa (3.0 in. Hg) 3. Refer to the submittal catalog for: a. The recommended critical silencer part number Example: 343616 b. Silencer inlet diameter in mm (in.) Example: 152 mm (6 in.) c. Silencer inlet position (end or side) Example: end inlet d. The flexible exhaust adapter part number Example: 343605 e. Flexible exhaust adapter, flexible section length Example: 857 mm (33.75 in.) Section 5 Exhaust System 39 4. Determine the exhaust gas velocity through the silencer as follows: a. Using the exhaust silencer inlet diameter determined in step 3, determine corresponding inlet area using Figure 5 -6. Example: 0.0187m2 (0.201 sq. ft.) b. Use this data to calculate the exhaust gas velocity. Divide the engine exhaust flow from step 2 in m3 /min. (cfm) by the silencer inlet area m2 (sq. ft.) to get flow velocity in m (ft.) per minute. Example: 57.5 m3 /min. / 0.0187 m2 = 3075 m /min. (2030 cfm / 0.201 sq. ft. = 10100 ft. /min.) Nominal Pipe Size, in. NPT Inlet Area, m2 Inlet Area, ft2 1 0.00056 0.0060 1 1/4 0.00097 0.0104 1 1/2 0.00131 0.0141 2 0.00216 0.0233 2 1/2 0.00308 0.0332 3 0.00477 0.0513 4 0.00821 0.0884 5 0.0129 0.139 6 0.0187 0.201 8 0.0322 0.347 10 0.0509 0.548 12 0.0722 0.777 14 0.0872 0.939 16 0.1140 1.227 18 0.1442 1.553 Figure 5-6 Cross Sectional Area for Standard Silencer Sizes 5. Refer to Figure 5 -7. Use the exhaust gas velocity determined in step 4 and find the exhaust gas velocity value in thousands on the bottom scale. Move vertically up until this value intersects the curve of the corresponding silencer type as determined in step 1. Move left on the horizontal axis and determine the backpressure drop value in kPa (in. of Hg). Example: Exhaust velocity, 3075 m /min. (10100 ft./ min.) intersects with critical silencer curve B and the corresponding backpressure value is approximately 2.8 kPa (0.85 in. of mercury). Silencer type is end inlet from step 3 information with no additional backpressure drop value per the following note. 40 Section 5 Exhaust System Note: When calculating backpressure drop for side inlet silencers, use the end inlet values shown and add 0.75 kPa (0.25 in. of mercury or 3.4 in. of water) to backpressure calculations. Note: Refer to Figure 5 -8 to calculate in inches of water and feet per minute. 6. Total the number of elbows and flexible sections in the exhaust system between the engine and the exhaust system outlet. Compare the radius of the bend (R) to the pipe diameter where (D) is the nominal pipe diameter in inches. Determine the equivalent length in m (ft.) of straight pipe for the elbows and flexible sections from the following: Bend Angle Type Bend Radius Conversion Factor 90° Close R = D 32 x D* / 12 90° Medium R =2D 10xD */12 90° Sweep R = 4D 8 x D* / 12 45° Close R = D 15 x D* / 12 45° Sweep R = 4D 9 x D* / 12 Flex Sections 2 x Lengthy / 12 * Use the diameter of the silencer inlet in inches from step 3 for the initial calculation. If the resuhts from step 9 indicate excessive backpressure drop, then recalculate using the larger- diameter pipe size selected. t Use the flexible exhaust adapter length from step 3 and add any additional flex sections in the exhaust system expressed in inches. Convert the equivalent pipe length calculated in feet to meters using ft. x 0.305 = m, as needed. Examples: 45 ° sweep elbows: 9 x 6.0 in. / 12 = 4.5 equiv. ft. or 1.4 equiv. m 90 ° close elbows: 32 x 6.0 in. / 12 = 16.0 equiv. ft. or 4.9 equiv. m Flexible sections: 2 x 33.75 in. / 12 = 5.6 equiv. ft. or 1.7 equiv. m Equivalent of straight pipe: 4.5 + 16.0 + 5.6 = 26.1 equiv. straight ft. 1.4 + 4.9 + 1.7 = 8.0 equiv. straight m TP -5700 9/08 • • • Pressure Drop kPa in. of Hg 6.4 1.9 6.1 1.8 5.8 1.7 5.4 1.6 5.1 1.5 4.7 1.4 4.4 1.3 4.1 1.2 3.7 1.1 3.4 1.0 3.0 0.9 2.7 0.8 2.4 0.7 2.0 0.6 1.7 0.5 1.4 0.4 1.0 0.3 0.7 0.2 0.3 0.1 0 0 A B 03 06 09 1.2 15 18 21 24 27 31 34 2 3 4 5 6 7 8 9 10 11 Exhaust Gas Velocity in Thousands A = Hospital Silencer B = Critical Silencer C = Residential Silencer D = Industrial Silencer 38 40 4.3 12 13 14 5.8 15 c D 4.9 (m/min.) 16 (ft. /min.) Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa (0.25 in. of mercury or 3.4 in. of water) to the backpressure. Figure 5 -7 Silencer Backpressure Drop (in. of Hg) TP -5700 9/08 Section 5 Exhaust System 41 Pressure Drop mm of Water in. of Water 680.4 26 609.8 24 558.8 22 508.0 20 457.2 18 408.4 18 355.8 14 304.8 12 254.0 10 203.2 8 152.4 8 101.8 4 50.8 2 A B 0 0.3 0.8 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.1 3.4 3.8 4.0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Exhaust Gas Velocity in Thousands A = Hospital Silencer B = Critical Silencer C = Residential Silencer D = Industrial Silencer c D 4.3 (m /min.) 14 (ft./min.) Note: When figuring the silencer pressure drop for side inlet, add 0.75 kPa (86 mm of water or 3.4 in. of water) to the backpressure. Figure 5-8 Silencer Backpressure Drop (in. of water) 42 Section 5 Exhaust System TP -5700 9/08 • • • 7. Determine the total length of straight pipe used in the exhaust system. Add this calculation to the equivalent length for elbows and flexible sections obtained in step 6. Example: Straight pipe = 3.0 m (10 ft.). Equivalentstraight pipe from step 6: 8.0 m (26.1 ft.) 3.0m +8.0m=11.0 mor 10 ft. + 26.1 ft. = 36.1 ft. total 8. Refer to Figure 5 -9 if the pipe size is 102 mm (4 in.) or less or Figure 5 -10 if the pipe size is 127 mm (5 in.) or larger. Place a straight edge across the chart with the edge in line with the pipe size in inches (D) on the right column from step 3 and the engine exhaust flow (Q) from step 2 on the left column. Read backpressure kPa /m or in. of Hg /ft. (AP) from the center column. Calculate the total piping system backpressure by multiplying the total equivalent straight pipe in m (ft.) from step 7 by the kPa/m or in. of Hg /ft. of pipe from this step. Example: 11.0 equiv. m x 0.04 kPa/m = 0.4 total system backpressure in kPa 36.1 equiv. ft. x 0.004 in. Hg/ft. = 0.14 total system backpressure in inches of Hg TP -5700 9/08 9. Add the backpressure of the piping determined in step 8 to the backpressure of the silencer determined in step 5. The total should not exceed the engine manufacturer's maximum allowable system backpressure determined in step 2 or on the generator set's specification sheet. If the total exceeds the maximum, use a larger pipe size or silencer or both. Repeat the calculation if new components are selected to verify that the system backpressure would not exceed the limit using the larger component(s). Example: 0.4 kPa (step 8) + 2.8 kPa (step 5) = 3.2 kPa Maximum allowable backpressure = 10.2 kPa 3.2<10.2 backpressure drop is acceptable 0.14 in. Hg. (step 8) + 0.85 in. Hg. (step 5) = 0.99 in. Hg. Maximum allowable backpressure = 3.0 in. of Hg. 0.99< 3.0 backpressure drop is acceptable Section 5 Exhaust System 43 Q Engine Exhaust Flow m3 /min. cfm 28.3 1000 25.5 900 22.7 800 19.8 700 17.0 600 14.2 500 11.3 400 8.5 300 7.1 250 5.7 200 4.2 150 2.8 100 2.5 90 2.3 80 2.0 70 1.7 60 1.4 50 1.1 40 A P Backpressure kPa per m 1.033 0.515 in. Hg per foot 1.0 0.5 0.104 0.1 0.052 0.05 0.009 0.01 0.005 0.005 0.001 0.001 0.001 0.0005 0.000 0.0001 0.000 0.00005 0.000 0.00001 (cfm x 0.02832 = m3 /min.) (in. Hg x 3.387 = kPa) D Pipe Diameter mm 25.4 31.8 38.1 44.5 50.8 63.5 76.2 88.9 101.6 114.3 inches 1.0 1.25 1.5 1.75 2.0 2.5 3.0 3.5 4.0 4.5 127.0 5.0 (in. x 25.4 = mm) Figure 5 -9 Backpressure using Pipe Size 4 in. (102 mm) or Less 44 Section 5 Exhaust System TP -5700 9/08 • • • Q Engine Exhaust Flow m3 /min. cfm 453.1 16000 339.8 12000 283.2 10000 254 9 9000 226.6 8000 198.2 7000 169.9 6000 141.6 5000 113.3 4000 85.0 56.6 42.5 28.3 25.5 22.7 3000 2000 1500 1000 900 800 (cfm x 0.02832 = m3 /min.) 0 P Backpressure kPa per m in. Hg per foot 1.033 1.0 0.515 0.5 0.104 0.1 0.052 0.05 0.009 0.01 0.005 0.005 0.001 0.001 0.001 0.0005 0.000 0.0001 0.000 0.00005 0.000 0.00001 D Pipe Diameter mm inches 76.2 3 101.6 127.0 152.4 177.8 203.2 228.6 254.0 304.8 330.2 355.6 406.4 4 5 6 7 8 9 10 12 13 14 16 (in. Hg x 3.387 = kPa) (in. x 25.4 = mm) Figure 5 -10 Backpressure using Pipe Size 5 in. (127 mm) or Larger TP -5700 9/08 Section 5 Exhaust System 45 • • • Section 6 Fuel Systems Comply with applicable state and local codes when installing any fuel system. 6.1 Diesel Fuel Systems The main components of a typical diesel fuel system are a main fuel storage tank, a day tank, fuel lines, and an auxiliary fuel pump. See Figure 6 -1. 6.1.1 Main Tank Storage. Because it is less volatile than gas or gasoline, diesel fuel is safer to store and handle. Regulations for diesel storage tank placement are less stringent than the regulations for gas or gasoline storage. In some locations, large main tanks are permitted inside the building or enclosure. 13 12 ■I■ 1 2 3 4 r- 11 l 10 1. Injector return line 2. Day tank vent 3. Day tank 4. Auxiliary fuel pump 5. Tank drain 6. Electric fuel level control switch 7. Fuel supply line from day tank to engine connection 8. Fuel supply line from main fuel tank to day tank 9. Overflow line 10. Foot valve 11. Main fuel storage tank 12. Fuel tank vent 13. Tank filling inlet TP- 5700 -8 Figure 6 -1 Diesel Fuel System TP -5700 9/08 Section 6 Fuel Systems 47 Tank location. Locate fuel storage tanks above ground or bury them underground in accordance with applicable codes. Figure 6 -2 shows a commonly used above - ground subbase tank contained in the generator set mounting base. Provide easy access to fuel filters and sediment drains for regular and frequent service. Clean fuel is especially important to diesel engines, which have easily clogged fuel injectors and pumps. Figure 6 -2 Subbase Fuel Tank Tank size. Codes requiring standby power often specify a minimum onsite fuel supply. Such requirements are included in NFPA 70, National Electrical Code, and NFPA 99, Standard for Health Care Facilities. Diesel fuel deteriorates if stored for more than one year; therefore, size the tank to ensure that regular generator set exercising will use the tank's contents within one year. If there are no applicable code requirements, the manufacturer recommends a tank sized for eight hours of operation at rated load. Refer to the generator set specification sheet for fuel consumption data. Tank venting. Vent the main fuel tanks to allow air and other gases to escape to the atmosphere without allowing dust, dirt, and moisture to enter the tank. Fuel expansion. Never fill the tank more than 95% full to allow for fuel expansion. On overhead main tanks, use a fuel shutoff solenoid to prevent hydraulic lock or tank overflow caused by excessive static head fuel pressures. Fuel alternatives. Most diesel engines operate satisfactorily on No. 2 domestic burner oil available in most parts of the US. If the site heating system is oil- fired, consider supplying the engine with fuel from the same tank used for heating oil to reduce costs and to ensure a continually fresh fuel supply for the engine. This practice necessitates that the fuel oil meets the engine manufacturer's minimum requirements for wax point, pour point, sulfur content, and cetane number as these factors influence cold weather starting and generator set power output. When supplying multiple applications from the same main fuel tank, provide each with a separate supply line. 48 Section 6 Fuel Systems TP -5700 9/08 6.1.2 Day Tanks The terms day tank and transfer tank are •interchangeable. Having a day tank adjacent to the engine allows the engine fuel transfer pump to easily draw fuel during startup and provides a convenient location to connect fuel injector return lines. See Figure 6 -3. • Connect a float- switch - controlled solenoid antisiphon valve or a float valve to prevent siphoning fuel from the main storage tank if the main tank fuel level is above the day tank inlet. Tank size. Standard tanks are available in sizes from 38 -3952 L (10 -1044 gal.) with or without integral electric fuel transfer pumps. Because engines are subject to fuel temperature deration above 38 °C (100 °F) and are subject to damage if operated with fuel temperatures above 60 °C (140 °F), a day tank providing at least four hours of fuel consumption should be used to provide enough capacity to cool the fuel returning from the engine. If smaller day tanks are used, the generator set manufacturer may recommend installing a fuel cooler or routing engine fuel return lines to the main storage tank. See Figure 6 -3. Optional equipment includes fuel level gauges, manual priming pumps, float switches for pump control, float valves, rupture basins, and low level alarms. Remove the plastic shipping plugs and install metallic pipe plugs in all unused fuel tank ports to provide a liquid -tight seal. 1 • I•M•M•111.•M• 1 1 7 12 11 10 1. Return line from fuel pump 2. Return line from fuel injectors/fuel rack 3. Vent (to outside) 4. Overhead main tank 5. Maximum 76 m (25 ft.), minimum 25 mm (1 in.) 6. Fuel supply line from main fuel tank to day tank 8 4 5 7. Fuel shutoff solenoid 8. Day tank 9. Fuel supply line from day tank to engine connection 10. Filter 11. Flexible line 12. Fuel pump TP- 5700 -6 Figure 6 -3 Diesel Fuel System with Overhead Main Tank and Day Tank TP -5700 9/08 Section 6 Fuel Systems 49 6.1.3 Fuel Lines The following items describe fuel line selection and application. Never use the fuel piping or fuel line damps to ground any electrical equipment. Line type. Use Schedule 40 black -iron pipe, steel tubing, or copper tubing for diesel fuel systems. Diesel fuel reacts adversely with galvanized tanks and piping, producing flaking sediment that quickly clogs filters and causes fuel pump and fuel injector failure. Ensure that any flexible fuel lines used are approved for diesel fuel. Line size. Use the smallest diameter fuel line that still delivers enough fuel to the engine with an acceptable pressure drop of 6.9 kPa (1.0 psi). Using oversize piping increases the chance of air introduction into the fuel system during engine priming, which increases the potential for fuel pump damage and hard starting. Flexible connectors. Use flexible connections spanning a minimum of 152 mm (6 in.) between the stationary piping and the engine fuel inlet connection. Return lines. A diesel system delivers more fuel to the injectors than the engine uses; therefore, a system has one supply line from the fuel tank and at least one return line from the fuel injectors. Size the fuel return lines no smaller than the fuel supply lines. Route the return fuel line to either the day tank or the main storage tank. Place the return lines as far away from the pickup or fuel diptube as possible to prevent air entry and to keep warm fuel from being reintroduced to the engine. If fuel lines are routed to the day tank, note the day tank size requirements in Section 6.1.2, Day Tanks. A properly designed fuel return line is unrestricted and as short as possible, and it allows gravity return of fuel to the storage tanks. In installations where gravity return is not possible, obtain approval of the design from the generator set supplier based upon the engine's specifications before installing a fuel system with static head pressure on the return lines. Fuel return line restriction can cause engine hydraulic lock or uncontrollable overspeed on some systems. 50 Section 6 Fuel Systems 6.1.4 Auxiliary Fuel Pumps Primary, engine- driven fuel pumps typically develop a maximum of 48 kPa (7 psi) pressure and draw fuel to approximately 1.2 -1.4 m (4 -5 ft.) vertically or 6 m (20 ft.) horizontally. When the main tank is located a greater distance from the engine or for a more reliable fuel system, use an auxiliary pump alone or in connection with a day tank. See Figure 6 -3. Limit auxiliary fuel pump pressure to approximately 35 kPa (5 psi). Use a shutoff solenoid valve wired into the engine run circuit or a check valve to help keep the fuel line primed. Install the check valve on the outlet side of the auxiliary fuel pump to minimize inlet restriction. Auxiliary fuel pump options. On engines using less than 38 L (10 gal.) of fuel per hour (approximately 100 kW or less), connect an engine starting battery- powered electric fuel transfer pump in series with the engine - driven transfer pump. Locate the electric pump nearer to the fuel tank than to the engine. An auxiliary pump located at the fuel tank approximately doubles the horizontal and vertical distance limits of a single engine - driven pump. On engines using more than 38 L (10 gal.) of fuel per hour or when drawing fuel more than 1.8 m (6 ft.) vertically or 12 m (40 ft.) horizontally, use an electric motor - driven positive displacement pump with a day tank and float switch. Electrically connect the fuel pump to the transfer switch load side for maximum reliability. This type of pump can typically lift fuel 5.5 m (18 ft.) or draw it horizontally up to 61 m (200 ft.). Where vertical runs exceed 5.5 m (18 ft.) or horizontal runs exceed 61 m (200 ft.), remote -mount the pump adjacent to the fuel storage tank. This type of installation allows these pumps to push fuel over 305 m (1000 ft.) horizontally or more than 31 m (100 ft.) vertically and deliver adequate fuel for generator sets up to 2000 kW. Always connect a positive - displacement pump directly to a day tank and float switch to protect the engine fuel system from excessive fuel pressures. TP -5700 9/08 • 6.2 Gasoline Fuel Systems •The main components of a typical gasoline fuel system are a fuel storage tank, fuel lines, and a fuel pump. See Figure 6 -4. • • 3. Gasoline shut -off 4. Gasoline carburetor Figure 6-4 Gasoline Fuel System 6.2.1 Fuel Storage Tank Gasoline fuel systems are usually limited to outdoor or portable trailer- mounted generator sets because codes typically restrict or prohibit storing more than 3.8 L (1.0 gal.) of gasoline inside a building. If a fuel storage tank is located higher than the engine, install an antisiphon fuel solenoid valve or air bleed hole in the fuel tank diptube (near the top of the tube inside the tank) to prevent siphoning. Gasoline deteriorates after six months; therefore, use the smallest storage tank allowed by code. 6.2.2 Fuel Lines Never use fuel piping to ground electrical equipment. Line type. Use Schedule 40 black -iron pipe, steel tubing, or copper tubing for gasoline fuel systems. Do not use galvanized pipe and fittings. Line size. Use the smallest diameter fuel line that will not restrict the required fuel flow. Flexible connectors. Use flexible connections spanning a minimum of 152 mm (6 in.) between the stationary piping and the engine fuel inlet connection. 6.2.3 Fuel Pumps Engine fuel pumps usually lift fuel up to 1.2 m (4 ft.) or draw it horizontally up to 6 m (20 ft.). Connect auxiliary engine starting battery - powered electric pumps in series with the engine- driven pump. See Figure 6 -4. An auxiliary pump located at the fuel tank approximately doubles the horizontal and vertical distance limits of a single engine- driven pump. Limit auxiliary fuel pump pressure to approximately 35 kPa (5 psi). 6.3 Gas Fuel Systems, Common Components Gas fuel systems operate on either LP (liquefied petroleum) or natural gas. Note: Design and install gas fuel systems in accordance with NFPA 54, National Fuel Gas Code, and applicable local codes. All gas systems include a carburetor, secondary gas regulator, electric gas fuel solenoid shutoff valve, and flexible fuel connector. 6.3.1 Gas Lines Never use fuel piping to ground electrical equipment. The gas supplier is responsible for installation, repair, and alteration to gas piping. Line type. Use Schedule 40 black -iron pipe for gas piping. Copper tubing may be used if the fuel does not contain hydrogen sulfide or other ingredients that react chemically with copper. Line size. Size piping according to the requirements of the equipment. Refer to the generator set specification sheet or the dimension drawing for detailed information on your system. In addition to the actual fuel consumption, consider the following pressure loss factors: • Pipe length • Other appliances on the same fuel supply • Number of fittings Flexible connections. Rigid -mount the piping but protect it from vibration. Use flexible connections spanning a minimum of 152 mm (6 in.) between the stationary piping and the engine fuel inlet connection. TP -5700 9/08 Section 6 Fuel Systems 51 6.3.2 Gas Regulators Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines. Refer to the generator set spec sheet for fuel supply pressures. Typical gas fuel pressures are shown in Figure 6 -5. Install a solenoid valve upstream from the gas regulator and the flexible fuel connector to prevent the accumulation of an explosive mixture of gas and air caused by leaks in the flexible connection or the gas regulator. The generator set installer normally wires the engine battery- powered solenoid valve to the engine starting controls to open the valve when the engine cranks or runs. For UL compliance, the fuel solenoid valves are needed per UL 2200, Section 35.3.2.2.1. Figure 6 -5 Recommended Gas Fuel Supply Pressures The typical gas system uses two gas regulators: • Primary gas regulator. Provides initial control of gas from the fuel supply. The primary gas regulator reduces the high pressure from atank or transmission line to the low pressure required by the secondary gas regulator(s). Typically, the primary gas regulator is set at the higher pressure value when a range is given. The gas supplier typically provides the primary gas regulator, as conditions that dictate the type of gas regulator used vary depending on the method of supplying fuel. The supplier is also responsible for providing sufficient gas pressure to operate the primary gas regulator. Primary gas regulator must be vented to the outside if installed within any building. • Secondary gas regulator. This low- pressure gas regulator is mounted on the engine and limits the maximum inlet pressure to engine. The engine operates satisfactorily at the lower pressure value when a range is given, but these lower pressures may result in poor response to load changes or a lack of power if the primary gas regulator is not near the engine. Modification for fuel type. Many gas regulators are compatible with both natural gas and LP gas. Typically, the user installs the spring and retainer in the gas 52 Section 6 Fuel Systems regulator when connecting to natural gas and removes it from the gas regulator when connecting to LP vapor gas. Refer to the appropriate generator set's operation manual and /or the decal attached to the generator set for information regarding spring /adjustment screw usage for specific models. Some models may require new diaphragm kits and /or inverting the gas regulator when changing fuel type. Installation position for fuel type. The gas regulator functions normally pointing downward for both natural gas and LP gas. If only natural gas fuel is used, the gas regulator may be installed pointing upward. Pressure testing. Some gas regulators provide for installation of a pressure gauge to test inlet and outlet pressures. If no such provision is available, install pipe tees in the fuel line to test pressure and use pipe plugs to plug unused openings. 6.4 LP Fuel Systems Fuel characteristics. LP fuel exists as a vapor and a liquid in pressurized tanks. Since LP fuel does not deteriorate in storage, a large supply of fuel can be kept onsite indefinitely for operation during emergency conditions. This makes LP gas ideal for applications with uninterrupted ( onsite) fuel supply requirements. Fuel mixture. LP gas is propane, butane, or a mixture of the two gases. The ratio of butane to propane is especially important when the fuel flows from a large outdoor tank. Afuel supplier may fill the tank in the warm summer months with a mixture composed mainly of butane; however, this mixture may not provide sufficient vaporized pressure at cold temperatures to start and operate the engine. A local fuel supplier is likely to be the best source of information on what size tank is necessary to provide adequate fuel vapor. The fuel mixture and vaporization pressure at the anticipated temperatures influence the selection of gas regulator equipment. Pure butane gas has little or no vaporization pressure in temperatures below 4 °C (40 °F). Even at 21°C (70 °F), the pressure is approximately 124 kPa (18 psi). Some primary gas regulators do not operate at tank pressures below 207 kPa (30 psi) while others operate at incoming pressures as low as 20.7 -34.5 kPa (3 -5 psi). Fuel consumption and tank size. Since LP fuel is supplied in pressurized tanks in liquid form, it must be converted to a vapor state before being introduced into TP -5700 9/08 Fuel Supp y Pressure Generator Water Column, Set Model Engine kPa (oz./in.2) cm (in.) 20 kW Ford 1.7 -2.74 (4 -6) 18 -28 (7 -11) 30 -125 kW GM 1.7 -2.74 (4 -6) 18 -28 (7 -11) 135 -275 kW Detroit Diesel Series 50/60 1.2 -5 (2.9 -11.6) 13 -51 (5 -20) 400 -800 kW Waukesha 2 -34 (4.6 -80) 20 -348 (8 -137) Figure 6 -5 Recommended Gas Fuel Supply Pressures The typical gas system uses two gas regulators: • Primary gas regulator. Provides initial control of gas from the fuel supply. The primary gas regulator reduces the high pressure from atank or transmission line to the low pressure required by the secondary gas regulator(s). Typically, the primary gas regulator is set at the higher pressure value when a range is given. The gas supplier typically provides the primary gas regulator, as conditions that dictate the type of gas regulator used vary depending on the method of supplying fuel. The supplier is also responsible for providing sufficient gas pressure to operate the primary gas regulator. Primary gas regulator must be vented to the outside if installed within any building. • Secondary gas regulator. This low- pressure gas regulator is mounted on the engine and limits the maximum inlet pressure to engine. The engine operates satisfactorily at the lower pressure value when a range is given, but these lower pressures may result in poor response to load changes or a lack of power if the primary gas regulator is not near the engine. Modification for fuel type. Many gas regulators are compatible with both natural gas and LP gas. Typically, the user installs the spring and retainer in the gas 52 Section 6 Fuel Systems regulator when connecting to natural gas and removes it from the gas regulator when connecting to LP vapor gas. Refer to the appropriate generator set's operation manual and /or the decal attached to the generator set for information regarding spring /adjustment screw usage for specific models. Some models may require new diaphragm kits and /or inverting the gas regulator when changing fuel type. Installation position for fuel type. The gas regulator functions normally pointing downward for both natural gas and LP gas. If only natural gas fuel is used, the gas regulator may be installed pointing upward. Pressure testing. Some gas regulators provide for installation of a pressure gauge to test inlet and outlet pressures. If no such provision is available, install pipe tees in the fuel line to test pressure and use pipe plugs to plug unused openings. 6.4 LP Fuel Systems Fuel characteristics. LP fuel exists as a vapor and a liquid in pressurized tanks. Since LP fuel does not deteriorate in storage, a large supply of fuel can be kept onsite indefinitely for operation during emergency conditions. This makes LP gas ideal for applications with uninterrupted ( onsite) fuel supply requirements. Fuel mixture. LP gas is propane, butane, or a mixture of the two gases. The ratio of butane to propane is especially important when the fuel flows from a large outdoor tank. Afuel supplier may fill the tank in the warm summer months with a mixture composed mainly of butane; however, this mixture may not provide sufficient vaporized pressure at cold temperatures to start and operate the engine. A local fuel supplier is likely to be the best source of information on what size tank is necessary to provide adequate fuel vapor. The fuel mixture and vaporization pressure at the anticipated temperatures influence the selection of gas regulator equipment. Pure butane gas has little or no vaporization pressure in temperatures below 4 °C (40 °F). Even at 21°C (70 °F), the pressure is approximately 124 kPa (18 psi). Some primary gas regulators do not operate at tank pressures below 207 kPa (30 psi) while others operate at incoming pressures as low as 20.7 -34.5 kPa (3 -5 psi). Fuel consumption and tank size. Since LP fuel is supplied in pressurized tanks in liquid form, it must be converted to a vapor state before being introduced into TP -5700 9/08 • • • the carburetor. The amount of vapor contained in 3.8 L (1.0 gal.) of liquid (LP) fuel is: Butane Gas Propane Gas 0.88 m3 (31.26 cu. ft.) 1.03 m3 (36.39 cu. ft.) See the generator set specification sheets for fuel consumption at different loads, and contact your fuel supplier for information regarding tank sizes. System types. Single- source gas fuel systems include LP gas vapor - withdrawal and LP gas liquid - withdrawal. 6.4.1 LP Gas Vapor - Withdrawal Systems A vapor - withdrawal system draws on the fuel vapor that collects in the space above the liquid fuel. Consider the following during installation: • Generally, allow 10 % -20% of tank capacity for fuel expansion from a liquid to a vapor state. The liquid level in LP gas tanks must never exceed 90% of the tank capacity. • Maintain air temperature surrounding the tank high enough to vaporize the liquid fuel. Applications in colder climates may require an independent heat source to increase natural vaporization within the tank. Withdraw liquid fuel and vaporize it in an electrically heated, engine water jacket - heated, or LP gas- heated vaporizer. Figure 6 -6 shows the components of the vapor - withdrawal system used in a typical stationary application. The LP gas regulator is typically installed in the inverted position (pointing downward). Note: Install a gauge to test fuel pressure during setup and replace with a pipe plug when setup in complete, if required. 1. Carburetor 2. Secondary gas regulator 3. Solenoid valve (quantity of two in series may be required for UL applications) 4. Pressure gauge 5. Primary gas regulator (supplied by gas supplier or installer) Figure 6-6 Typical LP Gas Vapor - Withdrawal System TP -5700 9/08 6.4.2 LP Gas Liquid - Withdrawal Systems LP liquid - withdrawal fuel systems are available for generator sets but are not recommended for automatic standby service. With liquid - withdrawal systems, liquid LP at 1034 -1379 kPa (150 -200 psi) flows to the engine. A combination of converters (vaporizers) and gas regulators then reduces the pressure to a usable level. In Figure 6 -7, a converter (a combination of a vaporizer and primary and secondary gas regulators) changes the liquid to vapor using heat from the engine's cooling system. For a period following startup, a liquid - withdrawal system may be unable to vaporize enough fuel for an engine running under Toad until the engine reaches operating temperature. The engine needs time to warm sufficiently to provide adequate heat to vaporize the fuel. 1. Carburetor 2. Converter (vaporizer) 3. Solenoid valve (quantity of two in series may be required for UL applications) 4. LP gas filter (supplied by gas supplier or installer) Figure 6 -7 LP Gas Liquid Withdrawal System Some codes prohibit gas fuel pressurization greater than 34.5 kPa (5 psi) inside buildings. This might preclude the use of a liquid - withdrawal system. To ensure code compliance, converters are sometimes located outside the building housing the generator set. However, the great length of pipe between the converter and the carburetor does not allow sufficient heat buildup and heat retention to maintain the fuel in its vapor state, which can cause startup problems. Section 6 Fuel Systems 53 6.5 Natural Gas Systems The utility supplies natural gas in a vapor state. A natural gas fuel system consists of the same basic components and operates with the same general sequence as LP gas vapor- withdrawal systems. See Figure 6 -8 and Figure 6 -9. Note that when the heat content of the fuel falls below 1000 Btu, as it does with sewage- derived and some other natural gas fuels, the generator set will not produce its rated power. The natural gas regulator is typically installed in the upright position (pointing upward). 1 2 3 4 5 I! f= 1 _ �IIIiIIi��NIIGII lii�1- �_L�,•��11 PI.; Note: Install a gauge to test fuel pressure during setup and replace with a pipe plug when setup is complete, if required. 1. Primary gas regulator (supplied by gas supplier or installer) 2. Pressure gauge 3. Solenoid valve (quantity of two in series may be required for UL applications) 4. Secondary regulator 5. Carburetor TP- 5700 -6 Figure 6-8 Natural Gas Fuel System with Pressure Gauge 1. Primary gas regulator (supplied by gas supplier or installer) 2. Manual shutoff valve 3. Solenoid valve (quantity of two in series may be required for UL applications) 4. Secondary gas regulator 5. Carburetor Figure 6 -9 Natural Gas Fuel System without Pressure Gauge and with Manual Shutoff Valve 54 Section 6 Fuel Systems 6.6 Combination Systems Combination fuel source systems include: • Natural gas and LP gas • LP gas or natural gas and gasoline 6.6.1 Combination Natural Gas and LP Gas Some applications use natural gas as the main fuel and LP gas as the emergency fuel when natural gas is not available. The natural gas and LP gas, liquid withdrawal system uses a converter (vaporizer) to change the LP liquid to gas vapor. A pressure switch on the primary fuel source closes when fuel pressure drops, which energizes a relay that closes the primary fuel solenoid and opens the secondary or emergency fuel solenoid. A separate LP gas load adjustment valve ensures the right fuel -to -air mixture in the carburetor. The load adjustment valve is located inline between the converter (vaporizer) and the carburetor. See Figure 6 -10. Note: Install a gauge to test fuel pressure during setup and replace with a pipe plug when setup is complete, if required. 8 7 TP- 5700 -8 1. Carburetor 2. Load adjustment valve 3. Converter (vaporizer) 4. Solenoid valve (quantity of two in series may be required for UL applications) 5. LP gas filter (supplied by gas supplier or installer) 6. LP gas supply 7. Natural gas supply 8. Primary gas regulator (supplied by gas supplier or installer) 9. Secondary natural gas regulator 10. Pressure gauge Figure 6 -10 Natural Gas and LP Gas System, Liquid Withdrawal TP -5700 9/08 • • • The natural gas and LP gas, vapor withdrawal system contains a separate secondary gas regulator and solenoid valve for each fuel. The LP gas regulator typically mounts in the inverted position. A pressure switch on the primary fuel source closes when fuel pressure drops, which energizes a relay that closes the primary fuel solenoid and opens the secondary or emergency fuel solenoid. A separate LP gas load adjustment valve ensures the right fuel -to -air mixture in the carburetor. The load adjustment valve is located inline between the secondary gas regulator and the carburetor. See Figure 6 -11. 1 2 4 5 1. Carburetor 2. Load adjustment valve 3. Secondary LP gas regulator 4. Solenoid valve (quantity of two in series may be required for UL applications) 5. LP gas supply 6. Natural gas supply 7. Low pressure switch 8. Secondary natural gas regulator 6 TP- 5700 -8 Figure 6 -11 Natural Gas and LP Gas System, Vapor Withdrawal 6.6.2 Combination LP Gas or Natural Gas and Gasoline Combination LP gas or natural gas and gasoline systems normally use a gas fuel as the primary fuel and use gasoline for emergency operation. Combination natural gas and gasoline fuel systems are sometimes used with gasoline as a standby fuel to meet code requirements for an onsite fuel supply. Since gasoline deteriorates after six months of storage, do not use a combination system unless it is operated on gasoline often enough to ensure that the fuel does not deteriorate and that the carburetor is not subsequently clogged by accumulated gum deposits. TP -5700 9/08 These systems use either a combination gas - gasoline carburetor or a gasoline carburetor with a gas adapter. With the exception of the carburetor, the combination gas - gasoline systems use the same basic components as those in the natural and LP gas systems. See Figure 6 -12. 7 1. Fuel pump 2. Gasoline shutoff 3. Gasoline carburetor 4. Fuel mixer 5. Secondary gas regulator 6. Solenoid valve (quantity of two in series may be required for UL applications) 7. Gas fuel supply 8. Gasoline fuel supply 6 5 TP- 5700 -8 Figure 6 -12 Combination Gas /Gasoline Fuel System Change fuel supplies manually at the generator set. Most engines, especially the smaller models, operate successfully on gas or gasoline without extensive modification or complicated mechanical changeover. With a combination gas - gasoline fuel system, changeover involves a few simple steps as outlined in the generator set's operation manual. When installing this combination system, follow the installation considerations outlined for LP gas, natural gas, and gasoline systems. Section 6 Fuel Systems 55 6.7 Pipe Size Requirements for Gas Fuel Systems The type of fuel, the distance it must travel from gas meter /tank to fuel shutoff solenoid, and the amount consumed by the engine must be considered when determining fuel line pipe size. To find the correction necessary for the different specific gravity of the particular fuel used, refer to Figure 6 -13. Fuel Specific Gravity Correction Factor Sewage Gas 0.55 1.040 Natural Gas 0.65 0.962 Air 1.00 0.775 Propane (LP) 1.50 0.633 Butane 2.10 0.535 Figure 6 -13 Fuel Correction Factors Figure 6 -14 is based on gas pressures of 3.4 kPa (0.5 psi, 13.8 in. water column) or less and a pressure drop of 0.12 kPa (0.018 psi, 0.5 in. water column) with a 0.60 specific gravity and with a normal amount of restriction from fittings. To calculate the correct pipe size for a specific installation, refer to the chart and follow the procedure outlined below. Nominal iron Pipe Size (IPS), in. internal IPS Diameter, mm (In.) Length of Pipe, m (ft.) 3.0 (10) 6.1 (20) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70) Fuel Consumption Value, m3 /hr. (ft3/hr.) 1/4 9.25 (0.364) 1.2 (43) 0.82 (29) 0.68 (24) 0.57 (20) 0.51 (18) 0.45 (16) 0.42 (15) 3/8 12.52 (0.493) 2.7 (95) 1.8 (65) 1.5 (52) 1.3 (45) 1.1 (40) 1.0 (36) 0.93 (33) 1/2 15.80 (0.622) 5.0 (175) 3.4 (120) 2.7 (97) 2.3 (82) 2.1 (73) 1.9 (66) 1.7 (61) 3/4 20.93 (0.824) 10.2 (360) 7.1 (250) 5.7 (200) 4.8 (170) 4.3 (151) 3.9 (138) 3.5 (125) 1 26.64 (1.049) 19.3 (680) 13.2 (465) 10.6 (375) 9.1 (320) 8.1 (285) 7.4 (260) 6.8 (240) 11/4 35.05 (1.380) 39.6 (1400) 26.9 (950) 21.8 (770) 18.7 (660) 16.4 (580) 13.9 (490) 13.0 (460) 11/2 40.89 (1.610) 59.5 (2100) 41.3 (1460) 33.4 (1180) 28.0 (990) 25.5 (900) 22.9 (810) 21.2 (750) 2 52.50 (2.067) 111.9 (3950) 77.9 (2750) 62.3 (2200) 53.8 (1900) 47.6 (1680) 43.0 (1520) 39.6 (1400) 21/2 62.71 (2.469) 178.4 (6300) 123.2 (4350) 99.7 (3520) 85.0 (3000) 75.0 (2650) 68.0 (2400) 63.7 (2250) 3 77.93 (3.068) 311.5 (11000) 218.0 (7700) 177.0 (6250) 150.0 (5300) 134.6 (4750) 121.8 (4300) 110.4 (3900) 4 102.26 (4.026) 651.2 (23000) 447.4 (15800) 362.5 (12800) 308.7 (10900) 274.7 (9700) 249.1 (8800) 229.4 (8100) Nominal Iron Pipe Size (IPS), In. Internal IPS Diameter, mm (in.) Length of Pipe, m (ft.) 24.4 (80) 27.4 (90) 30.5 (100) 38.1 (125) 45.7 (150) 53.3 (175) 61.0 (200) Fuel Consumption Value, m3 /hr. (ft3/hr.) 1/4 9.25 (0.384) 0.39 (14) 0.37 (13) 0.34 (12) 0.31 (11) 0.28 (10) 0.25 (9) 0.23 (8) 3/8 12.52 (0.493) 0.88 (31) 0.82 (29) 0.76 (27) 0.68 (24) 0.62 (22) 0.57 (20) 0.54 (19) 1/2 15.80 (0.622) 1.6 (57) 1.5 (53) 1.4 (50) 1.2 (44) 1.1 (40) 1.0 (37) 0.99 (35) 3/4 20.93 (0.824) 3.3 (118) 3.1 (110) 2.9 (103) 2.6 (93) 2.4 (84) 2.2 (77) 2.0 (72) 1 26.64 (1.049) 6.2 (220) 5.8 (205) 5.5 (195) 5.0 (175) 4.5 (160) 4.1 (145) 3.8 (135) 11/4 35.05 (1.380) 13.0 (460) 12.2 (430) 11.3 (400) 10.2 (360) 9.2 (325) 8.5 (300) 7.9 (280) 11/2 40.89 (1.610) 19.5 (690) 18.4 (650) 17.6 (620) 15.6 (550) 14.2 (500) 13.0 (460) 12.2 (430) 2 52.50 (2.067) 36.8 (1300) 34.5 (1220) 32.6 (1150) 28.9 (1020) 26.9 (950) 24.1 (850) 22.7 (800) 21/2 62.71 (2.469) 58.1 (2050) 55.2 (1950) 52.4 (1850) 46.7 (1650) 42.5 (1500) 38.8 (1370) 36.2 (1280) 3 77.93 (3.068) 104.8 (3700) 97.7 (3450) 92.0 (3250) 83.5 (2950) 75.0 (2650) 69.4 (2450) 64.6 (2280) 4 102.26 (4.026) 212.4 (7500) 203.9 (7200) 189.7 (6700) 169.9 (6000) 155.7 (5500) 141.6 (5000) 130.3 (4600) _ Note: When the fuel has a specific gravity of 0.7 or less no correction factor is necessary-use this table without a correction factor. Figure 6 -14 Maximum Flow Capacity of Pipe in Cubic Meters (Cubic Feet) of Gas per Hour 56 Section 6 Fuel Systems TP -5700 9/08 • • • 1. Refer to the fuel consumption on the generator set specification sheet. Note type of fuel used, generator set application rating, and the m3 /hr. (ft3 /hr.) consumption at 100% load. Example: 80 kW, propane gas, 60 Hz standby rating = 12.0 m3/hr. (425 ft3/hr.). 2. Refer to the Fuel Correction Factors in Figure 6 -13. Locate the correction factor for specific gravity of the selected fuel. When the fuel has a specific gravity of 0.7 or less no correction factor is necessary—use Figure 6 -14 without a correction factor. Example: propane gas specific gravity = 1.50 fuel correction factor = 0.633. 3. Divide the consumption value from step 1 by the correction factor from step 2. Example: 12.0 m3/hr. (425 ft3/hr.) divided by 0.633 = 19.0 m3/hr. (671 ft3 /hr.). 4. Determine the length of pipe between the gas meter/tank and the fuel shutoff solenoid at the generator set. Example: 34.7 m (114 ft.). TP -5700 9/08 5. Find the value closest to pipe length in the Length of Pipe column in Figure 6 -14. Example: 38.1 m (125 ft.). Example: At 28.9 m3 /hr. (1020 ft3 /hr.) the pipe size = 2 in. IPS. 6. Move vertically down the table in Figure 6 -14 from the determined value in Length of Pipe column. Example: 38.1 m (125 ft.) Stop at the value that is equal to or greater than corrected consumption value from step 3. Example: 28.9m3/hr. (1020 ft.3/hr.). 7. Move to the left column from the value in step 6 to determine the correct pipe size. Section 6 Fuel Systems 57 • Section 7 Electrical System • • • Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible connections. Comply with all applicable codes when installing a wiring system. AC circuit protection. All AC circuits must include circuit breaker or fuse protection. Select a circuit breaker for up to 125% of the rated generator set output current. The circuit breaker must open all ungrounded conductors. The circuit breaker or fuse must be mounted within 7.6 m (25 ft.) of the alternator output terminals. A WARNING '‘7)1\ -614* 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 equipment connected to the set, disable the generator set as follows: (1) Turn the generator set master switch and switchgear engine control 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 the starting of the generator set by an automatic transfer switch or a remote start/stop switch. 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. TP -5700 9/08 A WARNING Hazardous voltage. Moving parts. Can cause severe Injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Short circuits. Hazardous voltage /current can cause severe Injury or death. Short circuits can cause bodily injury and /or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. 7.1 Generator Set Voltage Reconnection To change the voltage of 10- or 12 -lead generator sets, use the procedure shown in the operation manual containing the respective controller setup. Adjust the governor and voltage regulator for frequency changes. Consult the generator set service manual for frequency adjustment information. Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/ dealer. Equipment damage. Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the selected line voltage. Reconnect the generator set stator leads to change the output phase or voltage. Reference the connection schematics shown in Figure 7 -1, Figure 7 -2, Figure 7 -3, and Figure 7 -4. Follow the safety precautions at the front of this manual and in the text and observe National Electrical Code (NEC) guidelines. Section 7 Electrical System 59 wa;si(S IsoAoal3 L uoi 138S 09 90 /6 00L6-d1 100 -120V, 50HZ 100 -120V, 50HZ LO GRD L1 L2 FACTORY TWO -POLE OR (2) ONE -POLE CIRCUIT BREAKERS 3 1 4 2 STATOR LEADS 100 -120 VOLT, 3 WIRE 3 4 2 STATOR LEADS 100 -120 VOLT, 2 WIRE PB3, PB5 OR ADC2100 REGULATORS 100 - 120/200 -240V, BOHZ 100- 120/200 -240V, 50HZ 1 -1M ,-2 3 2 4 1 STATOR LEADS 100 -120/ 200 -240 VOLT, 3 WIRE PB3, PBS, ADC2I 00. PERMANENT MAGNET (PM) AND WOUND FIELD (WF) REGULATORS 220 -240V, 50HZ 220 -240V, 50HZ 11 000 r4 -3 LO (NEUTRAL) LO o GRD GROUND LI ONE -POLE PROW BREMERR 3 2 4 1 STATOR LEADS 200 -240 VOLT, 2 WIRE NON- ADC2100 REGULATORS LO r3 -WV- LO (NEUTRAL) LO 0 GROUND VDT SINE 4 1 3 STATOR LEADS 2 GRD ONE -POLE CIRCUIT BREAKER 200 -240 VOLT, 2 WIRE ADC2100 REGULATORS LO 3 2 NOTE: FOR 230 VAC, 1PH, 50 HZ CONNECT LEADS #2 AND i3 PER GM35314 DRAWING • • • 80/6 00LS-di 1.9 walsA9 IBouloal3 L uopes • 20 -300 kW Permanent Magnet and 20 -60 kW Wound Field Alternators, ADV-5875B-J • • 12 LEAD ALTERNATOR. 3 WIRE. SINGLE PHASE 12 LEAD ALTERNATOR 3 WIRE SINGLE PHASE 12 LEAD ALTERNATOR. 4 WIRE. DELTA SOME SINGLE CT3 - NOT USED O V7 �7 7 L1 1 1",,��4 CT1 I—I METER SCALE TB3 IuPIv7IWI LAMP JUMPER 60 HZ: 60 HZ: 50 HZ: 50 HZ: SETS NOT PHASE 1/9 10!06 LO 100/200V 120/240V 100/200V 110/220V RATED FOR - SEE MANUALS OPTIONAL DROOP COMP. CT 9 11 (MARINE CT3 - NOT USED © VO LO1 C 1 CT1 \ W`/ — METER SCALE 60 HZ: 240V 50 HZ: 220V ONLY) V9 g 11 60 HZ: 120/240V 50 HZ: 110/220V p L2 4 8 CT2 4 8 V8 \ VO L001 11 V7 10 2 OPTIONAL CTI 7 5 CT3 DROOP CT ,7 �� 6-NW-3-0-12 9 0� \` 6 L1 — METER SCALE V9 L3 •VS 0 2 0 CT2 2 • L2 OV8 12 2 4 6 ` CT2 2 •L1 TAPE TO INSULATE FROM GROUND TB3 d ©m LAMP JUMPER TB3 m©m LAMP JUMPER 12 LEAD ALTERNATOR. 4 WIRE. LOW WYE 12 LEAD ALTERNATOR. 4 WIRE. HI WYE 6 LEAD ALTERNATOR. 4 WIRE. WYE 60 HZ: 120/208V 60 HZ: 127/220V 60 HZ: 139/240V OPTIONAL COMP. CT L3 3 ¢ \tJ_ e LO ` �� 3 CT3 9 1 V9 50 HZ: 110/190V 50 HZ: 115/200V 50 HZ: 120/208v DROOP VO V7 �Li 7 �� 7 1 CT1 1 4 V8 60 HZ: 220/380V 60 HZ: 240/416V 60 HZ: 277/480V L1 rrr��� �1 .115 J, CT1 �, 1 4 �711C " yC 10` LD V9 OPTIONAL DROOP CT3 COMP. CT — METER SCALE 50 HZ: 220/380V 50 HZ: 230/400V 50 HZ: 240/416v L2 2P �� co CT2 VD 1 I 12 V8 9 6 3 611 • 11 6 60 HZ: 347/600V L1 L1 9 9 1 1 CT1 1/ CT1 \���/// 1 * CT WIRING FOR 20 -50 KW OPTIONAL OPTIONAL DROOP COMP. VO 4 CT2 65 LO 2 V9 2b CT3 3 CT3 * 3. 2 , =/ VS CT2 • 2ro 0'3 No METER SCALE L2 • CT2 2 8 METER SCALE O �3 L3 L3 TB3 ©m LAMP JUMPER L2 TIC LAMP JUMPER B3 EP TB3 d ©0 LAMP JUMPER L3 NOTES: PHASE ROTATION CURRENT TRANSFORMER DOT OR "H1" TOWARD GENERATOR. A B C CURRENT TRANSFORMERS NOT USED ON ALL SETS. L1 L2 L3 0) 11 ca c ID at V 5 m a 0 5 m 0 ED 3 ID rn N ED m 7 j) 0 O 0 0 O 7 O (D d ((00 0)) O N 0 C W 03 v 01 0 90/6 00L6-dl • • • 12 LEAD ALTERNATOR. 3 WIRE. SINGLE. PHASE 12 LEAD ALTERNATOR. 3 WIRE SINGLE PHASE 12 LEAD ALTERNATOR 4 WIRE DELTA L1 60 HZ: 100/200V 60 HZ: 120/240V 50 HZ: 100/200V 50 HZ: 110/220V SOME SETS NOT RATED SINGLE PHASE - SEE MANUALS CT3 - NOT USED V9 OPTIONAL 9 DROOP COMP. CT w �7 7�1 12 6 1 1 4LO CT1 i LO VO METER SCALE FOR 11 ♦� CT2 • TAPE LO `-ti 60 50 (MARINE CT3 - NOT USED © TO INSULATE FROM GROUND �0 i� (�/_ 1'4 CT1 NE METER SCALE HZ: 240V HZ: 220V ONLY) V9 12 • 6 • 1 t CT2 2 `L1 60 HZ: 120/240V 50 HZ: 110/220V V8 8 CT2 4 LO 1 0 1 V0 10 2 2 /•S' 41 5 CT1 CT3 7 4 6- VJ��3-0-12 /-9 Q� ......0 v9 Ll m METER SCALE OPTIONAL DROOP 9- -C)L3 TB3 CM 10 LAMP JUMPER COMP. CT T83 V7 Lo LAMP JUMPER TB3 d ©m LAMP JUMPER 12 LEAD ALTERNATOR. 4 WIRE. LOW WYE 12 LEAD ALTERNATOR. 4 WIRE. HI WYE 6 LEAD ALTERNATOR. 4 WIRE. WYE L3 60 HZ: 120/208V 60 HZ: 127/220V 60 HZ: 139/240V OPTIONAL COMP. CT �` LO CT3 `•• 371•, 6 2 �� 50 HZ: 110/190V 50 HZ: 115/200V 50 HZ: 120/208V DROOP V7 VO i 1 CT1 10 CT2 8 V8 L1 60 HZ: 220/380V 60 HZ: 240/416V 60 HZ: 277/480V L1 0.� V7 710 LO • OPTIONAL DROOP CT3 COMP. CT TB3 IuPfYJILDI LAMP JUMPER L 50 HZ: 220/380V 50 HZ: 230/400V 50 HZ: 240/416V 2 ...-° CT2 11 VS 12 9 ��1 3 11 6 60 HZ: 347/600V (TO PT1 -H2) L1 4 LO �CT1 L1I1 1 OPTIONAL DROOP COMP. CT L3 am PT2 PT3 • H: . a I • • vo El V8 V9 E3 (TO PT1 -H1) l0— B 5 CT3 , CT2'0 (TO PT2 -H2) L03 (TO PT3 -H2) T83 LAMPRJUMPE TH3 rr Lo LAMPRJUM ER NOTES: PHASE ROTATION CURRENT TRANSFORMER DOT OR "H1" TOWARD GENERATOR. A B C CURRENT TRANSFORMERS NOT USED ON ALL SETS. L1 L2 L3 • • • 80/6 00L9-d1. 350 -3250 kW Pilot- Excited, Permanent Magnet Alternator, ADV- 5875D -J £9 wa3sis 1e3143813 L uoiloag • • • GENERATOR CONNECTIONS 12 LEAD ALTERNATOR. 3 WIRE. SINGLE PHASE 12 LEAD ALTERNATOR. 4 WIRE. DELTA 10 OR 12 LEAD ALTERNATOR. 4 WIRE. LOW WYE 60 HZ: 100/200V 60 HZ: 120/240V 50 HZ: 100/200V 50 HZ: 110/220V SOME SETS NOT RATED FOR SINGLE PHASE - SEE MANUALS CT3 - USED 60 HZ: 120/240V E2 50 HZ: 110/220V T 4 'I' /V8 L2 OPTIONAL COMP. CT F El V7 LI 60 HZ: 120/208V 50 HZ: 110/190V E2 60 HZ: 127/220V 50 HZ: 115/200V 60 HZ: 139/240V 50 HZ: 120/208V T8 T1\ cri CT2 r " LAMP JUMPER 1 �I P T T T11 OPTIONAL 1 DROOP CT T12 L 1 T9 T3 T9 L3 O O CTI T12 T7 L1 T1 F�1T1�T4 E1 „' ���JJJ i�711 T9 T3T5 "ti T8 CT2 T2 •` 76 T8 T2 L2 I \IO VD CT2 MI 4 TB VO T T1I LO T 6- W,73-0412-AM-T. ill) L1 CTI CT3 9 L3 V7 El E3 V9 METER SCALE - METER SCALE }� TB3 LAMP JUMPER TB3 LPL ©O LAMP JUMPER E3 V9 10 OR 12 LEAD ALTERNATOR. 4 WIRE. HI WYE 4 LEAD ALTERNATOR. 4 WIRE. WYE [!d7ATOR, WIRE. WYE 4 LEAD AL1ETd1ATOR. 4 WIFE. WYE 6 LEAD ALT(MARATHON) (BAILOR) LI E1- 60 HZ: 220/380V 50 HZ: 220/380V 60 HZ: 240/416V 50 HZ: 230/400V 60 HZ: 277/480V 50 HZ: 240/4I6V T5----73— V8 �1'� L2 1 CT1 ale �1 _iy�h' n' " CT2 T10 T71 DROOP DONAL COMP. CT 60 HZ: 220/380V 50 HZ: 220/380V 60 HZ: 240/416V 50 HZ: 230/400V 60 HZ: 277/480V 50 HZ: 240/416V 60 HZ: 347/600V E2 LI OPTIONAL DROOP COMP. CT I l2 E1—ITI 4 CTt T1 T2 CT2 TO PT1 60 HZ: 2400/4160V 60 HZ: 4160/7200V 50 HZ: 1905/3300V 60 HZ: 7200/12470V 50 HZ: 3810/6600V 60 HZ: 7620/13200V 60 HZ: 7970/13800V 50 HZ: 6350/11000V OPTIONAL DROOP COMP. .O LI (TO PT1 -H2) 01 T2 L2 (TO PT2-H2) fe TI Cf1 • iy,_ T2 IK CT2 T4 T5 PT1 HI %1 W LO Tw 1::3r)9 CT3 T3 T3 LO 10 L1 CT3 T III Pf2 III V7 (TO PT1 -H1) LO T6 T3 CO LO LI CT3 12 ����!!!!!��!�� 0E110 El • PT2 O III V7 Li H2 EI 12 VB L3 H3 E2 %2 V8 %3 X4 VO T3 E3 METER SCALE TB3 LAMP JUMPER b I L3 L3 • III ,• METER SCALE T3 PT3 (TO PT3-H2) L3 b L3 •. I • ,• V9 LO HO ■ METER SCALE E3 TH3 LAMP JUMPER TB3 d ©Q LAMP JUMPER 3 SINGLE PHASE PTS 3 PHASE PT PHASE ROTATION A B C NOTES: L1 L2 L3 ON 10 LEAD GENERATORS, LEADS T10, Tit & T12 ARE ALL BROUGHT OUT TOGETHER AND LABELED i0 ". CURRENT TRANSFORMER DOT OR "H1" TOWARD GENERATOR. CURRENT TRANSFORMERS NOT USED ON ALL SETS. 7.2 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Because of the large number of accessories and possible combinations, this manual does not address specific applications. Refer to the submittal catalog accessory drawings and wiring diagrams for connection and location. Most field - installed accessory kits include installation instructions. For customer - supplied wiring, select the wire temperature rating in Figure 7 -5 based upon the following criteria: • Select row 1, 2, 3, or 4 if the circuit rating is 110 amperes or Tess or requires #1 AWG (42.4 mm2) or smaller conductors. • Select row 3 or 4 if the circuit rating is greater than 110 amperes or requires #1 AWG (42.4 mm2) or larger conductors. Comply with applicable national and local codes when installing a wiring system. Row Temp. Rating Copper (Cu) Only Cu /Aluminum (Al) Combinations Al Only 1 60 °C (140 °F) Use No. * AWG, 60 °C wire or Use 60 °C wire, either No. * AWG Cu, or No. * Use 60 °C wire, No. * AWG or or use No. * AWG, 75 °C wire AWG Al or use 75 °C wire, either No. * AWG use 75 °C wire, No. *AWG 75 °C (167 °F) Cu or No. * AWG Al 2 60 °C (140 °F) Use No. * AWG, 60 °C wire Use 60 °C wire, either No, * AWG Cu or No. * Use 60 °C wire, No. * AWG AWG Al 3 75 °C (167 °F) Use No. *t AWG, 75 °C wire Use 75 °C wire, either No. *t AWG Cu or No. Use 75 °C wire, No.*t AWG *t AWG Al 4 90 °C (194 °F) Use No. *t AWG, 90 °C wire Use 90 °C wire, either No. *t AWG Cu or No. Use 90 °C wire, No.*t AWG *t AWG Al * The wire size for 60 °C (140 °F) wire is not required to be included In the marking. If included, the wire size is based on ampacities tor the wire given in Table 310 -16 of the National Electrical Codee, in ANSI /NFPA 70, and on 115% of the maximum current that the circuit carries under rated conditions. The National Electrical Code is a registered trademark of the National Fire Protection Association, Inc. t Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the guidelines in the preceding footnote. Figure 7 -5 Terminal Markings for Various Temperature Ratings and Conductors 7.3 Load Lead Connections Feed load leads to the generator junction box from one of several different areas. Generator sets rated 300 kW and below commonly use the bottom entry where conduit is stubbed up into the junction box from the concrete slab. Other methods include flexible conduit roughed into the sides or top of the junction box. When using flexible conduit, do not block the front or rear of the controller. See Figure 7 -6. Use a minimum of 13 mm (0.5 in.) spacing between the conduit bushing and any uninsulated live parts in the junction box. All conduit openings in the junction box must be made such that no metal particles including drill chips contaminate the components in the junction box. Generator sets larger than 300 kW have the junction box mounted on the rear of the generator set. Larger sets may have oversized junction boxes supplied as an option or to accommodate bus bar connections. Refer to the generator set dimension drawing and /or the electrical contractor prints for detailed information including stub -up area recommendations. 64 Section 7 Electrical System 1. Conduit from ceiling 2. Conduit stubbed up from below Figure 7-6 Typical Load Lead Connection The four bus bars contained in the optional bus bar kits simplify the connection process by offering a neutral bus bar in addition to the three load bars. Optional bus lugs offer an array of terminal and wire connections. TP -5700 9/08 • • • 7.4 Grounding and Grounded Conductor (Neutral) Connections Connect the electrical system grounding conductor to the equipment grounding connector on the alternator. See Figure 7 -7. Depending upon code requirements, the grounded conductor (neutral) connection is typically grounded. Figure 7 -7 Generator Set Equipment Grounding Connection Ungrounded neutral connections use an insulated standoff (not supplied) to isolate the neutral connection from the grounding connection. For grounding lug selection, see Figure 7 -8. The four bus bars contained in the optional bus bar kits simplify the connection process by offering a neutral bus bar in addition to the three Toad bars. Optional bus lugs offer an array of terminal and wire connections. Generator sets are typically shipped from the factory with the neutral attached to the alternator in the junction box for safety reasons per NFPA 70. At installation, the neutral can remain grounded at the alternator or be lifted from the grounding stud and isolated if the installation requires an ungrounded neutral connection at the generator set. The generator set will operate properly in either configuration. Various regulations and site configurations including the National Electrical Code® (NEC), local codes, and the type of transfer switch used in the application determine the grounding of the neutral at the generator set. Allowable Ampaclty, Amps Min. Size of Equipment Copper Grounding Conductor, AWG or kcmil Recommended Compression Lug, ILISCO Part No. or Equivalent (UL Listed) 20 12 SLUH -90 60 10 SLUH -90 90 8 SLUH- 90/125 100 8 SLUH- 90/125 150 6 SLUH- 90/125/225 200 6 SLUH- 90/125/225 300 4 SLUH - 90/125/225 400 3 SLUH- 90/125/225 500 1 SLUH- 125/225 600 1 SLUH- 125/225 800 1/0 SLUH - 225/300/400 1000 2/0 SLUH- 225/300/400 1200 3/0 SLUR- 225/300/400 1600 4/0 SLUH- 225/300/400/650 2000 250 SLUH - 225/300/400/650 2500 350 SLUH- 300/400/650 3000 400 SLUH- 400/650 4000 500 SLUH- 400/650 5000 700 SLUH -650 6000 800 SLUH -650 Figure 7-8 Grounding Lug Selection The National Electrical Code® is a registered trademark of the National Fire Protection Association, Inc. TP -5700 9/08 Section 7 Electrical System 65 7.5 Terminal Connector Torque Use torque values shown in Figure 7 -9 or Figure 7 -10 for terminal connectors. Refer to UL 486A-486B and UL 486E for information on terminal connectors for aluminum and /or copper conductors. See Section 7.2, Electrical Connections, for information on temperature rating of the customer- supplied wire. Comply with applicable national and local codes when installing a wiring system. If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the connector using both applicable torque values provided in Figure 7 -10. Socket Size Across Flats, mm (In.) Tightening Torque, Nm (In. Ib.) Slot Head 4.7 mm (No. 10) or Larger* 3.2 (1/8) 5.1 (45) Slot Width <1.2 mm (0.047 in.) Slot Length <6.4 mm (0.25 In.) 4.0 (5/32) 11.4 (100) Other Connections 4.8 (3/16) 13.8 (120) 4.0 (35) 5.6 (7/32) 17.0 (150) 8 (8.4) 6.4 (1/4) 22.6 (200) 9.0 (80) 7.9 (5/16) 31.1 (275) 4.0 (35) 9.5 (3/8) 42.4 (375) 12.4 (110) 12.7 (1/2) 56.5 (500) 5.6 (50) 14.3 (9/16) 67.8 (600) Note: For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size. Slot width is the nominal design value, Slot length is to be measured at the bottom of the slot. Figure 7 -9 Tightening Torque for Pressure Wire Connectors with Internal -Drive Socket -Head Screws Wire Size for Unit Connection Tightening Torque, Nm (in. Ib.) Slot Head 4.7 mm (No. 10) or Larger* Hexagonal Head - External Drive Socket Wrench AWG, kcmll (mm2) Slot Width <1.2 mm (0.047 in.) Slot Length <6.4 mm (0.25 In.) Slot Width >1.2 mm (0.047 In.) Slot Length >6.4 mm (0.25 In.) Split -Bolt Connectors Other Connections 18 -10 (0.82 -5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75) 8 (8.4) 2.8 (25) 4.5 (40) 9.0 (80) 8.5 (75) 6 -4 (13.3 -21.2) 4.0 (35) 5.1 (45) 18.6 (165) 12.4 (110) 3 (26.7) 4.0 (35) 5.6 (50) 31.1 (275) 16.9 (150) 2 (33.6) 4.5 (40) 5.6 (50) 31.1 (275) 16.9 (150) 1 (42.4) - 5.6 (50) 31.1 (275) 16.9 (150) 1/0 -2/0 (53.5 -67.4) - 5.6 (50) 43.5 (385) 20.3 (180) 3/0 -4/0 (85.0 - 107.2) - 5.6 (50) 56.5 (500) 28.2 (250) 250 -350 (127 -177) - 5.6 (50) 73.4 (650) 36.7 (325) 400 (203) - 5.6 (50) 93.2 (825) 36.7 (325) 500 (253) - 5.6 (50) 93.2 (825) 42.4 (375) 600 -750 (304 -380) - 5.6 (50) 113.0 (1000) 42.4 (375) 800 -1000 (406 -508) - 5.6 (50) 124.3 (1100) 56.5 (500) 1250 -2000 (635 -1016) - - 124.3 (1100) 67.8 (600) * For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size. Slot width is the nominal design value. Slot length is to be measured at the bottom of the slot. Note: If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the connector using both applicable torque values. Figure 7 -10 Tightening Torque for Screw -Type Pressure Wire Connectors 66 Section 7 Electrical System TP -5700 9/08 ▪ 7.6 Batteries • • • Battery location. When determining the battery placement, ensure that the location: • Is clean, dry, and not exposed to extreme temperatures • Provides easy access to battery caps for checking the electrolyte level (when using maintenance type batteries) • Is close to the generator set to keep cables short, ensuring maximum output Refer to the submittal drawings for the generator set when choosing a battery rack. Figure 7 -11 shows a typical battery system. 1. Battery cables 2. Battery secured in mounting rack 3. End view 4. Generator set skid TP- 5700 -7 Figure 7 -11 Typical Battery System, Side View Battery type. Starting batteries are usually the lead - acid type and are sized according to the engine manufacturer's recommendation for a particular ambient temperature and required cranking time. NFPA 110 recommends cranking periods, including a single 45- second cycle for generator sets below 15 kW and three 15- second crank cycles separated by 15- second rests for larger models. Refer to the respective generator set specification sheet for the required battery cold- cranking ampere (CCA) rating. Nickel- cadmium batteries are sometimes used for standby generator sets because of their long life (20 years). However, initial high cost, larger space requirements, and special charging requirements can offset this benefit. Therefore, conventional lead -acid batteries have proven satisfactory for the majority of generator set applications. Battery cables. A UL 2200 listed generator set requires battery cables with positive ( +) lead boots. Factory - supplied and optional battery cables include positive ( +) lead boots. When battery cables are not factory - supplied, source battery cables with positive ( +) lead boots for UL 2200 compliance. TP -5700 9/08 Note: Some units are equipped with a reflective heat shield insulative sleeve on the battery cables and other wires that are fastened to the starter solenoid. This sleeve is a conductive material and must be secured approximately 25 mm (1 in.) away from the exposed cable terminal. 7.7 Battery Chargers Engine- driven, battery- charging alternators charge the batteries whenever the generator set operates. Engine- driven systems are normally capable of charge rates of 30 amps or more and can quickly restore the charge used in a normal cranking cycle. When the engine is not operating, a very low charge rate from an AC- powered battery charger is usually sufficient to maintain a full charge on the batteries. Some small industrial generator sets have no battery- charging alternators and, therefore, require a separate AC- powered battery charger. Select an automatic or manual battery charger with a high charge rate of 2 amps and a trickle charge rate up to 300 milliamps. The low maximum charge rate makes the charger ill- suited to restore fully discharged batteries. For full recovery capability independent of the engine - driven charging system, use an automatic float battery charger with a high charge rate of at least 10 amps. Use separate, self- contained battery chargers or units built into the automatic transfer switch. Run leads from a transfer switch- mounted battery charger in conduit separate from the conduit that holds the generator load cables or remote engine -start circuits. Note: Digital controllers with microprocessor circuitry and vacuum fluorescent displays typically draw more than 300 milliamps, making trickle charge battery chargers inappropriate for systems with these controllers. Select only automatic float/ equalize battery chargers with a 3 amp or greater rating for units with digital controllers. Battery failure is the most common reason for emergency generator set start failure. Two common battery failure causes are a manual charge rate set too low to maintain the battery and a manual charge rate set too high, resulting in loss of battery electrolyte. To avoid battery failure, use an automatic float charger, which varies the charge rate in response to battery condition. For large engines with two starters, use either one bank of batteries and chargers for both starters or use separate battery systems. The latter system is preferable because it reduces the chance of a single component failure rendering the entire system inoperative. Section 7 Electrical System 67 7.8 - Optional Accessories The generator set manufacturer offers optional accessories that require connection to other components in the system. These accessories enable the generator set to meet standards for local and national codes, make operation and service more convenient, or satisfy specific customer installation requirements. Accessories vary with each generator set model and controller. Accessories are available factory - installed and /or shipped loose. Some accessories are available only with the microprocessor and digital controllers. Obtain the most current list of accessories from the respective generator set specification sheet or by contacting your local authorized service distributor/ dealer. The following sections detail a few common accessories and their functions. Accessory kits generally include installation instructions. See the wiring diagrams manual for electrical connections not shown in this section. See the installation instructions and drawings supplied with the kit for information on the kit mounting location. The instructions provided with the accessory kit supersede these instructions, if different. In general, run AC and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national and local electrical codes during accessory installation. Accessory wiring. To determine the appropriate size for the customer - supplied wiring of the engine battery- powered accessories, use the guidelines in Figure 7 -12. Use 18 -20 gauge wire for signal wires up to 305 m (1000 ft.). Length, m (ft.) Wire Gauge 30.5 (100) 18 -20 152.4 (500) 14 304.8 (1000) 10 Figure 7 -12 Wire Length and Size, Lead N and 42B Match the wire terminals to the terminal strip conductor screw size. Use a maximum of two wire terminals per terminal strip screw unless otherwise noted on the respective accessory drawing or installation instruction. Accessory connections. Do not direct - connect accessories to the controller terminal strip. Connect accessories to either a single -relay dry contact kit or ten -relay dry contact kit. Connect the dry contact kit(s) to the controller (customer) connection kit. Connect all accessories except the emergency stop kit to the connection kit terminal strip(s). 68 Section 7 Electrical System Terminal strips and available connections vary by controller. Refer to the respective controller operation manual and the accessory wiring diagrams in the wiring diagram manual for connection of kits. Field- installed accessories include installation instructions and /or wiring diagrams. 7.8.1 Audiovisual Alarm An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions (except battery charger fault and low battery voltage) at the generator set. Audiovisual alarms include an alarm horn, an alarm silence switch, and a common fault lamp. See Figure 7 -13. Figure 7 -13 Audiovisual Alarm 7.8.2 Bus Bar Kits /Bus Lugs The four bus bars contained in the optional bus bar kits simplify the connection process by offering a neutral bus bar in addition to the three load bars. Optional bus lugs offer an array of terminal and wire connections. See Figure 7 -14. Figure 7 -14 Bus Bar Kits /Bus Lugs TP -5700 9/08 • • 7.8.3 Common Failure Relay Kit The common failure relay kit provides one set of contacts to trigger customer - provided warning devices if a fault occurs. The user defines common failure relay faults. Connect up to three defined common fault relay kits to the controller output. See Figure 7 -15. Figure 7 -15 Common Failure Relay Kit 7.8.4 Controller (Customer) Connection Kit The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip. The kit uses a wiring harness to link the controller terminal strip(s) with a remote terminal strip. With the exception of a few terminals, the remote terminal strip has connections similar to the controller. Connect all accessories except the emergency stop kit to the connection kit terminal strip(s). 7.8.5 Float/Equalize Battery Charger Kit with Alarm Option The float/equalize battery charger with alarm option charges the engine start battery(ies) and connects to the controller for fault detection. Your distributor /dealer offers battery chargers for 12- or 24 -volt models. See Figure 7 -16. BATTERY CHARGER ALARM TERMINAL STRIP TT -880 Figure 7 -16 Float/Equalize Battery Charger Connections TP -5700 9/08 7.8.6 Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. See Figure 7 -17 for electrical connections. Use the instructions with the kit when provided to install and set up this accessory. POWER SUPPLY DC 12 - TB3-9 or 24 V + TB3-4 GFA 300 GENERATOR N TB4 -8 (DCHB) TB4.27 (GND) GFI WIRED TO DEC550 /See assembly drawing and pick list for neutral to ground cable. Genoretor system ground \ connect to ground bus. GM53028- Figure 7 -17 Ground Fault Connections 7.8.7 Line Circuit Breaker The line circuit breaker interrupts generator output if an overload or short circuit occurs. Use the line circuit breaker to manually disconnect the generator set from the Toad during generator set service. See Figure 7 -18. The circuit breaker must open all ungrounded connectors. Refer to Service Bulletin 611 for circuit breaker instantaneous overcurrent trip adjustment information. TP- 5352 -1 Figure 7 -18 Line Circuit Breaker 7.8.8 Low Fuel (Level or Pressure) Switch Some gaseous - fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel- or gasoline - fueled models. See Figure 7 -19. Section 7 Electrical System 69 Note: The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel level switch. LOW FUEL SWITCH (OPTIONAL) LOCATED IN MAIN TANK AS PROVIDED BY FUEL TANK SUPPLIER 63 H 1 BATTERY GROUND TP- 5700 -7 Figure 7 -19 Low Fuel Switch (Level or Pressure) 7.8.9 Remote Annunciator Kit A remote annunciator allows convenient monitoring of the generator set's condition from a remote location. See Figure 7 -20. ▪ ) 7FIPERAIUQ LJ $I R FALT O Am O ▪ O �YLO.TA�aE'ro" OFO� MR'" O TOPFRATdRF O SSTTOP Y O FAILT R' O I�AUY Ol.OwFIR1 pow OereRrwAn OAlIfO \%.,... / wrO,FST . I 01E 7E. MEN Figure 7 -20 Remote Annunciator with 14 -Relay Dry Contact Kit 70 Section 7 Electrical System The remote annunciator includes an alarm horn, an alarm silence switch, a Tamp test, and the same lamp indicators (except air damper and auxiliary prealarm/ high battery voltage) as the microprocessor controller, plus the following: • Line power. Lamp illuminates to indicate that the power source is a commercial utility. • Generator set power. Lamp illuminates to indicate that the power source is the generator set. 7.8.10 Remote Serial Annunciator (RSA) The remote serial annunciator (RSA 1000) (Figure 7 -21) monitors the condition of the generator set from a location remote from the generator set using RS 485 connection. If a generator alarm condition occurs, the remote annunciator alerts the operator through visual and audible signals. CMI 'ititNoo1S•. • !tar }DO Naasiae toRCarrmis-le rel lComsioi But?n — �rU- ;er�- *Cienrg,�ers'Fu ul FZZ3 iS NA £PS- -5443 bl Load. Generator l�: — FommrinWlbnSgtw+ (iimii Of Ru!ln g PAhrinSI ed MEM KOHLER. POWER 5151-EMS Figure 7 -21 Remote Serial Annunciator (RSA 1000) The remote serial annunciator kit includes components for flush and surface mounting. One RSA (master) can support up to a maximum of three additional RSAs (slaves). The RSA will function as master or slave by changing the DIP switch position on the RSA board. If a generator set fault occurs, the RSA 1000 horn activates and the corresponding LED illuminates. TP -5700 9/08 SIDealICRIOL ■ ▪ ) 7FIPERAIUQ LJ $I R FALT O Am O ▪ O �YLO.TA�aE'ro" OFO� MR'" O TOPFRATdRF O SSTTOP Y O FAILT R' O I�AUY Ol.OwFIR1 pow OereRrwAn OAlIfO \%.,... / wrO,FST . I 01E 7E. MEN Figure 7 -20 Remote Annunciator with 14 -Relay Dry Contact Kit 70 Section 7 Electrical System The remote annunciator includes an alarm horn, an alarm silence switch, a Tamp test, and the same lamp indicators (except air damper and auxiliary prealarm/ high battery voltage) as the microprocessor controller, plus the following: • Line power. Lamp illuminates to indicate that the power source is a commercial utility. • Generator set power. Lamp illuminates to indicate that the power source is the generator set. 7.8.10 Remote Serial Annunciator (RSA) The remote serial annunciator (RSA 1000) (Figure 7 -21) monitors the condition of the generator set from a location remote from the generator set using RS 485 connection. If a generator alarm condition occurs, the remote annunciator alerts the operator through visual and audible signals. CMI 'ititNoo1S•. • !tar }DO Naasiae toRCarrmis-le rel lComsioi But?n — �rU- ;er�- *Cienrg,�ers'Fu ul FZZ3 iS NA £PS- -5443 bl Load. Generator l�: — FommrinWlbnSgtw+ (iimii Of Ru!ln g PAhrinSI ed MEM KOHLER. POWER 5151-EMS Figure 7 -21 Remote Serial Annunciator (RSA 1000) The remote serial annunciator kit includes components for flush and surface mounting. One RSA (master) can support up to a maximum of three additional RSAs (slaves). The RSA will function as master or slave by changing the DIP switch position on the RSA board. If a generator set fault occurs, the RSA 1000 horn activates and the corresponding LED illuminates. TP -5700 9/08 Figure 7 -22 shows the status of the system ready LED, generator running LED, communication status LED, common fault LED, common fault output, and horn for each fault or status condition. See Figure 7 -23, Figure 7 -24, and Figure 7 -25 for RSA wiring connections. The RSA requires connection to the controller Modbus® RS -485 port. If the RS -485 port is needed for switchgear monitoring or a wireless monitor, the RSA cannot be connected to the controller. If the RS -485 port is unavailable, please select an alternate annunciator kit. Modbus® is a registered trademark of Schneider Electric. Fault and Status Condition Fault LEDs System Monitoring LEDs and Functions System Ready LED Generator Running LED Comm. Status LED Common Fault LED Common Fault Output Horn Overcrank Shutdown Red Red SF Off Green Off On On High Engine Temperature Warning Yellow Red SF Green Green Off On On High Engine Temperature Shutdown Red Red SF Off Green Off On On Low Oil Pressure Warning Yellow Red SF Green Green Off On On Low Oil Pressure Shutdown Red Red SF Off Green Off On On Overspeed Shutdown Red Red SF Off Green Off On On Emergency Stop Red Red SF Off Green Off On On Low Coolant Level Red Red SF Off Green Off On On Low Coolant Temperature Yellow Red SF Off Green Off On On Low Fuel —Level or Pressure * Yellow Red SF Green Green Off On On EPS Supplying Load (550 Controller) Yellow Green Green Green Off Off Off EPS Supplying Load (RSA) Yellow Green Green or Off Green Off Off Off System Ready Green Green Green or Off Green Off Off Off System Not Ready Red Red SF Green or Off Green Off On On No Device at Powerup Red Off Off Red SF Off On On Loss of Controller Comm. (Master RSA) Red Off Off Red FF Off On On Loss of Controller Comm. (Slave RSA) Red Off Off Red SF Off On On Not -In -Auto Red Red SF Green or Off Green Off On On Battery Charger Fault * Yellow Red SF Green or Off Green Off On On High Battery Voltage Yellow Green Green or Off Green Off Off Off Low Battery Voltage Yellow Green Green or Off Green Off Off Off User Input #1 (RSA) Red Green Green or Off Green Off On On User Input #2 (RSA) Red Green Green or Off Green Off On On User Input #1 (550 Controller) Red Red SF Green or Off Green Off On On User Input #2 (550 Controller) Red Red SF Green or Off Green Off On On User Input #3 (550 Controller) Red Red SF Green or Off Green Off On On Common Fault Red Green Green or Off Green Red SF On On SF = Slow Flash, FF = Fast Flash * May require optional kit or user - provided device to enable function and LED indication. Figure 7 -22 System Monitoring LEDs and Functions TP -5700 9/08 Section 7 Electrical System 71 a o b m a _ - m �. .g g 11 yy h ic7� d 3 h.F N. O g z3 a 99; i 1 kr i E E k _ ".. -- 3 U / i 8 bps ; Q N O $ `2 aJ ] gP w. g s i i i:4,1.4 !, 1!9 "= 3..4 % 8 0,i 0 I i l Iz S E. c n ;.@ 82i 1 mo q 3¢333¢, pN 3 2 ., n " 4 R � O ?LLrt U N w nrnw 2 NQgniidh NIOAMflil aRRdRR�RR° " e�������- I ll ®M�M d I 1 1 1 o_ Z m 72 PI y,G= 41 d� \ aN5 ,< IIUH i-4., b H_ a 'r a z' m W aE igsz gESS 5z 2' _ cc 2 ki ¢� to A -gin- 7 \ / f: \ 1 NM /as g" `1113 F ° H113 9gxj9[yj. €;i 9ti7 E. ; oil S — -e e 0 1 0 4 m 1 a Figure 7 -23 RSA Wiring Connections 72 Section 7 Electrical System TP- 5700 9/08 80/6 00L8-dl EL uia;sAg 1173143013 L uoilas Figure 7 -24 RSA Interconnection Diagram ADV- 6990A -C • • • 4 1 3 b 2 I 1 D C -0 B A DC POWER REQUIREMENTS FOR EACH RSA1000: IF MULTIPLE RSA100'S ARE USED, RESIZE POWER WIRES AS REQUIRED. API DATE APARON B , 0 10-11 -04 ALL DEC 550 REFERENCES CHANGED TO 600, ALL DEC 3. REFERENCES CHANGED TO 18 -UONT (735401 DFS C 1607-05 0041 SEE NOTE 4 ADDED 10-6) SEE NOTE 6 WAS BELDEN 0841; (A-0) EPS SUPPLYING LOAD NOTE UPDATED. NOTE 5 ADDED; (A- 1)(3WU45 WAS G6OM14. SHEET 1 -2 WAS 1- 11(0 -4) 1114 SLAVES ADDED. (D-4) DC POWER NOTED UPDATED MGR TLN 12 -/24 VOLT, 200mA DC POWER 0 -450 FT. [0 -138 m], 2 WIRES, 22 GA 450 -700 FT. [138 -214 m], 20 GA. 700 -1125 FT. [214 -344 m], 18 GA. 1125 -1800 FT. [344 -550 m], 16 GA. 1800 -2800 Ff, [550 -856 m], 14 GA. (SEE NOTE 4) RS 485 BATTERY POSITIVE D _ C a— B _ A DC VOLTAGE FROM GENERATOR BATTERY ,n �--� © CONNECTION BATTERY NEGATIVE II I CONNECTION ON 16 LIGHT CONTROLLER, CONNECT TO P21, ON 550 CONTROLLER, CONNECT TO P20 2 WIRES 10 GA. MINIMUM f I CONTROL PANEL - 16- LIGHT: 4 WIRES 18 -20 GA 550: 2 WIRES 18 -20 GA BATTERY CHARGER ALARMS BATTERY CHARGER (10A) W /FAULT ALARMS _ RSA1000 REMOTE SERIAL ANNUNCIATOR (MASTER) (MODBUS RTU) (SEE NOTE 5) _ r BLOCK HEATER L I- -1 16—LIGHT COMM MODULE (GM32644 —KA1 OR —KP1) _� 2 WIRES 18-20 GA ENGINE START WIRES GENERATOR SET OUTUNE r _ RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) I _ I —I I 3 WIRES (INCLUDING GROUND) SIZED AS REQUIRED 16 -LIGHT ONLY (REQUIRES RED MAIN LOGIC BOARD GM28725) L _ I RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) I _ J I I L_ 2 WIRES AUTOMATIC TRANSFER SWITCH TO POSITION CONTACTS IN OPTIONAL REMOTE E -STOP TO CUSTOMER'S 15 -AMP OVERCURRENT AS REQUIRED PROTECTIVE/DISCONNECT DEVICE. BATTERY CHARGER VOLTAGE IS 120VAC TO CUSTOMER'S OVERCURRENT PROTECTIVE/DISCONNECT DEVI CE. STANDARD. CAN BE REWIRED FOR VOLTAGE AND CURRENT RATING TO 240VAC (SEE DRAWING ADV -5971 BE DETERMINED FROM BLOCK OR TT -680 INSTRUCTION). HEATER NAMEPLATE. SOURCE TO SOURCE TO BE INDEPENDENT OF BE INDEPENDENT OF GENERATOR. GENERATOR. L_ RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) I J _ L - (CLOSED EMERGENCY) (SEE SHEET 2 WHEN USED WITH AN ETHERNET NETWORK) 16 -UGHT ONLY: ' EPS SUPPLYING LOAD INDICATION VIA TWO 14 -20 GA. WIRES. CONNECT TO EITHER 16 -UGHT COMM. MODULE BOARD OR RSA 1000. REFER TO WIRING DIAGRAM GM41145 FOR USE CONNECTION TO 16 -UGHT COMM. MODULE BOARD CONNECTION DETAIL. NOTES: WHEN RSA1000 IS CONNECTED VIA NETWORK. DIMENSIONS IN [ ] ARE METRIC EQUIVALENTS. 1. TYPICAL CUSTOMER WIRING SHOWN DASHED. ONLY: 550 2. CUSTOMER RESPONSIBLE FOR ADDITIONAL WIRING SHOWN IF COMPONENTS THIS CONNECTION IS NOT USED. ARE SHIPPED LOOSE (BATTERY CHARGER, DRY - CONTACT BOX. ETC.) EPS SUPPLYING LOAD INDICATION VIA RS -485. 3. IF BATTERY CHARGER IS SHIPPED LOOSE ADDITIONAL WIRES MAY BE REQUIRED FOR PROPER VOLTAGE SENSING. REFERENCE DRAWING ADV -5971 FOR INTERCONNECT. 4. DC VOLTAGE FOR EACH RSA1000 REMOTE ANNUNCIATOR MAY ALSO BE SUPPUED _ 2 .. 'm ° Pm L w' ° 5 ^ An PARPNwspt , '""°° O4,1wvALS DATE n� DIAGRAM, RSA INTERCONNECTION INTERCONNECTION DIAGRAM °"'^' JS 7-26.04 BY A LOCALLY MOUNTED 12 OR 24 VDC, 200 mA MIN., AC ADAPTER. CONTROLLER ^° JL 23 04 X114 AO�BOADNR' �� 1� 5. USE BELDEN 89841 OR EQUIVALENT. MAXIMUM DISTANCE = 4000 FT. [1219 mJ WITH RSA ANNUNCIATOR ' "'°"'' JS ' ' 7 -lid .A ADV -6990 C G 4 1 3 ? 2 1 1 walsAs Roupaig L uopes 90/6 00LS-dl Figure 7 -25 RSA Interconnection Diagram ADV-6990B-C 4 ( 3 b 2 I 1 D C -n B — A C 10-07 -05 SHEET 2 •DDEO 17532.11 T110 ON 16- UGHTCONTROLLER CONNECT TO P21, ON 550 CONTROLLER CONNECT TO P20 0 — C (I- B — A RS CONTROL PANEL (SEE SHEET 1 FOR BATTERY CHARGER 8 REMOTE E -STOP CONNECTIONS) MODBUS/ ETHERNET CONVERTE- -485 (MODBUS RTU) (SEE NOTE 5) _ L _ A MAXIMUM OF 3 SLAVES ETHERNET CAN BE CONNECTED TO (MODBUS TCP/IP) A MASTER RSAI000, INCLUDING SLAVES CONNECTED THROUGH CATEGORY 5 THE ETHERNET NETWORK I OR EQUIVALENT I 16 -LIGHT COMM. MODULE (GM32644 -KA1 OR -KP1) SEE SHEET 1 FOR / AUTOMATIC TRANSFER -1 SWITCH CONNECTION. RSA1000 REMOTE SERIAL ANNUNCIATOR (MASTER) RS-485 (MODBUS RTU) (SEE NOTE 5) I - -- MODBUS/ ETHERNET CONVERTER (MODBUS CAGOC 5P) OR EQUIVALENT ETHERNET NETWORK (CUSTOMER SUPPLIED) T ONLY (REQUIRES RED MAIN LOGIC BOARD GM28725) I ETHERNET GENERATOR SET OUTLINE I _ _ (MODBUS TCP/IP) CATEGORY 5 I OR EQUIVALENT RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) I RS -485 RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) AN RSA1000 SLAVE CONNECTED THROUGH THE ETHERNET NETWORK, REQUIRES AN RSA1000 MASTER BE CONNECTED THROUGH THE ETHERNET NETWORK. SEE SHEET 1 FOR REQUIRED DC POWER VOLTAGE TO EACH RSA1000. I MODBUS/ ETHERNET CONVERTER (MODBUS RTU) — (SEE NOTE 5) _ I RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) _ 1 RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) _ J RSA1000 REMOTE SERIAL ANNUNCIATOR (SLAVE) L - SEE SHEET 1 FOR REQUIRED DC POWER VOLTAGE TO EACH RSA1000. SEE SHEET 1 FOR GENERAL NOTES. ...au 3 In a t wx 51122.0045 0012 DIAGRAM, RSA INTERCONNECTION INTERCONNECTION DIAGRAM °w- 11. 10..07-05 CONTROLLER c"''' ruc 10-1.-0s '1f �n A4wexowc. I� 2-2 WITH RSA ANNUNCIATOR '^°*" Em 10-10at '''p ADV -6990 C D 4 1 3 i 2 1 1 • • • • • 7.8.11 Remote Emergency Stop Kit Figure 7 -26 shows the remote emergency stop switch. Activating the emergency stop switch in the remote emergency stop kit lights the controller lamp and shuts down the unit. Before restarting the generator set, reset the emergency stop switch by replacing the glass piece and reset the generator set by placing the master switch in the OFF /RESET position. The switch holds a single replacement glass piece. Order additional replacement glass as a service part. Figure 7 -26 Emergency Stop Kit 7.8.12 Run Relay Kit The run relay kit energizes only during generator set operation. The three sets of contacts typically control air intake and /or radiator louvers. However, alarms and other signaling devices can also connect to the contacts. See Figure 7 -27. 4 7 0 2 5 6 0 3 6 0 9 0 273705 Figure 7 -27 Run Relay Kit TP -5700 9/08 7.8.13 Safeguard Breaker The safeguard breaker senses output current on each generator phase and shuts off the AC voltage regulator if a sustained overload or short circuit occurs. It is not a line circuit breaker and does not disconnect the generator from the load. See Figure 7 -28. Figure 7 -28 Safeguard Breaker 7.8.14 Single -Relay Dry Contact Kit The single -relay dry contact kit has a common fault relay that uses one set of contacts to trigger customer - provided warning devices if a fault condition occurs. Any controller fault output can connect to the single -relay kit. The kit typically signals the following common fault conditions: • Emergency stop • High coolant temperature • Low oil pressure • Overcrank • Overspeed • Low oil pressure • High engine temperature A total of three dry contact kits may connect to a single controller output. Figure 7 -29 shows the single -relay dry contact kit. Figure 7 -29 Single -Relay Dry Contact Kit Section 7 Electrical System 75 7.8.15 Ten -Relay Dry Contact Kit The ten -relay dry contact kit allows monitoring of the generator set and /or activating accessories. The kit includes ten sets of relay contacts for connecting customer - provided devices to desired generator set functions. Atotal of three dry contact kits may connect to a single output on the controller. Refer to Figure 7 -30 for an internal view of the contact kit. O 0 A- 273938 Figure 7 -30 Ten -Relay Dry Contact Kit Warning devices (lamp and /or audible alarms) and other accessories typically connect to the following controller outputs: • Overspeed • Overcrank • High engine temperature • Low oil pressure • Low water temperature • Auxiliary fault • Air damper, if equipped • Anticipatory high engine temperature • Anticipatory low oil pressure • Emergency stop 7.9 Wiring Connections Although equipment and connections vary, Figure 7 -31 shows examples of the options and wire connections necessary to make an industrial system operational. Always refer to the wiring diagram for details of wire size, location, and number. AUDIOVISUAL ALARM KIT 3 WIRES 1620 GA REMOTE EMERGENCY STOP Krr r 2 WIRES 1620 GA GENERATOR SET CONTROLLER MUST BE MOUNTED AT GENERATOR 14 -RELAY DRY CONTACT CUSTOMER ACCESSORIES 3 WIRES MAX. 10-20 OA 14 W 21E312-20 GA 2 WT0ES 30 m (100 IL) 113.20 GA 132 m (500114 14 GA 303 81 (1000 L) IS GA. CUSTOMER ACCESSORIES 3 WIRES MAX 18-20 GA 1 3 WIRES 1620 GA_ REMOTE ANNUNCIATOR COMMON FAULT RELAY KIT CUSTOMER CONNECTION KIT LGENERATOR JUNCTION BOX MUST BE MOUNTED AT GENERATOR SINGLE RELAY DRY CONTACT KIT 3 WIRES 1620 GA 01 m R00 R) MAX -O ENGINE START TERMINALS 2 WIRES ,18-22 Gk. REMOTE START SWITCH (Installer Supplied) TRANSFER SWITCH (OPTIONAL) 1 WIRE 1620 OA. 2 WIRES 1620 GA SAFEGUARD CIRCUIT BREAKER TERMINAL STRIP (IN JUNCTION BOX) BATTERY HEATER KIT GENERATOR HEATER KIT J RUN RELAY KIT BATTERY L CHARGER KtT 10 -RELAY DRY CONTACT KIT CUSTOMER GENERATOR BATTERY NEGATIVE *008330123 11 POSITIVE CONNECTION WIRES MAIL 2 WIRES 14 GA SEE NOTE 2 19 OA • LOW FUEL SWITCH KIT J AC CONNECTION BOX (Installer Supplied) GENERATOR BATTERY SEE NOTE POSITIVE 00 ON 0 GENERATOR BATTERY NEGATIVE CONNECTION BLOCK HEATER KIT NOTE 1: HARD WIRED TO GENERATOR BATTERY NEGATIVE ENGINE CONNECTION. NOTE 2 FOR REMOTE ANNUNCIATOR'. TERMINALS OF THE REMOTE ANNUNCIATOR DRY CONTACTS MUST BE HARD WIRED TO THE GENERATOR BATTERY NEGATIVE ENGINE CONNECTION 11. TERMINAL OF THE REMOTE ANNUNCIATOR DRY CONTACT MUST BE HARD WRED TO THE GENERATOR BATTERY POSITIVE ENGINE CONNECTION. OPTIONAL EQUIPMENT _ AC POWER INDEPENDENT OF GENERATOR Based on ADV- 5795 -S -E Figure 7 -31 Generator Set Connections, Typical 76 Section 7 Electrical System TP -5700 9/08 • • • Section 8 Paralleling and Remote Start /Control Systems This section provides information about changes and adjustments when the system involves paralleling generator sets and /or remote start applications. Use the respective switchgear literature as supplied with the unit. Some of the items mentioned are available generator set accessories. Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible connections. Comply with all applicable codes when installing a wiring system. See Section 7, Electrical System for additional wiring information. A 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 equipment connected to the set, disable the generator set as follows: (1) Turn the generator set master switch and switchgear engine control 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 the starting of the generator set by an automatic transfer switch or a remote start/stop switch. 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. TP -5700 9/08 A WARNING Hazardous voltage. Moving parts. Can cause severe Injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Short circuits. Hazardous voltage /current can cause severe Injury or death. Short circuits can cause bodily injury and /or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. 8.1 Automatic Transfer Switches A typical standby system has at least one automatic transfer switch connected to the generator set output to automatically transfer the electrical load to the generator set if the normal source fails. When normal power returns, the switch transfers the load back to the normal power source and then signals the generator set to stop. The transfer switch uses a set of contacts to signal the engine /generator to start. When the normal source fails and the generator set master switch is in the AUTO position, the transfer switch contacts close to start the generator set. The engine start terminals are usually located near the transfer switch contactor with an engine start decal identifying the terminals. Refer to the transfer switch decal, operation /installation manual, or wiring diagram manual to identify the engine start terminals prior to making connections. Make connections to the transfer switch engine -start terminals and remote manual engine -start switch using wire run through conduit. Use separate conduits for engine -start leads, generator set load cables, battery charger leads, and remote annunciator wiring. Use a minimum of 13 mm (0.5 in.) spacing between the conduit bushing and any uninsulated live parts in the ATS enclosure. All conduit openings in the ATS enclosure must be made such that no metal particles including drill chips contaminate the components in the ATS enclosure. Section 8 Paralleling and Remote Start/Control Systems 77 8.2 550 Controller, Menu 15 Paralleling Relays Menu 15 provides the necessary paralleling relays for units with the optional paralleling protection feature. If the generator set personality profile did not include the paralleling option, this menu will not appear on the display. The following list shows the paralleling relays. See the 550 controller operation manual for further details regarding Menu 15, Paralleling Relays, • PR Overvoltage VAC o Time Delay Seconds • PR Undervoltage VAC o Time Delay Seconds • PR Overfrequency Hz o Time Delay Seconds • PR Underfrequency Hz o Time Delay Seconds • PR Reverse Power kW o Time Delay Seconds • SD Reverse Power kW o Time Delay Seconds • PR Over Power kW o Time Delay Seconds • SD Over Power kW o Time Delay Seconds • PR Loss of Field kVAR o Time Delay Seconds • SD Loss of Field kVAR o Time Delay Seconds • PR Overcurrent Amps o Time Delay Seconds • SD Overcurrent Amps o Time Delay Seconds • Synchronization o Synch Voltage Match VAC o Synch Freq. Match Hz o Synch Phase Match Degrees o Time Delay Seconds 8.3 550 Controller, Menu 11 Voltage Regulator Menu 11 provides the setup of the voltage regulator functions including the line -to -line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor, and kVAR adjustments. See Appendix G, Voltage Regulator Definitions and Adjustments, for additional information. The user must enable the programming mode to edit the display. Note: Press the Menu Right key prior to entering the decimal values where necessary. 78 Section 8 Paralleling and Remote Start/Control Systems Paralleling Applications Only. Analog input A07 is the voltage adjustment for paralleling applications only. This input adjusts input up or down from value entered in Menu 11, Voltage Regulator. If keypad entry does not match the displayed value for voltage adjust, the analog input is not at zero (2.5 VDC). Analog input A07 can be monitored or checked in Menu 3, Analog Monitoring. Note: Paralleling applications require enabling VAR /PF controls. Utility Gain Adjust is used for VAR or PF stability adjustment while paralleling to a utility. See the 550 controller operation manual for further details regarding Menu 11, Voltage Regulator, and changing the voltage configuration. 8.4 Reactive Droop Compensator The reactive droop compensator is used to distribute the Toad evenly when two generator sets are used in parallel. A qualified electrician or technician should install these kits. See Figure 8 -1 and Figure 8 -2. Additional generator set connections are shown in Figure 7 -1 through Figure 7 -4. GENERATOR CONNECTIONS 60112.- 120 /2409 -3PH. 4 50Hz.- 110 /220V -3PH. 4 L2 56 4 8 CT2 10 • LO CT V�. WIRE DELTA WIRE DELTA 0 2 1- �-j`f CT3 �(CCrr���`��``��.��,, L3 C.T. SCALE 3UM80R 50Hz.- 120/2060 OR 136/2408, 50Hz.- 120/206V OR 110/1900, u OPTIONAL DROOP COMPENSATION 9 3 tk9 ♦I CT3 6 12 C72 2 V8 3111.1 4 WIRE LOW WYE 3PH 4 WIRE LOW WYE V7 C.T. 10 / • 8 L2 SCALE JUMPER v O Jf / 3 12 L1 • V7 OPTIONAL DROOP COMPENSATION TB2 UP V7 L0 METER LAMP T82 UP V7 OL METER LAMP 6011z.- 277/4800 HIGH WE 50Hz.- 220/3805 HIGH WYE L1 --Q 1 L2� 2 CT1 ,,J v CT2 4.7 • �- -� • 5 8 L1 600 LEAD 8 STATOR 11 80 • 1 1 C51 • • • V7 10 V7 • 11 58 2 LO 4 • - • LO 5 • VB • DROOP C.T. CT2 LAMP RJUMPER 2� 59 6 C3 •4 OPTIONAL p4 COMPENSATION OPTIONAL DROOP COMPENSATION C.T. • 6,9 ,v CT3 t T82 I UPI ILOI LAMPRJUMCPER 3 • .3 l33 T82 UP Wi�1 Notes: Current transformer toward generator except as optional droop C.T. 1 phase The 380 volt, 480 volt, and generator sets require two leads through current transformer. others require one tum of output through current transformer. Phase Rotation: dot or 'HI' noted tor connections. 800 volt turns of output All leads 50Hz.- 120/2209, 1PH, 3 WIRE 50Hz.- 1Pht, 3 WIRE (26-1DOFM 0ENERATo00 ONLY) 081109AI DROOP COMPENSATION f T. (DDT TOWARD 'LO' 9 11 7 cn 1 3 to 6 co cT2 4 LC 8 2• L2 A e C L1 L2 L3 METER SCALE T82 UP V7 LO LAMP JUMPER DC- 273000 -U Figure 8 -1 Generator Set Connections TP -5700 9/08 Wiring Instructions: 1. Remove lead connecting TB4 -VB & (black) stator or PT2 lead "V8' 2. Reroute this lead and connect it to QCON2 3. Reroute (black) stator or PT2 lead "V8" and connect it to QCON1 TO AVR (P5) IFRIO SEE DWG. GM35941 OR TO AVR (PAD) [WEE] SEE DWG. GM35942 OCON1 7 T1 I di II i g S 5 S X -487 -4 (Rheostat) 263669 (Nameplate) Note: Position locating ring or rheostat so terminals are in the 6 o'clock position as shown. Nameplate is located on front of rheostat. OCON2 NOTE: FOR 70 KW& UP CURRENT TRANSFORMER DOT OR "1-11' TOWARD GENERATOR. NOTE: FOR UP TO 60 KW Th STAT (12 LEAD) vT TBo -V0 vo GM39328 -A Figure 8 -2 Wiring Diagram Test Procedure To test and adjust the reactive droop compensator, proceed as follows. Read the entire procedure before beginning. 1. With the reactive droop rheostat set at minimum (full counterclockwise position), record the rpm or frequency and voltage at 1/4 Toad steps to full load on unit #1. Repeat Step 1 for unit #2. 2. Compare the readings and make final adjustments so that the voltage is within 1 volt at each Toad step and the speed is within 3 rpm or the frequency is within 0.1 Hz for each unit. Adjust the voltage using the local or remote voltage adjusting potentiometer. Adjust the speed at the governor or at the remote speed adjusting potentiometer. 3. Check the droop compensation on each unit as follows: a. With unit #1 operating at the correct speed and voltage, apply a lagging power factor load. This load should preferably be 1/2 to full Toad and must be inductive, as resistance Toads cannot be used. b. Observe the voltmeter on unit #1 with the reactive droop rheostat set at minimum. As the rheostat is turned clockwise, the voltmeter should show a decrease in voltage. If a larger voltage is obtained when the reactive droop rheostat is turned clockwise, shut down the system and reverse the direction of the generator load line through the current transformer, or reverse the transformer leads. Recheck the droop. c. Adjust the reactive droop rheostat to a value at approximately 4% below rated voltage at full Toad. As an example, the voltage will droop (decrease) 19.2 volts on a 480 -volt system at full load or 9.6 volts at 1/2 load. To determine voltage droop at other than full load, use the following formula: Rated Voltage x 0.04 x Actual Load (expressed as a percent of full Toad) = Voltage Droop Note: With full load 0.8 power factor, a droop of 3 % -5% should be adequate for paralleling. TP -5700 9/08 Section 8 Paralleling and Remote Start/Control Systems 79 d. Repeat Steps 3 a., b., and c. for unit #2 and be certain the amount of voltage droop is equal at the same Toad point as on unit #1. e. With this procedure, the two units will share reactive currents proportionately. 4. In addition to Steps 1 -3, it is desirable to use the following procedure to check that the units are sharing the reactive load correctly. a. Parallel the units at 1/2 to full Toad. Check the wattmeters to determine that each unit is carrying equal kW load or a load proportional to its capacity. If the loads are incorrect, adjust and recheck the governor throttle control to correctly balance loading. Engine speed will determine load sharing ability. Note: Use wattmeters, not ammeters, to verify Toad balance. b. With the Toad balanced, check the ammeters to see that equal current is being produced or the current is proportional according to capacity of each generator set. If the currents are incorrect, adjust the reactive droop rheostat to reduce the current of the unit(s) that has the highest reading. Adjust the rheostat to increase current on the unit(s) with the lower reading. Continue making minor adjustments until each unit supplies current proportional to its capacity as a proportion of the total system capacity. c. As a result of performing Steps 4 a. and b., the governors have been adjusted to balance the load and the reactive droop rheostat has been adjusted to balance the current. These settings would be optimum for parallel operation. Note: The voltage must droop on lagging power factor loads (inductive loads). A little change in voltage is acceptable on unity power factor loads (resistive loads). 8.5 Remote Speed Adjustment This kit provides remote engine speed adjustments with an approximate range of ±5% at 1800 rpm. This kit requires a generator set with an electronic governor. See Figure 8 -3 and Figure 8 -4. Note: Dimensions shown in mm w 2) 254.0 REF. GM30882 DECAL, SPEED ADJUST •PA# Mblo USE GM30860 BRACKET AS TEMPLATE FOR DRILLING 2X 08.40 HOLES GM30860 GM31213 M933- 06014 -60 (2) EXP M6923 -08 -80 (2) EXP DETAIL D (INSIDE OF BOX) C.T. TERMINAL BLOCK (INSIDE OF J- BOX) EXISTING TERMINAL BLOCK (INSIDE OF J -BOX) SEE DETAIL 0 VIEW A -A USE GM30860 BRACKET AS TEMPLATE FOR DRILLING 2X 06.40 HOLES 78.2 REF. VIEW B -B USE GM30880 BRACKET AS TEMPLATE FOR DRILLING 2X 06.40 HOLES SEE DETAIL D SEE DETAILD EX STING TERMINAL BLOCK 230 -300 KW 350 -400 KW EXISTING TERMINAL BLOCK 78.2 REF. VIEW C -C 450 -2000 KW GM3085B -A Figure 8 -3 Remote Speed Potentiometer Installation 80 Section 8 Paralleling and Remote Start/Control Systems TP -5700 9/08 DDEC CONNECTIONS MDEC CONNECTIONS Notes: GM30859 -A • Wire number is 542 on 2000/4000 series engine or 545 on 60 series engine (for DDEC connections only). ▪ Remove and tape wire 542 (545) when installing manual speed adjust kits. 1. GM31213 potentiometer assembly ref. 2. Existing terminal block 3. Existing engine wiring harness Figure 8-4 Remote Speed Adjusting Control Wiring Diagram To program the 550 controller, MDEC- equipped DDC/ MTU engines only, use the following instructions. See the 550 controller operation manual for further information, if necessary. 1. Go to Menu 14— PROGRAMMING MODE to enable LOCAL programming. 2. Go to Menu 7— GENERATOR SYSTEM. 3. Press MENU Down 4. Key to access ENABLE VSG (variable governor speed) data. 4. Press the YES Key. 5. Press the ENTER .– Key to confirm entry. 6. Verify ENABLE VSG code YES appears on the display. 7. Go to Menu 14— PROGRAMMING MODE to change to programming mode OFF. 8.6 Remote Voltage Adjustment This kit provides the ability to fine adjust the generator output voltage from a remote location. Use this kit on 20 -300 kW 16 -light controller models. The maximum recommended wire length from the potentiometer to the generator set is 15 ft. (4.6 m); 18 -gauge twisted pair wire is recommended. Use a remote voltage regulator kit if further distance is required. See Figure 8 -5 and Figure 8 -6. 1 TT -919 3.51 mm (1.38 in.) 1.27 mm (0.5Q in.) 3.35 mm (1.32 in.) 1. Potentiometer 2. Panel 3. Nameplate 4. Nut 01.03 mm (0.048 in.) 00.48 mm (0.188 in.) 00.40 mm (0.156 in.) 6.67 mm (2.625 in.) 5. Knob 6. Screw 7. Washer Tr-941 Figure 8 -5 Potentiometer Installation TP -5700 9/08 Section 8 Paralleling and Remote Start/Control Systems 81 3B 5B JUNCTION BOX VOLTAGE REGULATOR BOARD r0® ® Q 0 0 0 7N 67 60 V3 V7 7 10 C2 70 C1 V 70 CO 70 SAFEGUARD O O O O O-7N TERMINAL STRIP 00 C1 02 03 70 7N 01 C2 C3 70 C1 C2 03 OPTIONAL SAFE GUARD BREAKER 7 ET (f I I I bc i I o ,-1- L - - --I BUCK BLACK cry Crs C73 18 L________ED VOLTAGE ADJUST Back View ea I Cut Wires Here 327097 -A Figure 8-6 Disconnection of Controller Voltage Adjusting Potentiometer 82 Section 8 Paralleling and Remote Start/Control Systems TP -5700 9/08 • • • 8.7 Remote Wiring Figure 8 -7 is the assembly drawing for the 16 -light controller and Figure 8 -8 is the accessory interconnection diagram showing the remote wiring for the 550 controller. 8.8 Remote Voltage Regulator Kit The remote mount voltage regulator kit is recommended whenever the voltage adjustment potentiometer is located beyond 4.3 m (15 ft.) from the generator set. Maximum distance between the generator set and voltage regulator is 287.4 m (1000 ft.). Maximum recommended distance between the voltage adjustment potentiometer and the voltage regulator is 4.3 m (15 ft.). See Figure 8 -9, Figure 8 -10, and Figure 8 -11 for 20 -300 kW models. See Figure 8 -12 for 350 -2000 kW models. Note: A remote voltage adjustment potentiometer kit is required when relocating the voltage regulator. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 NAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 17 18 19 20 BLOCK TERM( RMI 00 0 0 0 0 0 0 o 0 o 0 g q 0 0 0 0 0 0 INNER PANEL REMOTE EMERGENCY NOTE: RESET STOP REMOVE JUMPER WHEN USED WITH SWITCHGEAR OR REMOTE E —STOP. REMOTE SHUTDOWN GM28831 C -B Figure 8 -7 16 -Light Controller Remote Wiring Figure 8-8 550 Controller Remote Wiring 0 0 3 V 5 V 6 67 OKA 0 NO. 2 ON MARKER STRIP MUST BE IN LINE WITH 7N LEAD ON TERMINAL BLOCK. 2 1. Remote Regulator Mounting Plate Assembly (A- 263266) 2. Regulator Assembly 3. Wiring Harness (273941) (TERMINALS 3 AND 4' REMOTE START SWITCH OR ENGINE START CONTACTS ON TRANSFER SWITCH) EMERGENCY EMERGENCY LOCAL EMERGENCY 3 - TB1 __4_ ENGINE START T84 1 &E -STOP DIGITAL INPUT 22 23 2 24 2.e 5 6 21 7 28 20 y 10 k 11 X12 514 30 l .I REMOTE STOP SWITCH STOP SWITCH (OPTIONAL) (STANDARD) TB1 STOP SWITCH to VW10,......_ - CONNECTIONS CONNECTIONS IA (STANDARD) ,A - p3 DC INPUT 5 5 29 ] 2. 228 125 D z 22 21 20 19 17 CONTROLLER INTERCONNECTION BOARD T82 .i2 REMOTE EMERGENCY STOP SWITCH CONNECTIOTL4 ANALOG INPUT TB3 CONNECTIONS OUTPUT CONNECTIONS 5 11 • ID 3 9 15 ]71j ale SHUroowN 1nWER RAISE REMOTE RESET 4 REMOTE VOLTAGE ADJUST T 19 o It i (OPTIONAL) O MODE s P7 4 15 —r— ENGINE HARNESS CONNECTIONS 4P, p� OUTPUT CONNECTIONS v (CUSTOMER PROVIDED) CONNECTIONS ■■■111:1■. 1 5 9 13 T2 21 25 29 13 1 4 7 ■■■■■■ 2 9 15 14 22 34 2 5 ■■■■■■ 3 7 11 15 19 23 27 31 33 3 ■■■.■■ 4 5 12 18 20 24 23 32 38 \ GM18088A -F Figure 8-8 550 Controller Remote Wiring 0 0 3 V 5 V 6 67 OKA 0 NO. 2 ON MARKER STRIP MUST BE IN LINE WITH 7N LEAD ON TERMINAL BLOCK. 2 1. Remote Regulator Mounting Plate Assembly (A- 263266) 2. Regulator Assembly 3. Wiring Harness (273941) BS- 272000 -D Figure 8 -9 Remote Voltage Regulator Kit Installation, 20 -300 kW TP -5700 9/08 Section 8 Paralleling and Remote Start/Control Systems 83 .0[TT] 4 (III (III Li l .I t, it% VW10,......_ _....4 BS- 272000 -D Figure 8 -9 Remote Voltage Regulator Kit Installation, 20 -300 kW TP -5700 9/08 Section 8 Paralleling and Remote Start/Control Systems 83 CONNECTIONS BETWEEN TERMINAL BLOCKS AND TO REMOTE VOLTAGE ADJUST POTENTIOMETER ARE CUSTOMER SUPPLIED SWITCHGEAR ADJUST POTENTIOMETER (BACK VIEW GENERATOR SET JUNCTION BOX ® 2 ® 0050 00807 CONNECT TO AC HARNESS 1 VOLTAGE REGULATOR 6 REMOTE REGULATOR KIT TG2 LEGEND 3B PHOTO - COUPLING 5B PHOTO - COUPLING 67 VOLTAGE ADJUST 68 VOLTAGE ADJUST V7 AC VOLTAGE SENSING V8 AC VOLTAGE SENSING 7N BATTERY GROUND 1B BATTERY VOLTAGE PLUS BS- 272000 -D Figure 8 -10 Wiring Diagram, 20 -300 kW REMOTE VOLTAGE REG. 2 » EXCRATION SYSTEM 4. 7 L1 8 10, 11, 12 6,9 REMOTE VOLT ADJUST POTENTIOMETER (BACK VIEW) PHASE ROTAT1ON A B C L1 L2 L3 L3 DROOP C.T (OPTIONAL) a SWITCHED BATTERY - BATTERY GROUND SAFE GUARD TERMINAL STRIP BS- 272000 -D Figure 8 -11 Schematic Diagram, 20 -300 kW 84 Section 8 Paralleling and Remote Start/Control Systems TP -5700 9/08 NEG. BATTERY 2 12-24 VDC 3 SENSING V8 240 V MAX 4 PHOTO-COUPLER NEG. 8 DROOP CT. X1 7 DROOP CT. X2 8 PHOTO-COUPLER POS. 9 SENSING V7 240 V MAX 10 SWITCHED POS. 12-24 VDC BATTERY 11 12 REMOTE 13 VOLTAGE ADJUST 14 2 » EXCRATION SYSTEM 4. 7 L1 8 10, 11, 12 6,9 REMOTE VOLT ADJUST POTENTIOMETER (BACK VIEW) PHASE ROTAT1ON A B C L1 L2 L3 L3 DROOP C.T (OPTIONAL) a SWITCHED BATTERY - BATTERY GROUND SAFE GUARD TERMINAL STRIP BS- 272000 -D Figure 8 -11 Schematic Diagram, 20 -300 kW 84 Section 8 Paralleling and Remote Start/Control Systems TP -5700 9/08 • SWITCHGEAR VOLLWE DTI GENERATOR SET JUNCTION BOX °°°°'�°w`°rcr i J r. TO GENERATOR Connect Between Terminal Block and Voltage Regulator c= 0 a 0 0 ° 0 View A See View C DVR TO SU REG. TO7 TERM'S 6D FROM T85 ENGINE GAUGE BOX 0132 OR SWITCH GEAR FROM Tay ENGINE GAUGE BOX 0133 OR SWITCH GEAR FROM T85 ENGINE GAUGE BOX 8131 OR SWITCH GEAR SW186- 1806 -2422 SW187 -1805 -2422 TB2 86 88 View C SW188- 1804 -2422 T81 E1 / E2 (E3 View B See View C GM129340 -B • Figure 8 -12 Remote Voltage Regulator Kit Installation, 350 -2000 kW 8.9 Voltage Regulator DVR 2000EC /Remote Voltage Regulator Kit, 350 kW and Above The DVR 2000E is used with nonparalleling applications and the DVR 2000EC is used when paralleling is required. If the voltage configuration is changed, make adjustments to the DVR 2000 voltage regulator at the voltage regulator. Remove the junction box cover to adjust the DVR 2000 voltage regulator. See Figure 8 -13, Figure 8 -14, and TP -5579, Operation Manual, DVR 2000 Voltage Regulator, for more information. Use Figure 8 -14 for installation and troubleshooting of the electrical wiring system. 0 DVR 2000'" is a trademark of Marathon Electric Mfg. Corp. 1. DVR 2000 voltage regulator GM16780 -A Figure 8 -13 DVR 2000 Voltage Regulator Mounting Location TP -5700 9/08 Section 8 Paralleling and Remote Start/Control Systems 85 TO L1 (BUS) 4 LEAD STATOR TO V7 (PT 1 6 LEAD STATOR TO L2(g US) 4 LEAD STATOR TO V8 (PT 2) LEAD STATOR TO L3 (BUS) 4 LEAD STATOR TO V9 (PT 3 6 LEAD STATOR Junction Box DVR 2000/2010 VOLTAGE p c- -.PMG REGULATOR PMG -PMG F- F2 I E1 F. 52J 526 52L -F1 52M 6U - - 60 - - 7 - CTB2 CTBI Generator F1 F2 EXCITER STATOR EXCITE ROTOR AC F- AC RROTOR AC RECTIFIER MODULE F+ VOLT UP REMOTE VOLTAGE ADJUST VOLT DOWN 56 PMG STATOR NOTE: FOR GENERATOR CONNECTIONS SEE: SEE ADV -5875 THREE PHASE PMG PMG 1 CAPACITOR Legend PMG - Permanent Magnet Generator STAT - Stator TB5 - Controller AC Fuse Block QCON( #) - Quick Connect 7 9 10 11 '� 12 AIN ROTO STAT 12 LEAD TO CON1, & TB5-W, V8, V9 (4 LEAD & 6 LEAD GENERATOR ONLY) V7 V8 V9 VO TO LOAD TB5 1 1 1 QCON 1 TO P10 ON CONTROLLER MAIN LOGIC BOARD GM20500- Figure 8 -14 DVR 2000 Voltage Regulator /Alternator Interconnection Wiring Diagram 86 Section 8 Paralleling and Remote Start/Control Systems TP -5700 9/08 • • 8.10 Voltage Regulator, PMG If the voltage configuration is changed, use the following procedure to make adjustments to the voltage regulator used on PMG alternators. The AVR monitors output voltage magnitude and frequency to supply current to the stationary LED board. The AVR circuit board includes volts /Hz and stability adjustment potentiometers. The volts /Hz adjustment is factory -set and normally requires no further adjustment. If operating the generator set under extreme Toads results in voltage instability, adjust the potentiometers according to the following procedure. See Figure 8 -15. 1. 60 Hz voltage adjustment 2. 50 Hz voltage adjustment C- 255870 -B 3. Stability adjustment Figure 8 -15 AVR Adjustment Stability Potentiometer. Fine tunes voltage regulator to reduce light flicker. Volt/Hz Potentiometer. This adjustment determines engine speed (Hz) at which generator output voltage will begin to drop. TP -5700 9/08 Volt/Hz Potentiometer Adjustment Procedure This adjustment determines engine speed (Hz) at which alternator output voltage will begin to drop. 1. Turn generator set master switch to OFF /RESET. 2. Turn stability potentiometer fully counterclockwise. 3. Connect a 100 -watt Tight bulb across terminals VO and V7 on controller terminal strip or across terminals on controller frequency meter. 4. Start generator set. With generator running at no Toad, observe light bulb flicker. Excessive light bulb flicker indicates poor stability. 5. Adjust stability potentiometer until minimum flicker is obtained. 6. Use controller voltage adjustment potentiometer (or remote voltage adjustment potentiometer) to make adjustments to the generator set while running under normal load (if required). 7. Adjust the engine speed to the desired cut -in frequency (factory setting is 57.5 -58.0 Hz for 60 Hz models or 47.5 -48.0 Hz for 50 Hz models) as measured on frequency meter. See the governor manual for information on engine adjustment. 8. Rotate the volts /Hz adjustment potentiometer clockwise until voltage level begins to drop (as measured on voltmeter). When set to these specifications, the generator set will attempt to maintain normal output until engine speed drops below the frequency set in the previous step (as load is applied). 9. Adjust the engine speed to obtain a full Toad engine speed of 1800 rpm (60 Hz) or 1500 rpm (50 Hz). Confirm and adjust the output voltage as needed. 10. Use controller voltage adjustment potentiometer (or remote voltage adjustment potentiometer) to make final adjustments to the generator set while running under normal load. 11. Readjust stability potentiometer (if necessary). Section 8 Paralleling and Remote Start/Control Systems 87 8.11 Voltage Regulator, Wound Field The voltage regulator is factory-set and, under normal circumstances, requires no further adjustment. However, for wound field alternators, if the voltage/ frequency reconnection has been done, readjust the voltage regulator according to the following procedure. The voltage regulator components are identified and described in the following paragraphs. Figure 8 -16 illustrates the voltage regulator features. Figure 8 -17 identifies the voltage regulator connections to the P40 socket. Note: Frequency reconnection. Refer to the respective generator set spec sheet to determine if engine frequency (speed) is fixed or field - convertible. 1 2 . / \ i Lead Description /Function 1 0 r_] eT.- i elErEtc f-T 2 V7 TB4 -V7 sensing input 3 V8 TB4 -V8 sensing input 4 7, IIyy - r, nl IEEE efz Ti 12 67 Remote voltage adjustment GM31850A -E 5 4 3 1. LED1 (red shutdown) 4. Stability potentiometer 2. LED2 (green output) 5. Volts /Hz potentiometer 3. 12 -pin socket P40 Figure 8 -16 Voltage Regulator Features Socket P40- Lead Description /Function 1 68 Remote voltage adjustment 2 V7 TB4 -V7 sensing input 3 V8 TB4 -V8 sensing input 4 FP Exciter field output 5 67 Remote voltage adjustment 6 EOV Overvoltage controller output signal 7 — Not used 8 FN Exciter field output 9 7N TB11 -7N (battery negative) 10 1B Safeguard circuit breaker (battery positive) 11 55 Voltage regulator power supply 12 66 Voltage regulator power supply Figure 8 -17 Voltage Regulator P40 Connections 88 Section 8 Paralleling and Remote Start/Control Systems Stability Potentiometer. Potentiometer fine tunes the regulator circuitry to reduce light flicker. Volts /Hz Potentiometer. Potentiometer adjustment determines the engine speed (Hz) at which the alternator output begins to drop. Voltage Adjustment (remote only). Use the generator set controller voltage adjustment control to adjust the alternator output. See the respective generator set operation manual for further information. Voltage Regulator Adjustment Procedure Figure 8 -18 illustrates the wiring connections necessary for the voltage regulator adjustment procedure. 1. Sensing leads 2. Stator main windings 3. Rotor main field 4. Voltage regulator power supply leads 5. Rotating rectifier assembly (RRA) 6. Exciter armature 7. Exciter field winding 8. Voltage regulator (P40 socket) TP-8349-4 Figure 8 -18 Voltage Regulator Connection 1. Verify that the generator set master switch is in the OFF /RESET position. 2. Turn the Volts /Hz and the stability potentiometers fully counterclockwise. Connect the voltmeter to the AC circuit or an electrical outlet. 3. Move the generator set master switch to the RUN position. TP -5700 9/08 • • 4. Change the voltage adjustment control (located at the generator set controller) until the desired output voltage is achieved. 5. Rotate the stability potentiometer clockwise until Tight flicker minimizes. 6. Readjust the voltage adjustment control (located at the generator set controller) until the desired output voltage is achieved. 7. If the engine has a speed adjustment governor, adjust the engine speed to the specified cut -in frequency as measured on the frequency meter. The factory setting is 57.5 -58 Hz for 60 Hz models and 47.5 -48 Hz for 50 Hz models. Note: Some engines do not permit engine speed adjustment. TP -5700 9/08 8. Rotate the volts /Hz potentiometer clockwise until the voltage level as measured on the voltmeter begins to drop. When the regulator is set to these specifications, the alternator will attempt to maintain normal output until the engine speed drops below the frequency set in step 7 as Toad is applied. 9. Readjust the engine speed to 1800 rpm for 60 Hz models or 1500 rpm for 50 Hz models. 10. Readjust the voltage adjustment control (located at the generator set controller) until the desired output is achieved. 11. Readjust the stability potentiometer until Tight flicker minimizes. 12. Move the generator set master switch to the OFF/ RESET position to stop the generator set. Section 8 Paralleling and Remote Start/Control Systems 89 Appendix A Abbreviations • • • The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu /min. C cal. CAN GARB CB cc CCA ccw. CEC cert. cfh cfm ampere after bottom dead center alternating current analog to digital advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing amp -hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute (formerly American Standards Association, ASA) anticipatory only Air Pollution Control District American Petroleum Institute approximate, approximately Air Quality Management District as required, as requested as supplied, as stated, as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator Battery Council International before dead center brake horsepower black (paint color), block (engine) block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius, centigrade calorie controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate, certification, certified cubic feet per hour cubic feet per minute TP -5700 9/08 .CG CID CL cm CMOS cogen. com coml Coml /Rec conn. cont. CPVC crit. CRT CSA CT Cu cUL CUL cu. in. cw. CWC cyl. D/A DAC dB dB(A) DC DCR deg., ° dept. DFMEA dia. DI/E0 DIN DIP DPDT DPST DS DVR E, emer. ECM EDI EFR e.g. EG EGSA EIA EI /EO EMI emiss. eng. EPA EPS ER ES ESD est. E -Stop etc. center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration communications (port) commercial Commercial /Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter's Laboratories Canadian Underwriter's Laboratories cubic inch clockwise city water - cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department Design Failure Mode and Effects Analysis diameter dual inlet/end outlet Deutsches Institut fur Normung e. V. (also Deutsche Industrie Nomienausschuss) dual inline package double -pole, double -throw double -pole, single -throw disconnect switch digital voltage regulator emergency (power source) electronic control module, engine control module electronic data interchange emergency frequency relay for example (exempt( gratia) electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet/end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge estimated emergency stop et cetera (and so forth) exh. ext. F fglass. FHM fl. oz. flex. freq. FS ft. ft. lb. ft. /min. ftp g ga. gal. gen. genset GFI GND, gov. gph gpm gr. GRD gr. wt. HxWxD HC HCHT HD HET hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IC ID IEC IEEE IMS in. in. H2O in. Hg in. Ib. Inc. ind. int. int. /ext. I/O IP ISO J JIS k K kA KB KBus exhaust external Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temp., high engine temp. hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal /external input/output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2.° bytes) Kohler communication protocol Appendix 91 kg kg /cm2 kgm kg/m3 kHz kJ km kOhm, k52 kPa kph kV kVA kVAR kW kWh kWm kWth L LAN LxWxH Ib. Ibm/ft3 LCB LCD Id. shd. LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m3/hr. m3 /min. mA man. max. MB MCCB MCM meggar MHz mi. mil min. misc. kilogram kilograms per square centimeter kilogram -meter kilograms per cubic meter kilohertz kilojoule kilometer kilo -ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kilowatt- thermal liter local area network length by width by height pound, pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water level low water temperature meter, milli (1/1000) mega (106 when used with SI units), male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte (220 bytes) molded -case circuit breaker one thousand circular mils megohmmeter megahertz mile one one - thousandth of an inch minimum, minute miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mg milliohm MOhm, MS2megohm MOV M Pa mpg mph MS ms m /sec. MTBF MTBO mtg. MTU MW metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure mean time between overhauls mounting Motoren -und Turbinen -Union megawatt 92 Appendix mW milliwatt microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight- coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper -Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce P.. PP. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., 0 phase PHC Phillips® head Crimptitee (screw) PHH Phillipse hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read -only memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad, radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res /Coml Residential /Commercial RFI radio frequency interference RH round head RHM round head machine (screw) rly relay rms root mean square rnd. round ROM rot. rpm RS RTU RTV RW SAE scfm SCR s, sec. SI SI/E0 sil. SN SNMP SPDT SPST spec specs sq. sq. cm sq. in. SS std. stl, tech. TD TDC TDEC TDEN TDES TDNE TDOE TDON temp. term. THD TIF TIR tol. turbo. typ. OF UHF UL UNC UNF univ. US UV V VAC VAR VDC VFD VGA VHF W WCR w/ w/o wt. xfmr read only memory rotate, rotating revolutions per minute right side remote terminal unit room temperature vulcanization read/write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d'unites, International System of Units side in /end out silencer serial number simple network management protocol single -pole, double -throw single -pole, single -throw specification specification(s) square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency Underwriter's Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP -5700 9/08 • • • Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/ScrewLength: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method. Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts, spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications. See Appendix C, General Torque Specifications, and other torque specifications in the service literature. Preferred Nut/Bolt Clearance Unacceptable Nut/Bolt Clearance 1. 1/2 of bolt diameter 2. Min. 1 full thread beyond top of nut 3. Below top of nut G -585 Figure 1 Acceptable Bolt Lengths TP -5700 9/08 Steps for common hardware application: 1. Determine entry hole type: round or slotted. 2. Determine exit hole type: fixed female thread (weld nut), round, or slotted. For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch in diameter or less. Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware 1/2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure 2. 3. Follow these SAE washer rules after determining exit hole type: a. Always use a washer between hardware and a slot. b. Always use a washer under a nut (see 2 above for exception). c. Use a washer under a bolt when the female thread is fixed (weld nut). 4. Refer to Figure 2, which depicts the preceding hardware configuration possibilities. 1. Cap screw 2. Entry hole types 3. Standard nut and SAE washer 4. Whiz nut or spiralock: up to 1/2 in. dia. hardware 5. Weld nuts: above 1/2 in. dia. hardware 6. Exit hole types G -585 Figure 2 Acceptable Hardware Combinations Appendix 93 Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Metric Fasteners Torque Specifications, Measured In Nm (ft. Ib.) Size Torque Measurement Assembled Into Cast iron or Steel Assembled Into Cast Iron or Steel Assembled Into Aluminum Grade 5.8 or 8.8 Assembled Into Aluminum Grade 2 or 5 Grade 2 Grade 5 Grade 8 8 -32 Nm (in. Ib.) 1.8 (16) 2.3 (20) - See Note 3 See Note 3 10 -24 Nm (in. Ib.) 2.9 (26) 3.6 (32) - M8 x 10 -32 Nm (in. Ib.) 2.9 (26) 3.6 (32) - M10 x 1/4 -20 Nm (in. Ib.) 6.8 (60) 10.8 (96) 14.9 (132) 1/4 -28 Nm (in. Ib.) 8.1 (72) 12.2 (108) 16.3 (144) 5/16 -18 Nm (in. Ib.) 13.6 (120) 21.7 (192) 29.8 (264) 5/16 -24 Nm (in. Ib.) 14.9 (132) 23.1 (204) 32.5 (288) 3/8 -16 Nm (ft. Ib.) 24.0 (18) 38.0 (28) 53.0 (39) 3/8 -24 Nm (ft. Ib.) 27.0 (20) 42.0 (31) 60.0 (44) 7/16 -14 Nm (ft. Ib.) . 39.0 (29) 60.0 (44) 85.0 (63) 7/16 -20 Nm (ft. Ib.) 43.0 (32) 68.0 (50) 95.0 (70) 1/2 -13 Nm (ft. Ib.) 60.0 (44) 92.0 (68) 130.0 (96) 1/2 -20 Nm (ft. Ib.) 66.0 (49) 103.0 (76) 146.0 (108) 9/16 -12 Nm (ft. Ib.) 81.0 (60) 133.0 (98) 187.0 (138) 9/16 -18 Nm (ft. Ib.) 91.0 (67) 148.0 (109) 209.0 (154) 5/8 -11 Nm (ft. Ib.) 113.0 (83) 183.0 (135) 259.0 (191) 5/8 -18 Nm (ft. Ib.) 128.0 (94) 208.0 (153) 293.0 (216) 3/4 -10 Nm (ft. Ib.) 199.0 (147) 325.0 (240) 458.0 (338) 3/4 -16 Nm (ft. Ib.) 222.0 (164) 363.0 (268) 513.0 (378) 1 -8 Nm (ft. Ib.) 259.0 (191) 721.0 (532) 1109.0 (818) 1 -12 Nm (ft. Ib.) 283.0 (209) 789.0 (582) 1214.0 (895) Notes: 1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and /or assembly drawings when they differ from the above torque values. 2. The torque values above are based on new plated threads. Increase torque values by 15% if non - plated threads are used. 3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to prevent stripped threads. 4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength and a friction coefficient of 0.125. 94 Appendix TP -5700 9/08 • • • Metric Fasteners Torque Specifications, Measured In Nm (ft. Ib.) Size (mm) Assembled Into Cast iron or Steel Assembled Into Aluminum Grade 5.8 or 8.8 Grade 5.8 Grade 8.8 Grade 10.9 M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10) See Note 3 M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24) M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25) M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48) M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50) M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85) M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133) M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140) M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205) M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212) M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288) M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305) Notes: 1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and /or assembly drawings when they differ from the above torque values. 2. The torque values above are based on new plated threads. Increase torque values by 15% if non - plated threads are used. 3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to prevent stripped threads. 4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength and a friction coefficient of 0.125. 94 Appendix TP -5700 9/08 • • • • • • Appendix D Fuel Physical Properties Physical Property @ 15 °C (60 °F) Butane Propane Natural Gas Manufactured or Sewage Gas Gasoline Diesel Fuel Normal atmospheric state Gas Gas Gas Gas Liquid Liquid Boiling point, Initial, °C ( °F) End, °C ( °F) — 0 (32) — 42 ( -44) — -162 ( -259) — — 36 (97) 216 (420) 177 (350) 357 (675) Heating value, Btu /gal. (net, LHV*) /gal. (gross) /ft3 (gas) 94670 102032 3264 83340 91500 2516 63310 — 1000 — — 600 -700 116400 124600 6390 130300 139000 — Density, Ft3 of gas /gal. 31.26 36.39 57.75 — 19.5 — Wt./gal. liquid, Ib. 4.81 4.24 2.65 — 6.16 7.08 Octane Number Research Motor 94 90 110+ 97 110+ — — — 80 -100 75 -90 — — * Lower Heating Value Figure 3 Engine Fuels, Physical Properties Characteristic, LP Gas* Butane Propane Formula C4Hto C3H8 Boiling point, °C ( °F) 0 (32) -42 ( -44) Specific gravity of gas (air = 1.00) 2.00 1.53 Specific gravity of liquid (water = 1.00) 0.58 0.51 Btu/lb. of gas 21221 21591 Ft.3 of vapor at 16 °C (60 °F) /Ib. of liquid at 16 °C (60 °F) 6.506 8.547 Latent heat of vaporization at boiling point, Btu /gal. 808.0 785.0 Combustion Data: Ft3 air required to burn 1 ft.3 of gas Flash point, °C ( °F) Ignition temperature in air, °C ( °F) Max. flame temperature in air, °C ( °F) 31.02 N/A 482 -538 (900 -1000) 1991 (3615) 23.86 -104 ( -156) 493 -549 (920 -1020) 1979 (3595) Limits of inflammability, percentage of gas in air mixture: At lower limit, % At upper limit, % 1.9 8.6 2.4 9.6 Octane Number (ISO - Octane = 100) 92 Over 100 * Commercial quality. Figures shown in this chart represent average values. Figure 4 Additional LP Gas Characteristics TP -5700 9/08 Appendix 95 Appendix E Gas Fuel Vapor Pressures 14.06 kg /cm2 (200 psi) 12.65 kg /cm2 (180 psi) 11.25 kg /cm2 (160 psi) 9.84 kg/cm2 (140 psi) • 8.44 kg/cm2 (120 psi) d • 7.03 kg/cm2 (100 psi) a 5.62 kg/cm2 (80 psi) 4.22 kg /cm2 (60 psi) 2.81 kg/cm2 (40 psi) 1.41 kg/cm2 (20 psi) 0 kg /cm2 (0 psi) VAPOR PRESSURE (APPROXIMATE VALUES) PROPANE 50 -50 MIXTURE BUTANE- -40 °C -28°C (-40 °F) (-20 °F) -18 °C -7°c 4 °C (0 °F) (20 °F) (40 °F) Temperature 15 °C (80 °F) 27 °C (80 °F) 38 °C (100 °F) Figure 1 Vapor Pressures of LP Gases Graph Temperature, °C ( °F) Approximate Pressure, kg /cm2 (PSIG) Propane 50/50 Mixture Butane -40 ( -40) 0.1 (1) - - -36 ( -33) 0.4 (5) - - -28 ( -20) 0.7 (10) - - -23 ( -10) 1.2 (17) 0.2 (3) - -18 (0) 1.7 (24) 0.4 (5) - -12 (10) 2.2 (32) 0.6 (8) -7 (20) 3.0 (42) 0.9 (13) - -1 (30) 3.7 (52) 1.3 (19) - 4 (40) 4.6 (65) 1.8 (26) 0.1 (2) 10 (50) 5.5 (78) 2.4 (34) 0.5 (7) 15 (60) 6.5 (93) 3.0 (42) 0.8 (12) 21 (70) 7.7 (109) 3.5 (50) 1.2 (17) 27 (80) 9.6 (136) 4.2 (60) 1.7 (24) 32 (90) 10.3 (147) 5.1 (72) 2.2 (32) 38 (100) 11.9 (169) 6.0 (85) 2.8 (40) 43 (110) 14.1 (200) 7.0 (100) 3.5 (50) Figure 2 Vapor Pressures of LP Gases Table 96 Appendix TP -5700 9/08 4 • Appendix F Gas Fuel System Installation Planning • • • Determining Propane Cylinder Quantity Guide for Installing 100 Ib. Cylinders For continuous draws where temperatures may reach -18 °C ( -0 °F). Assume the vaporization rate of 100 Ib. cylinder as approximately 50000 Btu /hr. Number of cylinders /side = Total Toad in Btu 50000 Example: Assume total load = 20000 Btu /hour. Cylinders /side = 20000 = 4 cylinders /side 50000 The chart in Figure 1 shows the vaporization rate of containers in terms of the temperature of the liquid and the wet surface area of the container. When the temperature is lower or if the container contains Tess liquid, the vaporization rate of the container is a lower value. Lb. of Propane In Cyi. Maximum Continuous Draw In Btu /Hour At Various Temperatures In °C ( °F) -18 °C (0 °F) -7 °C (20 °F) 4 °C (40 °F) 16 °C (60 °F) 21 °C (70 °F) 100 113000 167000 214000 277000 300000 90 104000 152000 200000 247000 277000 80 94000 137000 180000 214000 236000 70 83000 122000 160000 199000 214000 60 75000 109000 140000 176000 192000 50 64000 94000 125000 154000 167000 40 55000 79000 105000 131000 141000 30 45000 66000 85000 107000 118000 20 36000 51000 68000 83000 92000 10 28000 38000 49000 60000 66000 Figure 1 Vaporization Rate, 100 Ib. Propane Cylinders, Approximate TP -5700 9/08 Determining Propane Vaporization Capacity Guide for ASME LP Gas Storage Containers % of Container Filled K Equals Propane* Vaporization Capacity at -18 °C (0 °F) In Btu /Hr.t 60 100 D x L x 100 50 90 D x L x 90 40 80 D x L x 80 30 70 D x L x 70 20 60 D x L x 60 10 45 DxLx45 * These formulae allow for the temperature of the liquid to refrigerate to -29 °C (- 20 °F), producing a temperature differential of -7 °C (20 °F) for the transfer of heat from the air to the container's wetted surface and then into the liquid. The vapor space area of the vessel is not considered since its effect is negligible. t D= outside diameter in inches L= overall length in inches K= constant for percent volume of liquid in container. Figure 2 Propane Vaporization Capacity Vaporizing Capacities for Other Air Temperatures Multiply the results obtained with the formulae in Figure 2 by one of the factors in the following table for the prevailing air temperature. Prevailing Air Temperature Multiplier -26 °C ( -15 °F) 0.25 -23 °C ( -10 °F) 0.50 -21°C ( -5 °F) 0.75 -18 °C (0 °F) 1.00 -15 °C (5 °F) 1.25 -12 °C (10 °F) 1.50 -26 °C (15 °F) 1.75 -7 °C (20 °F) 2.00 Figure 3 Propane Vaporization Temperature Appendix 97 Appendix G Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator, integrated in the Decision - Maker"" 550 controller, beyond the default settings in order to customize the alternator for a specific application. This information is not intended to be a comprehensive explanation of all the terms mentioned. There are numerous documents available that define these terms more completely than described herein. Any user planning to change the generator set controller adjustment settings or to apply the generator set to these types of applications should understand these terms. This appendix contains references to other sections of this manual. Please refer to these sections for further information and explanation. Paralleling generator sets can be a complicated and dangerous exercise. Application programming must be performed by appropriately skilled and suitably- trained personnel. Definitions Underfrequency Unloading Underfrequency unloading is a function used in the alternator excitation control system to improve the overall generator set system (engine and alternator) response. In particular, underfrequency unloading relates to large -block load applications. When applied to engine- driven alternators, large -block loads cause a subsequent transient torque Toad on the engine. This torque load can reduce the engine's speed below the normal operating point. Typically, the engine speed controller or governor will compensate for this by commanding an increase in fuel. If, however, the fuel system is inadequate to recover from a relatively large load, the speed may never recover. In these instances, other measures must be taken. This is where the underfrequency unloading occurs. When the excitation control system detects a drop in the speed or electrical frequency below some predetermined point, the control system enters an unloading condition. This can be described as moving to a lower voltage regulation point. By reducing the output voltage of the alternator, the Toad on the generator set is reduced. This can be shown mathematically by Ohm's law, which states that power is equal to the voltage squared divided by the impedance. As the voltage is reduced, the power delivered by the alternator decreases by a squared relationship. Since it is the power in the alternator that translates into engine torque, the engine load is also reduced. By changing various parameters of this compensation technique, the controlling system can be tailored to match the performance capabilities of most engine and alternator combinations. The point at which the unloading begins to act or how much unloading occurs can be adjusted to impact maximum voltage droop, maximum speed droop, or time to recover. Some applications may not need unloading and, in these cases, set the unloading parameter to disable the function. These parameters are further described below. An example is provided to help clarify the relationship between these parameters. Underfrequency Unload Slope Underfrequency unload slope is the term used to describe the amount that the voltage is reduced, per - cycle -per- second or per -hertz (Hz), when in an underfrequency condition. The slope or schedule is sometimes called the volts - per -hertz slope. When the electrical frequency drops below the cut -in point (see below), the excitation control system temporarily reduces the regulated voltage to reduce the subsequent torque on the engine. The amount that the control system reduces voltage is defined as the product or multiplication of the slope and the amount of frequency or speed below the cut -in point. For every Hz below the cut -in point, the control system reduces the line -to -line voltage by an amount equal to the slope. Because each engine responds differently to the various Toads encountered, the slope may be adjusted to improve the system response. If, when large loads are applied to the generator set, the engine speed drops below the acceptable limit (as determined by the particular loads applied), the slope may need to be increased. Increasing the slope will cause the voltage to droop more during load applications, consequently reducing the load torque on the engine and allowing the speed to increase. If, however, the voltage drops below an acceptable lower limit (as determined by the particular loads connected to the generator set), a lower slope may work better. The underfrequency unloading function may be disabled by setting the slope to zero. 98 Appendix TP -5700 9/08 • • • Frequency Setpoint or Cut -In Point The point at which the underfrequency unloading begins to take effect is adjustable, allowing the system to be tailored for each application. Because the characteristics of the engine have the largest effect on the system's performance, the engine's response should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will reduce the voltage so that the engine may begin to recover. The cut -in point, or frequency setpoint, should be set 0.5 -3.0 Hz lower than the normal steady -state band of operation. If the engine normally operates within a very narrow range of speeds close to the nominal, a setpoint of 0.5 to 1.0 Hz below nominal should be suitable. If the engine normally operates over a wide range of speeds, the setpoint may need to be 2.0 -3.0 Hz from the nominal. The underfrequency unloading function can be eliminated by setting the cut -in point below the minimum expected operating frequency. Example A 90 kW load is applied to a 100 kW, 60 Hz generator set driven by a turbocharged diesel engine with an electronical control module (ECM). The speed drops 10% and takes 20 seconds to recover to at least 59.5 Hz. The voltage, meanwhile, drops from 480 to 460 and recovers to 480 within 15 seconds. Therefore, some underfrequency unloading should be provided. A good starting point would be a frequency setpoint or cut -in of 59 Hz. A slope of 15 volts per - cycle -per- second is appropriate as well. If after these adjustments the speed recovers very quickly, in about 5 seconds, but the voltage drops below 440 volts, the slope should be reduced to 12 volts per cycle. More adjusting may be required to get the most desirable compromise between speed and voltage. Three -Phase Sensing Three -phase sensing describes how the excitation control or voltage regulator determines the condition of the alternator output voltage. Early types of regulators sensed the voltage on just one phase of the alternator. Single -phase sensing is not uncommon today as most alternators are designed to produce balanced, equal voltage on all three phases. If the Toads applied to the generator set including no load are equal and balanced, the output voltage on each phase will be nearly equal. TP -5700 9/08 However, in some applications, individual phases may have unequal or unbalanced loads. In these cases, the output voltages will not be equal on each phase. In general, the phase with the greatest load will have the lowest voltage while the phase with the least load will have the highest voltage. This is true regardless of the type of sensing used in the regulator system. A single -phase sensing excitation controller will keep the voltage of the sensed phase at the voltage adjustment value. A three -phase sensing system will average the three phases and hold the average to the adjustment setting. The average is the sum of the voltages of three phases divided by 3. As stated above, three -phase sensing does not eliminate the unequal voltage phenomenon. Three -phase sensing balances the inequality of voltage between the phases to the desired value. In other words, if a system with unbalanced Toads uses a single -phase control feedback, the voltage on the sensed phase would be at the setpoint while the other two phases would vary by their proportional loads. For example, if the sensed phase had rated load while the two other phases were only loaded at half the rated value, those two phases would have higher- than -rated voltage which may be undesirable. If a three -phase sensing feedback were utilized, the phase with rated load would be regulated to a voltage slightly below the rated voltage while the other two phases would be slightly above the rated voltage (but lower than in the previous case). The sum of the three, divided by 3, would be equal to the regulation setpoint. In a single -phase system, line -to -line voltage is held equal to the line -to -line voltage adjust setting. In a three -phase system, the average of the three line -to -line voltage is regulated to the voltage adjust setting. In some cases, it may be desirable to keep one phase at a particular value. Modify the voltage adjust setting higher or lower accordingly for any unique requirements for the particular application. Each of the individual phase voltages is available in Menu 11, Voltage Regulator. Appendix 99 Reactive Droop Reactive droop refers to another compensation technique used in excitation control systems. Reactive droop means that the generator set voltage droops with increasing reactive current. Although this sounds like an undesirable effect, it is quite beneficial in paralleling applications with multiple generator sets. Because the terminals of the generator set are connected to another generator set(s), the voltage at the terminals is not solely determined by either generator set's excitation. Rather, it is determined by the combination of the excitation level, the generated voltage, and the voltage drop across the armature impedance or armature reactance for each generator set. Normally the generated voltage is higher than the voltage at the terminals because the generator set current causes a drop across the armature impedance. In a parallel application, the generated voltage of one generator set may be slightly higher than the generated voltage of another generator set. Differences in potential between the generator sets will cause current to flow into the lower voltage generator set and will also cause the generator sets to share the Toad current disproportionately. Both results are undesirable. By introducing reactive droop, the reactive current can be better predicted and controlled. If the current is measured, the regulator /controller can adjust the excitation up or down accordingly, reducing excitation as more current is supplied or increasing excitation as the reactive current decreases. If all the parallel generator sets incorporate this type of compensation, the reactive current can be shared equally based on the proportional size of the generator sets. For an example, see below. The stability and accuracy of this technique depends on several factors. Most important, the regulation point for each generator set must be equal. That is, each voltage adjust setting must be the equal to the other(s). This is a basic requirement prior to the actual paralleling connection. Also, the effects of the reactive current in each generator set must be compensated for individually, which requires an adjustable droop for each generator set. This adjustment happens to be the reactive droop adjust. The reactive droop adjust is quantified as the droop in operating voltage from the adjusted setting when full rated Toad with 0.8 power factor (PF) is applied. A droop setting of 4% voltage at full rated load is a recommended starting point. If the reactive current is not shared proportionately in each generator set, the respective droops may need adjustment. Adjust those generator sets that have proportionately higher current for more droop and those generator sets with lower reactive current for less droop. If the reactive current is not stable in the system, adjust the droop lower in all generator sets. As implied above, the reactive droop is not usually necessary in stand -alone applications. Therefore, some means of disabling the feature is provided. If the generator set will not be paralleled with other generator sets, the reactive droop feature should be disabled. A reactive droop setting of 0 will also effectively disable the reactive droop feature. It should be noted that reactive droop applies strictly to the reactive current or volt- ampere - reactive (VAR) loading. Primarily, the fueling or speed governing system controls the real current which contributes to watts loading. The gain of the reactive droop function is determined by the voltage droop setting. For most applications, a droop of 3 % -5% of rated voltage at rated load at 0.8 PF is adequate. Prior to actually connecting the generator sets in parallel, test the droop by applying full rated Toad at 0.8 PF. The system is operating correctly if this test shows a reduction in voltage equal to the voltage droop setting. If the available load is less than full load, the correct voltage droop should be proportional to the applied VAR load as a fraction of the rated VAR output for the generator set. For instance, a 480 -volt generator set with a voltage droop setting of 4% should drop 19.2 volts with full rated (0.8 PF) load applied (480 x 0.04) or 9.6 volts with half the rated load applied (480 x 0.04 / 2). When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If there are multiple generator sets in parallel as well, then reactive droop should be ENABLED also, Example Two 100 kilowatt (kW) generator sets are paralleled to provide 150 kW of power at 0.8 PF and wired for a 277 /480 -volt wye system. Total kVA Toad: kVA =kW /PF 187.5 = 150 / 0.8 KVAR load: kVAR = kVA * sin (acos [ PF ] ) 112.5 = 187.5 * 0.6 Line current: I= (VA /3) /VL_N 226 amps = (187500 / 3) / 277 Reactive current: I = (VAR / 3) / VL_N 135 amps = ( 112500 / 3) / 277 100 Appendix TP -5700 9/08 • • Where: acos is arccosine or inverse cosine W is Watt L -N is Tine -to- neutral PF is power factor VA is volt- ampere k is kilo (= 1000 ) Therefore, each generator set in this case should carry 113 amps per phase or half the 226 calculated line amps. The 113 amps includes 67.5 amps of reactive current, half of the calculated reactive current of 135 amps. The reactive droop should be adjusted until each generator set carries equal reactive current. The load sharing control should be adjusted so that real current and /or watts are shared equally as well. If one generator set is larger than the other, it should be adjusted to carry proportionate current. For this example, if a 150 kW generator set is paralleled to a 75 kW generator set, the larger generator set would carry 90 amps reactive (135* 2 / 3) and the other would carry 45 amps reactive (135 * 1 / 3). Adjust the reactive droop based on the ratio of the actual measured currents, not the calculated values. VAR Control VAR control is analogous to the reactive droop function described above. It differs in that it applies to utility paralleling applications. Because the utility represents a nearly infinite bus, the voltage at the load terminals is not controlled at all by the generator set, and it is impossible to compare the ratio of the generator set current to the utility based on its rated output. In this situation, the excitation control changes from voltage feedback to VAR feedback. More specifically, the excitation is controlled to maintain a certain VAR output rather than a voltage output. This is called VAR control and again is used only in utility paralleling applications. The VAR adjust can be set to any value within the generator set's rated capability. Because the VARs cause heating in the armature, any value beyond the generator set's rating could damage the alternator. In most cases, the generator set will be adjusted to generate VAR (lagging PF) but could absorb VARs (leading PF) as well. However, the VAR setting is maintained regardless of the relative PF. If the particular load requires more VARs than the generator set setting, the excess is derived from the utility bus. The term rated VARs is a bit obscure. In essence, it is a value derived from the rated kW of the generator set. For a typical standby rating, the full load of the generator set is defined to have 0.8 PF. This means that the kW load is eight- tenths of the VA load. As described earlier, the PF for a linear load may be calculated as the cosine of the angle between voltage and current. This TP -5700 9/08 relationship is based on the power triangle. Using this power triangle concept, it can be shown that the reactive power for a linear load is equal to the sine of the power angle. Then, using these trigonomic functions, it can be shown that for a PF of 0.8, the VARs are related similarly to the VA by a factor of 0.6. More explicitly, the power angle is equal to the inverse cosine (arccosine) of the PF. For a PF of 0.8, the power angle is 36.9 degrees (0.2 radians). The sine of this angle, sine (36.9 degrees) is 0.6. This is the factor for calculating rated VARs from the rated VA. The ratio of these two factors is 0.75 (0.6 / 0.8), which can be used to calculate rated VARs directly from the rated kW; rated VARs equals rated watts * 0.75. When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If multiple generator sets are in parallel as well, then reactive droop should be ENABLED also. Additionally, note that VAR control should be used only when the generator set is connected in parallel with the utility. Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for VAR /PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the VAR or PF control is not enabled, the control will not switch to VAR or PF control. Because the active state for the digital input is a HI or open connection, the default for the digital input (VAR /PF Mode) is DISABLED (displays ENABLED NO). If the input is ENABLED by the user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s). The proper control method, VAR or PF, must be ENABLED within the regulator's configuration menu. Power Factor Control PF control is much like the VAR control above. PF control is used only when the generator set is paralleled to the utility grid. The difference is that the PF of the generator set current is held constant. The setting for the PF adjust determines the relationship of the current and voltage from the generator set. The PF is a term that defines the ratio of real watts to the volt - ampere (VA) product. For linear loads, a trigonomic relationship can describe the PF. The PF equals the cosine of the angle between the current and voltage. PF is further defined as leading or lagging. That is to say, if the current lags the voltage (i.e., is later in time), the PF is lagging; if the current leads the voltage (i.e., is earlier in time), the PF is leading. Inductive loads have lagging PF while capacitive loads have leading PF. The current in a purely resistive load is in phase with the voltage (not leading or lagging) and the PF is 1.0 (cos. [0] ). Appendix 101 Set the PF adjust according to the requirements of the application. When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If there are multiple generator sets in parallel as well, then reactive droop should be ENABLED also. Additionally, note that PF control should be used only while the generator set is connected in parallel with the utility. Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for VAR /PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the VAR or PF control is not enabled, the control will not switch to VAR or PF control. Because the active state for the digital input is a HI or open connection, the default for the digital input (VAR /PF mode) is DISABLED (displays ENABLED NO). If the input is ENABLED bythe user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s). The proper control method, VAR or PF must be ENABLED within the regulator's configuration menu. Adjustment and Setting Specifications Voltage Adjust The voltage adjust is entered as the rated or otherwise desired line -to -line voltage. The average of the line -to -line voltages is then regulated to the corresponding value as previously described. The setting may be as fine as tenths of volts. The voltage adjust defaults to the rated system voltage whenever the system voltage is changed. The voltage adjust may be set to any value within t10% of the system voltage. The upper limit is ±10% above the system voltage and the lower limit is t10% below the system voltage. If a value beyond these limits is entered, a RANGE ERROR message will be displayed. As a reference, the present voltage adjust setting is displayed as well as the average value of the line -to -line voltages. The individual line -to -line voltages are also displayed on the subsequent menu screens. This allows the user to monitor any individual phase, if desired. 102 Appendix The voltage adjust setting may be changed by means other than the menu including user - defined digital input or remote communications. If voltage adjustment occurs, the new value will be displayed accordingly in the voltage adjust menu. Underfrequency Unload Enable The underfrequency unload enable menu is used to turn the underfrequency unload on or off. A YES entry will turn the feature on and the display will show ENABLED YES. A NO entry will turn the feature off and the display will show ENABLED NO. The underfrequency unload defaults to an enabled (ON) condition. Frequency Setpoint The frequency setpoint is the cut -in point for underfrequency unloading. At any operating frequency below the frequency setpoint, the output voltage will be reduced. The frequency may be entered with resolution to tenths of a Hz. The range of acceptable entries is 30 to 70 Hz. Any entry beyond these limits causes a RANGE ERROR display and the setting will not change. The default value is one cycle -per- second (or two for non -ECM engines) below the normal system frequency. The frequency setpoint changes to the default value if the system frequency changes. A setting of 30 Hz essentially disables the underfrequency unload feature because most engines do not normally drop to speeds this low, even during load applications. Underfrequency Unload Slope The slope determines how much voltage is reduced during an unloading condition. The line -to -line voltage is regulated to a value less than the voltage adjust setting by this amount for every cycle below the frequency setpoint. The voltage may be entered with resolution as fine as one -tenth of one volt. The default value is 2.0 volts per - cycle -per- second. A zero entry for the slope in effect turns the underfrequency unload feature off. Reactive Droop Enable This menu allows the user to enable the reactive droop feature. A YES entry turns the feature on and the display shows ENABLED YES. A NO entry turns the feature off and the display shows ENABLED NO. Reactive droop is intended to be used in a generator set -to- generator set paralleling application. TP -5700 9108 Voltage Droop •The amount of reactive droop is entered here. The droop is entered as a percentage of system voltage when a fully rated load at 0.8 PF is applied. The entry may be made with resolution as fine as one -tenth of one volt. This entry determines how much the voltage will droop when the alternator provides reactive current. The actual amount the voltage changes is equal to the voltage droop setting times the VAR load as a fraction of the rated VARs (at 0.8 PF). If the generator set were providing full rated load (at 0.8 PF), the expected voltage change would equal the voltage droop setting as a percentage of system voltage. A voltage droop setting of zero in effect disables the reactive droop feature. The default value is 4% droop at full rated load at 0.8 PF. • • The present voltage droop setting is displayed for reference. The display may change if this value is changed via remote communication. VAR Control Enable In order for the VAR control function to operate, it must be enabled. Entering YES at this menu will turn the feature on. Because the function is designed to operate while the generator set is in parallel with the utility, VAR control also requires the proper indication that all tying circuit breakers are closed. This is done through the user - programmable digital inputs. Because VAR control cannot be enabled at the same time that PF control is enabled, turning VAR control on (ENABLED) when PF control is enabled turns the PF control off (DISABLED). KVAR Adjust Using the kVAR adjust sets the desired operating value for the generator set's reactive load when the generator set operates in a utility paralleling application. The desired generator set load is entered directly as kVARs. The value entered may be as low as zero or as high as the rated value (rated kW x 0.75). Any entry beyond the rated value will not be accepted, and a RANGE ERROR message will be displayed. The default value for kVAR adjust is zero. Each time the system's rated kW is changed, the kVAR adjust will revert to zero. The displayed kVAR setting may change if the kVAR setting is changed via other inputs. TP -5700 9/08 Generating /Absorbing While operating in the VAR control mode, the reactive load on the generator set may be specified to be out of GENERATING or into ABSORBING the generator set. Specifying the VAR type or direction is done through the GENERATING /ABSORBING menu. Because the normal flow of reactive current is out of the generator set, the default value is GENERATING. If ABSORBING is desired, a NO entry at this menu will change the control mode to ABSORBING. When ABSORBING is selected, another NO entry will revert the control mode back to GENERATING. It is assumed that this mode will not be changed when the generator set is running. An attempt to change the mode while running will return a RANGE ERROR message. The generator set will need to be shut down in order to change this setting. PF Adjust Use the PF adjust to set the desired operating relationship for the generator set's output voltage and current when the generator set is connected in parallel with the utility. The excitation is regulated to maintain a PF equal to the entered value. The value entered may be as low as 0.7 for leading PFs or as low as 0.6 for lagging PFs. Any entries below these limits will cause a RANGE ERROR message to display. The upper limit for PF adjust is 1.0 and the default value is 0.8 lagging. Each time the system's rated kW is changed, the PF adjust will revert to this default value. The PF adjust display setting may change if the PF adjust is changed via other inputs. Lagging /Leading It is possible to select either a leading or lagging PF for utility parallel applications. The selected mode is displayed. A NO entry switches the controller to use the other reference. Because the most common mode of operation will be with a lagging PF, LAGGING is the default value. Because this mode should not be changed while the generator set is running, attempting to change this mode during operation will return a RANGE ERROR message. Always shut down the generator set to change the lagging /leading mode setting. Appendix 103 TP -5700 9108k ® 1993, 2001, 2006, 2007, 2008 by Kohler Co. All rights reserved. KOHLER® POWER SYSTEMS KOHLER CO. Kohler, Wisconsin 53044 Phone 920 - 565 -3381, Fax 920 -459 -1646 For the nearest sales /service outlet in the US and Canada, phone 1- 800 - 544 -2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264 -6422, Fax (65) 6264 -6455 • :. • City of'Tukwila Jim Haggerton, Mayor Department of Community Development Jack Pace, Director MIKE HEALY 625 NW 45 ST SEATTLE WA 98107 RE: Permit No. M10 -130 RPI 3325 S 116 ST TUKW Dear Permit Holder: In reviewing our current records, the above noted permit has not received a final inspection by the City of Tukwila Building Division. Per the International Building Code, International Mechanical Code, Uniform Plumbing Code and/or the National Electric Code, every permit issued by the Building Division under the provisions of these codes shall expire by limitation and become null and void if the building or work authorized by such permit has not begun within 180 days from the issuance date of such permit, or if the building or work authorized by such permit is suspended or abandoned at any time after the work has begun for a period of 180 days. Your permit will expire on 04/09/2012. Based on the above, you are hereby advised to: 1) Call the City of Tukwila Inspection Request Line at 206 - 431 -2451 to schedule for the next or final inspection. Each inspection creates a new 180 day period, provided the inspection shows progress. -or- 2) Submit a written request for permit extension to the Permit Center at least seven (7) days before it is due to expire. Address your extension request to the Building Official and state your reason(s) for the need to extend your permit. The Building Code does allow the Building Official to approve one extension of up to 180 days. If it is determined that your extension request is granted, you will be notified by mail. In the event you do not call for an inspection and/or receive an extension prior to 04/09/2012, your permit will become null and void and any further work on the project will require a new permit and associated fees. Thank you for your cooperation in this matter. Sincerely, Bill Rambo Permit Technician File: Permit File No. M10 -130 6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206 - 431 -3670 • Fax: 206 - 431 -3665 City of Tukwila Jim Haggerton, Mayor Department of Community Development Jack Pace, Director September 28, 2011 Mike Healy Beach Electric PO Box 17462 Seattle, WA 98107 RE: Request for Extension Mechanical Permit No. M10 -130 RPI — 3325 S 116 Street Dear Mr. Healy, This letter is in response to your written request for an extension to Permit Number M10 -130. The Building Official has reviewed your letter and considered your request to extend the above referenced permit. The City of Tukwila Building Division will be extending your permit an additional 180 days from the date of expiration, through April 9, 2012. If you should have any questions, please contact our office at (206) 431 -3670. Sincerely, Je fer Marshall Pe it Technician File: Permit No. M10 -130 W:\Pennit Center\Extension Letters\Permits\2010\M10 -130 Permit Extension.doc 6300 Southcenter Boulevard, Suite #100 o Tukwila, Washington 98188 • Phone: 206 - 431 -3670 • Fax: 206 - 431 -3665 Beath Electric. ELECTRICAL CONTRACTORS To: 13I/ ;Q*+lJ'c2 Attn: C 1' 1L o F Th 1Lev- 04 �c. ii it From: y Re: f er f 0' # M 1 O 625 NW 4514 Street PO Box 17462 Seattle WA 98107 (206) 784 -5551 (206) 784 -6803 Fax Washington Beachel 960)L Date: No. of Pages l (including this page) 1-0 i Fax # `'3 6 6 ; Pc tic This- everit # r Jar ye* fa hive.. co✓iot_Se- i 11-. Per t '4G g7OcIe Oct � a�teed � r Q AJ L e 0040 to G t) OA" d/ G q � it e.,st /1 rnc re 71--o `^• A v a (/ J,• 1 /T`/ oT 9 q.f' l.r. {44e.. bee gJ'`u ioY' ke de") 41 Plm/ ey-1(ivid rrh14 -19 4131-i 'IlYYl6 -h1) ravi Qd fr Sl1 n a'I1Gt!li. k e j Heoi/ e '2.-1) ret c4-4( agNh-exie7sti RECEIVED 09- 21 -'11 16:43 FROM- -610 yt 10 112, Oq Qt1\11, TO- publicworks /dcd P001/007 Mike Healy From: Matthew Andersen [matthewa @rpiprint.comj Sent: Wednesday, September 21, 2011 9:15 AM To: Davis, Jan Cc: Mike Healy; Mark Waiters Subject: RE: 60KW Kohler Genset Thanks Jan, Can 1 get a quote for all of this? I will be heading to our Europe factory early next week and out for 10 days, but I would like to get you a PO and moving forward so when I get back the week of 10/10 we can be ready to get this project completed. Do you have the link of what paperwork I need to fill out for King County? I am guessing there should be no problem getting approval? Mike, The current pad its the correct width, but only 102" long. The new generator is 114" long, so I am guessing we will need to extend that pad 10-15 inches. 1 will give you a call today and we can discuss. I will have McKinstry come out and remove the Natural Gas piping as well. Thanks everyone, Matthew From: Davis, Jan [ mailto :JDAVIS @pacificpowergen.com] Sent: Monday, September 19, 2011 9:17 AM To: Matthew Andersen Subject: RE: 60KW Kohler Genset Hi Matthew, See below answers. Jan From: Matthew Andersen [mailto: matthewa @rpiprint.com] Sent: Monday, September 19, 2011 9:10 AM To: Davis, Jan Cc: Mark Watters Subject: RE: 60KW Kohler Genset Jan, I just want to confirm a few things. First 'I show we paid $19,865.00 for the Natural Gas generator. So if my assumptions are correct we would be looking at the following costs: Purchase of Diesel Generator: $20,300 Credit for NG Generator: $16885.25 Cost from RPI $3414.75 t freight charge to bring the unit back. Can you give me en estimate on the freight cost? $295,00. You will need to provide forklift to mount on truck. ( 111 11 RECEIVED 09- 21 -'11 16 ;43 FROM- TO- publicworks /dcd PO03/007 Also how many gallons of Diesel does the new generator hold for the 24 hour run? 147 gallons 24 -29 hrs at full load. Any additional costs from Pacific Power that 1 need to worry about? You will have to apply for a fuel tank permit with King County. Thanks, Matthew From: Davis, Jan [ mailto :JDAVIS @pacIfIcpowergen.com] Sent: Friday, September 16, 2011 1:45 PM To: Matthew Andersen Subject: RE: 60KW Kohler Genset Matthew, The LP Vapor requires 5 -11 inches WC. Natural Gas 7-11 inches WC. Maybe that will help on the LP conversion. The 60KW diesel unit is in a sound enclosure, 24 hour UL142 double wall sub -base tank, block heater, 120/208V, Control panel, starting battery, battery charger, $20,300.00 114 "L x 41 "W We would be looking at a 15% restocking fee and any frt charges to bring the unit back to our warehouse. All electrical disconnecting by your licensed contractor. From: Matthew Andersen (mailto:matthewa@rpiprint.com) Sent: Friday, September 16, 2011 10:57 AM To: Davis, Jan Subject: RE: 60KW Kohler Genset 1 am exploring the costing for an LP solution, but it would help me to compare the diesel option as well. Can you work up a quote for me to swap this out? Also can you confirm that the pad size, etc. is the same? Thank you for your help, Matthew Matthew Andersen j IT Director RPI 3326 S. 1 16th St. Suite 161, Seattle, WA 96168 01206.905.3260 j M: 425.766.7636 F: 206.443,4322 I E: matthewa(cD_rpjrint.com www.rpiprint.com -- 'Unleashing Creative Expression" From: Davis, Jan [ mailto :JDAVIS @pacificpowergen.com] Sent: Friday, September 16, 2011 10:50 AM To: Matthew Andersen Subject: RE: 60KW Kohler Genset f1 F' 1 MA11 RECEIVED 09- 21 -'11 16:43 FROM- TO- publicworks /dcd PO04/007 Hi Matthew, We would take back your unit with a restocking fee and sell you a new diesel unit. I do have a 60KW diesel in stock, sound enclosure on a 24 hour a142 listed tank, Jan From: Matthew Andersen [maitto:matthewa @rpiprint.com] Sent: Friday, September 16, 2011 10:46 AM To: Davis, Jan Subject: RE: 60KW Kohler Genset Jan, As we are exploring all our options. What would it take to make the Kohler system we have able to run Diesel? I am assuming it is pretty much a generator swap? Thanks, From: Davis, Jan [ mailto :JDAVIS @pacificpowergen.com] Sent: Wednesday, September 14, 2011 4:04 PM To: Matthew Andersen Subject: RE: 60KW Kohler Genset Sure - Call me anytime. Jan Jan Davis Pacific Power Generation Kohler Power System Sales Ph 253 - 395 -9077 Fax 253- 3954145 Cell 253 - 293.4336 Email: jdavisapacificooweroen.com From: Matthew Andersen [mailto:matthewa @rpiprint.com] Sent: Wednesday, September 14, 2011 4:03 PM To: Davis, Jan Cc: Hunting, Nan Subject: RE: 60KW Kohler Genset Interesting. 1 got this one. Can we talk tomorrow sometime? Matthew Andersen l IT Director i RPi 3325 S. 116th St, Suite 161, Seattle, WA 98168 0: 206.905.3260 I M: 425.766.7636 F: 206.443.4322 ( E: matthewaeroiprint.com www.rpiprint.com - `Unteashtng Creative Expression" From: Davis, Jan [ mailto :JDAVIS @pacificpowergen.com] RECEIVED 09- 21 -'11 16 :43 FROM- TO- publicworks /dcd PO05/007 Sent: Wednesday, September 14, 2011 4:03 PM To: Matthew Andersen Cc: Hunting, Nan Subject: RE: 60KW Kohler Genset Matthew — Nan Hunting has been trying to email you but keeps coming back. I copied her on this emaii so she can forward to you. Jan From: Matthew Andersen [mailto:matthewa @rpiprint.com] Sent: Wednesday, September 14, 2011 11:48 AM To: Davis, Jan Subject: RE: 60KW Kohler Genset Jan, haven't heard anything back on this. 1 have received additional info from PSE, and could use some expertise from your team on our generator. 1 have included the info below. Would there be somebody ! could talk to about the 6 "WC vs the 7 "WC? Thanks, Matthew FROM PSE: If 7 "WC is the requirement for the generator, our 6 "WC deliver might not be sufficient (depending on fuel line size, etc.) and wanted you to verify that 6 "WC will work. Here are some estimated costs: $1892 for a 6" WC A1000 meter added onto the current assembly (includes bollards in the cost). This would be a firm cost and would not have any changes. $17,366 for a new 41000 meter set at 2 #, this includes the underground work for changing the riser and bollards. Since there is excavation involved, the actual cost would be presented after the job is constructed so it could be more or less than what you see right now. From: Davis, Jan [ mailto :JDAVIS @pacificpowergen,com] Sent: Tuesday, September 06, 2011 10:31 AM To: Matthew Andersen Subject: RE: 60KW Kohler Genset Hi Matthew, Sorry to hear about the problem with the cost of not getting natural gas to your genset. I'm turning this over to our service dept. to quote on the parts and labor to convert this for you. You will hear directly back from them. Attached is the spec sheet that shows the fuel consumption for LP vapor. Jan Davis r / 1 ThA1 1 RECEIVED 09 -21 -' 1l 16:43 FROM- TO- publicworks /dcd P006/007 Pacific Power Gene atlon Kohler Power System Sales Ph 253 -395 -9077 Fax 253 -395 -4145 Cell 253- 293 -4336 Email: jdavisjpacificpowergen.com From Matthew Andersen [mailto:matthewa @rpiprint.com] Sent: Tuesday, September 06, 2011 10:13 AM To: Davis, Jan Cc: Mike Healy Subject: RE: 60KW Kohler Genset Jan, We have been working with PSE and have not come up with an affordable resolution to get as installed for this unit yet. I am hoping you can put me in touch with someone in your office that may be able to help let me know what our options around LP would be? need to know how much to convert this unit to LP, as well as what the LP burn rate would be so we could size a tank appropriately, Not sure we are going to go this route, but the current quote to get enough natural gas to this unit Is more than we paid for the generator. Thanks, Matthew Matthew Andersen I IT Director I RPI 3325 S. 116th St. Suite 161. Seattle, WA 98168 0: 206.905.3260 I M: 425.766.7636 F: 206.443.4322 I E: ma tthewaArpiprintcom www.rpiprint.com — '`Unleashing Creative Expression" From: Davis, Jan [ mailto :JDAVIS ©pacificpowergen.com] Sent: Tuesday, September 14, 2010 11:49 AM To: Matthew Andersen Cc: Mike Healy; Wyatt, Ruth Subject 60KW Kohler Genset Hi, Just a note to let you know that I checked on the shipping status of your generator set. Kohler shows ship date of 9/21/10. Allow 6 -7 days transit time. I'll continue to keep you posted. Thanks Jan Davis Pacific Power Generation Kohler Power System Sales Pn 253- 395 -9077 Fax 253 - 395 -4145 RECEIVED 09- 21 -'11 16:43 FROM- TO- publicworks /dcd P007/007 09 -01 -2011 Gity of Tukwila Jim Haggerton, Mayor Department of Community Development Jack Pace, Director MIKE HEALY 625 NW 45 ST SEATTLE WA 98107 RE: Permit No. M10 -130 3325 S 116 ST TUKW Dear Permit Holder: In reviewing our current records, the above noted permit has not received a final inspection by the City of Tukwila Building Division. Per the International Building Code, International Mechanical Code, Uniform Plumbing Code and/or the National Electric Code, every permit issued by the Building Division under the provisions of these codes shall expire by limitation and become null and void if the building or work authorized by such permit has not begun within 180 days from the issuance date of such permit, or if the building or work authorized by such permit is suspended or abandoned at any time after the work has begun for a period of 180 days. Your permit will expire on 10/12/2011. Based on the above, you are hereby advised to: 1) Call the City of Tukwila Inspection Request Line at 206 - 431 -2451 to schedule for the next or final inspection. Each inspection creates a new 180 day period, , provided the inspection shows progress. -or- 2) Submit a written request for permit extension to the Permit Center at least seven (7) days before it is due to expire. Address your extension request to the Building Official and state your reason(s) for the need to extend your permit. The Building Code does allow the Building Official to approve one extension of up to 180 days. If it is determined that your extension request is granted, you will be notified by mail. In the event you do not call for an inspection and/or receive an extension prior to 10/12/2011, your permit will become null and void and any further work on the project will require a new permit and associated fees. Thank you for your cooperation in this matter. Sincerely, "et_ Bill Rambo Permit Technician File: Permit File No. M10 -130 6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206 - 431 -3670 • Fax: 206 - 431 -3665 03 -02 -2011 City of Tukwila Jim Haggerton, Mayor Department of Community Development Jack Pace, Director MIKE HEALY 625 NW 45 ST SEATTLE WA 98107 RE: Permit No. M10 -130 3325 S 116 ST TUKW Dear Permit Holder: In reviewing our current records, the above noted permit has not received a final inspection by the City of Tukwila Building Division. Per the International Building Code, International Mechanical Code, Uniform Plumbing Code and /or the National Electric Code, every permit issued by the Building Division under the provisions of these codes shall expire by limitation and become null and void if the building or work authorized by such permit has not begun within 180 days from the issuance date of such permit, or if the building or work authorized by such permit is suspended or abandoned at any time after the work has begun for a period of 180 days. Your permit will expire on 04/12/2011. Based on the above, you are hereby advised to: 1) Call the City of Tukwila Inspection Request Line at 206 - 431 -2451 to schedule for the next or final inspection. Each inspection creates a new 180 day period, , provided the inspection shows progress. -or- 2) Submit a written request for permit extension to the Permit Center at least seven (7) days before it is due to expire. Address your extension request to the Building Official and state your reason(s) for the need to extend your permit. The Building Code does allow the Building Official to approve one extension of up to 180 days. If it is determined that your extension request is granted, you will be notified by mail. In the event you do not call for an inspection and/or receive an extension prior to 04/12/2011, your permit will become null and void and any further work on the project will require a new permit and associated fees. Thank you for your cooperation in this matter. Sincerely, Bill Rambo Permit Technician File: Permit File No. M10 -130 6300 Southcenter Boulevard, Suite #100 • Tukwila, Washington 98188 • Phone: 206 - 431 -3670 • Fax: 206 - 431 -3665 • • PER k � PY PLAN REVIEW /R UTING SLIP ACTIVITY NUMBER: M10 -130 DATE: 09 -24 -10 PROJECT NAME: RPI SITE ADDRESS: 3325 S 116 ST — SUITE 113 X Original Plan Submittal Response to Incomplete Letter # Response to Correction Letter # Revision # After Permit Issued DEPARTMENTS: �� di l� .Obi ul ng Division Il� Public Works WA A We 10-2-f-( D re Prevention Structural Planning Division ❑ Permit Coordinator DETERMINATION OF COMPLETENESS: (Tues., Thurs.) Complete lg] Incomplete n DUE DATE: 09-28 -10 Not Applicable Comments: Permit Center Use Only INCOMPLETE LETTER MAILED: LETTER OF COMPLETENESS MAILED: Departments determined incomplete: Bldg ❑ Fire ❑ Ping ❑ PW ❑ Staff Initials: TUES/THURS ROUTING: Please Route TX Structural Review Required REVIEWER'S INITIALS: No further Review Required DATE: APPROVALS OR CORRECTIONS: Approved ❑ Approved with Conditions Not Approved (attach comments) ❑ Notation: REVIEWER'S INITIALS: DATE: DUE DATE: 10 -26 -10 Permit Center Use Only CORRECTION LETTER MAILED: Departments issued corrections: Bldg ❑ Fire ❑ Ping ❑ PW ❑ Staff Initials: Documents/routing slip.doc 2 -28 -02 Contractors or Tradespeople Pf ter Friendly Page • Electrical Contractor A business licensed by L&I to contract electrical work within the scope of its specialty. Electrical Contractors must maintain a surety bond or assignment of savings account. They also must have a designated Electrical Administrator or Master Electrician who is a member of the firm or a full -time supervisory employee. Business and Licensing Information Name Phone Address Suite /Apt. City State Zip County Business Type Parent Company BEACH ELECTRIC LLC UBI No. 2067845551 Status 625 Nw 45Th St License No. License Type Seattle Effective Date WA Expiration Date 98107 Suspend Date King Specialty 1 Limited Liability Company Specialty 2 602372562 Active BEACHEL960JL Electrical Contractor 4/13/2004 4/13/2012 General Unused Master Electrician INFORMATION License HEALYM`971C1 Name HEALY, MICHAEL Status Active Business Owner Information Name Role Effective Date Expiration Date VAN DYKE, VIRGINIA Partner /Member 04/13/2004 Bond Amount HEALY, MIKE Partner /Member 04/13/2004 2066291 Bond Information Page 1 of 1 Bond Bond Company Name Bond Account Number Effective Date Expiration Date Cancel Date Impaired Date Bond Amount Received Date 3 FEDERATED MUTUAL INS CO 2066291 04/13/2010 Until Cancelled $4,000.00 04/09/2010 2 DEVELOPERS SURETY ft INDEM CO 790926C 02/04/2008 Until Cancelled $4,000.00 01/30/2008 1 RLI INS CO SRS1017420 03/11/2004 Until Cancelled 04/30/2008 $4,000.0004/13/2004 Assignment of Savings Information No records found for the previous 6 year period Insurance Information No records found for the previous 6 year period Summons /Complaint Information Summons and Complaints are not filed with the department for this contractor type Warrant Information Warrants are not filed with the department for this contractor type Infractions /Citations Information Infraction / Citation Date RCW Code Type Status Violation Amount E46886 12/2/2004 19.28.101 RCW ELECTRICAL CITATION Satisfied $250.00 https: / /fortress.wa.gov /lni/bbip /Print. aspx 10/11/2010 Legal Description: BARRIER FREE DESIGN TAX PARCEL #: 0923049068 LOT 1 OF CITY OF TUKWILA SHORT PLAT NO 90 -2 —SS RECORDING NO 9003121482 SD SHORT PLAT DAF — POR OF GOV LOT 3 & OF SE 1/4 OF NE 1/4 OF SEC 09 -23 -04 TGW POR OF GOV LOT 6 & OF SW 1/4 OF NW 1/4 OF SECTION 10 -23 -04 — BAAP 70 FT RGT OF ENGR STA H 556 +57.3 BEING A PT ON NELY MGN SHEET 1 OF 7 FOR R/W SR 99 S 118TH ST TO JUNCTION SSH NO 1 —K APPROVED JULY 23, 1957 SD PT BEING PT OF TANGENCY OF CURVE THRU POINT BEARING N 42 -02 -03 E 748.51 FT TH SELY ALG SD MGN & SAID CURVE THRU C/A OF 04 -26 -56 ARC DISTANCE OF 58.12 FT TH N 41 -57 -30 E 499.81 FT TH N 15 -27 -21 E 75.56 FT TO POB TH S 74 -32 -39 E 212.89 FT TH S 78 -39 -54 E '128.28 FT TH S 81 -20 -44 E 447.24 FT TAP OF .CURVE CONCAVE TO N TH ELY ALG SD CURVE RAD OF 170 FT THRU C/A OF 15 -51 -28 ARC DIST OF 47.05 FT TH N 82 -47 -48 E 101.13 FT TO WLY MGN OF POR OF SECTION 9 CONDEMNED IN SUPERIOR COURT CAUSE NO 646697 TH S 07 -08 -23 E 544.81 FT ALONG WESTERLY MARGIN TO A LN 60 FT N OF & PLW ENGR B— LINE AS SHOWN ON SHEET 1 OF 7 FOR R/W SR 99 SOUTH 118TH ST TO JUNCTION SSH 1 —K APPROVED JULY 23, 1957 TH N 88 -10 -42 W 630.87 FT TAP 60 FT RGT OF ENGR STA B 548 +00 SAID R/W PLANS TH N 79 -41 -19 W 359.21 FT TAP 70 FT RGT OF ENGR STA H 551 +64.4 SD PT ALSO BEING PT OF CUVE CONCAVE TO NORTH RAD PT BEARING N 10 -18 -41 E 748.51 FT TH NWLY ALG SD CURVE THRU C/A OF 30 -03 -04 ARC DISTANCE OF 392.59 FT TH N 41 -57 -30 E 499.81 FT TH N 15 -27 -21 E 75.56 FT TO POB Vicinity Map: PROJECT LOCATION 3325 S 116th Street Suite 113 Tukwila, WA 98168 EP,RATE PERMIT REQUIRED FOR: 0 Mechanical Electrical Plumbing Gas Piping City of Tukwila 1 F 6 I1' G ENViSi0N REVISIONS No changes shall be made to the scope of work without prior approval of Tukwila Building Division. NOTE: Revis!ons will require a new plan submittal and may in::!ude additional plan review fees. iEVi : JJLU FOR CODE COMPLIANCE City of T ,IIa BUILDING Dmsfolg EX APR 0 9 2012 FILE{ pry' Permit No. ,&k I D'I�D Plan review approval is subject to errors and omissions. 11:9rovat of construction documents does not authorize violation of any adopted code or ordinance. Rec.:Apt approved Field Cop ^d conditions is acknowiedvd: By Date: City Of Tukwila BUILDING DIVISjc» ,4 BEach kEIectricLLC ELECTRICAL CONTRACTORS 625 NW 45th St PO Box 17462 Seattle, WA 98107 LIC. #BEACHEL960JL Mike Healy 206- 789 -8848 Office 206 -484 -1244 Cell 206 -784 -6803 Fax mike@beachelectric.us Keyplan AREA OF WORK Sheet Title MIO (30 RECEIVED SEP 24 2010 PERMIT CENTER E CONTRACTORS 625 NW 45th St PO Box 17462 Seattle, WA 98107 L1C, #BEACHEL960J1. e Healy 206 - 789 -8848 Office 206 -484 -1244 Cell, 206 - 784-6803 Fax mike @beachelectric.us t5p. o.e. 24'-€ 19.05 LISI 127 (54 1(”.6 [4.01 SET. ONLY NO TANK. •12117 P4.751 230-275 RODE (.75) 1788 254 tt04: 120.1 .[4.751 0471051 131) 12.0) 35) AFLX OF 32 HD/VP le120X25W5D A-ee, estvAleiterA- 0-0/17/ 4/ •64A1 4., 40" tilz. P/9-A 4..4C PAD *ANCHOR PLATE A — ANCHOR BRAND S — QTY C — ANCHOR MODEL D — SHANK VA. • E - °moues F —IAN ANCHOR SPACING: SEE DETAIL A • TANK OR SKID ANCHOR SOU ANCHOR NUT G MIN EDGE DISTANCE * G MIN EDGE DISTANCE ANCHOR PLAIE. 'CONCRETE , REVIEWED FOR CODE COMPLIANCE A.PmWRIFTP NoTZ-7-% 5-PL---Tc.//9-Z Z&Wai4e-5-13 OCT 1 City of Tukwila 1 BUILDING DIVISION EX DETAIL A NOIT.:: 1) SPECIAL INSPECTION PER IBC SECTION 1704 IS REQUIRED ON ALT. INSTALIATIONS. •ALL ANCHORS MUST 8E nisTAwso TO MEET COMPLIANCE I 2) NG OTHER ANCHORS ARE ALLOWED WHIN MINIMA) 1 SPACING DISTANCE WITHOUT ADVANCED APPROVAL OF THE STRUCTURAL PROJECT ENGINEER OF RECORD. 3) *SEE NOTES ON SHEET 4 4) UNITED STRUCTURAL CONNECTORS. 18 APR 0 g 2012 METRIC CAD FILE •DIMENSIONS f ARE INCH EOUNALENT I A w MN CONCRETE THICKNESS 60' KO= SNOW SETSMIC.:01 MKS VOLVO JOHN MAE :AND 'OM 2 M(04--613 ADV-4595 • • 1 RECEIVED SEP 2 4 2010 PERMIT CENTER SEISMIC INSTALLATION REOLIIREMENTS: The following ore requirements for seismic installation: 1, The design of post—installed anchors • in concrete used for the component anchorage is pre—qualified for seismic applications in accordance with VI 3552 and documented in a report by a reputable testing agency. (ex. The Evoluation Service Report issued by the International code Council) 2. Anchors must be installed to on embedment depth as recommended in the pre—qualification test report as defined in Note 1. 3. Anchors must be installed in Mirliffliall 4000 psi compressive strength normal weight concrete. Concrete oggregatfs must comply with ASTM C33. Instollation in structural lightweight concrete is not permitted unless otherwise approved by the structural engineer of • record, 4. Anchors must be installed to the torque specification os recommended by the onchor manufacturer to obtain maximum loading 5, Anchors must be installed in the toes:Mons specified the Kohler ADV dimension print 6. Anchor bolt design loads or specific anchors are specified on seismic Kohler ADV. 7. Anchor plates from Kohler must be instolled ot each anchor locotion between anchor head and equipment to tension load distribution. EL Concrete floor slob ond concrete housekeeping pads must be designed and rebar reinforced for seismic applications in accordance with AC 318. 9. All housekeeping pod thickness must be designed in accordance with pre—qualification test report os defined in Note 1 or minimum of 1,5x the anchor embedment depth, whichever is largest . 10. All housekeeping pods must be doweled or cost into the building structural floor slab and designed for seismic application per ACf 318 and as approved by the structural engineer of record 11. Wall mounted equipment must be installed to a rebar reinforced structural concrete wail that is seismically designed and approwd by the engineer of record to resist the added seismic loads from the components being anchored to the wall. 12. Floor mounted equipment (with or without housekeeping pod) must be installed to a rebar reinforced structural concrete floor that is seismically designed and approved by the engineer of record to resist the added seismic loads from components being anchored to the floor. 13. When • installing to a floor or Wail, rebar Interference must be considered. 14. Attoching seismic certified equipment to any floor or wall other than those constructed of structural concrete and designed to accept the seismic loads form sold equipment is not permitted by this specification and beyond the scope of this certificotion. 18, Attaching seismic certified equipment to any concrete block walls or cinder block walls is not permitted by this specificotion and beyond the scope of this certification. 17. for instollotions upon rooftop, steel dunnage shall be coordinated with the Structural Engineer of Record. 113. Installation upon only rooftop curb shall be coordinated with the curb manufacturer and the Structural Engineer of Record. Any curb or concrete pod that supports the RTU ,unit is beyond the scope of this certification. 19. Anchor locations, size, type and load requirements are specified on the instollotion drawing. Mounting requirements details such as brand. type, embedment depth, edge spacing, anchor spacing, concrete strength, wall bracing, and special inspection must be outlined and approved by the project Structural Engineer of Record to withstand the seismic anchor loads as defined on the seismic installotkin drawing. The installiN contractor is responsible for the proper installation of all anchors and mounting hardware, absenting the mounting requirement details outlined by the Engineer of Record. Contact Kohler if a detail Seismic Installation Colculation Package is required. 20. Electrical wiring, piping, duct and other connections to the equipment is the responsibility of the installing contractor. it is necessory that "these remain in tact, functional and do not inhibit the functionality of the generator set after o seismic event. Adequate slack shall be allowed cable and piping to allow for motions of set during a seismic event. *21. Concrete pad dimensioris are minimum values to satisfy only the anchor bolt requirements. The pad must be designed by the project structurol engineer of record. *22 Anchor bolt and concrete recommendations are for the moxirnum seismic design levels shown. 0 the specific application hos a lower level, thinner concrete or alternate anchors may be acceptable. Consult Kohler. se MET t [05410/ REVIEwL) FOR CODE COMPLIANCE • pponvFn . OCT City of Tukwila BUILDINO flfn EX APR 0 92012 METRIC CAD FILE DIMENSIONS IN ARE Mt MIVALENT RECEIVED SEP 24 2010 PERMIT CENTER MUST RAIN CAP 0 xP .n 0 f NOTE: IF 18C CERTIFICATION IS REQUIRED, SEE SEISMIC ADti FOR INSTALLATION I NSTRUCT I OI1S nmeMilra. .11 25kW 4P4f404 MAW 4PSl4o 30kW 4P71407 4OkW 4P51405 OENSET M: `EW En 1111114 . EACLOSIME STEEL WEATHER 855: tt STEEL SOUND 860 .K .. ALUMINUM : SOUND 760 ( '. STEM WEATHER 878 K • . STEEL SOUND :883: Kg. ALUMINUM SOUND- 791.;K STEEL :WEATHER STEEL SOUi!D : :... ALUMINUM SQ BD 91:9 924 K :. L2037 1551.244 832 K ...t 1834 LBS1 • .11885. LDS 1.$96. LEST •[1693 LBS1. _ t52.:K9..E3 - ` ST C.t.836 LOS] • 239 K :.15271551 1.194'7• L0S1 1.1744. LOST. 3 MiECLOIRAIE ONLY MODEL 2 aeRmaT mow ENCLOSURE Y 244 52 14M E 2026 LOS] 152. P €.335 ;LBSI 239 STEEL: Y€ATHER 936 .K • .1.2064. L6$]. STEEL SOUND 40kW 407 418kW 4P7 941 :K = . E 2075 .LSO ALUUI NEM SOUND .i 849 K • E 1872 LES]: STEEL WEATHER 977 K9_12154 LOST STEEL SOUND 982 Kg. 12.1.65.. LBS.I' A€.Bt4I NUt1 SOONti 890 .K E 0962 .LOS].: 1E K 152 (52.7 E $38 LBSI LBSI E335 e1S 1 239 Ka .E527t:BSI STEEL WEATHER ` 1099 ...K t :2423 : LBS 1 g STEEL 'SOt ND: .. 1104.K ; t2434:: LOS:: STEELT1►ER. '4S7/4V7 4P10!4 STEEL SO/11.1I1... 1:200 K .'[2646: L$S :l I:205 ..K • [2657. t.13S1 #L C 11C S SOUND 11 13 K. •1.2454 LOS • STEEL WEATHER STEEL. SOUND 230.H E527 t.BSI .244 K •t 53B LEIS ] 239 K .. [ 527 .L1S 1 244 :K • 1638 LEIS 1. 152 K 335 • • LOS .1. 1142 Ka. 12.518. LBS)`.239 .K 1527 LEIS/ 1 147 K ALUM( NUM SOUND €055 K ;STEEL :WEATHER 4S9l4V9 `AE.UMINBI.. SOUND 12529 .LSS3.244 K. 12326. LBS 11 152 .K 1:33S LDS) 1538 18S 1 2.53�K3 C 2762 ;�I'"6S ] 239 K .[.527! . LBS 1 ,STEEL _SOUND 1258 Kft 12713 .tBS3 244 #t 1538 LESS] i.t69 :K 12571 1857 152...K K. 1335 L8S 244 Kg [538. LOS] 4SkW 4PS/408 STEEL WEATHER 997..iti 12198 LDS :I /52 • .K _ ':E 335 1:SS1 239. Kg ES27 LBSI STEEL ''SOUND 1002 Ki 12209.LBS 415kW 4P10 /4010 ALUM NM SOUND STEEL WEATHER STEEL .SODUND. 910..:.x.` 1200.6 LBS 1040 K 12293 LBS:: 244: K < [ 538 LOS] 152 K [335 LBS1 234 K E52T LSS] 1045.1 1.2304 LB51 244 >t .. 1538 t.BS 1 AL U141 NUM SOUND •:953 Kt 12101 LBS:] SO 4P7/401 STEEL WEATHER STEEL SOUND 1079 K. 12379 LBS I ALUMINUM M :.SOUND 1084 K0.12390.. LSS I 992' K t 2187.1 BS•I 52. K q . (3» LBS 14 239 Kg .(527 LBS3 244 K9 [538 UM 1 4Pt0i1401t3 078 . 4x1 11.42 Kt :12518 LOST i 4 K [2529 LISS: 1055 If (2326 152. K (33S :1651 239 Kg 152T: CBS] 244 K t538•LBS L BS 1 152 K • t335 LBS ] 1 02.62 ALTERNA ACCESS PANEL .4 4X 1617.5 .691 40.94 KW MA w 2009: EMISSIONS : N D ..B : RECONNECrrABLE.IPH . AND . 4300V ALTERNATORS 4 A PiRED APR 092012 REVIEWED FOR CODE COMPLIANCE C 2] City of Tukwila BUILDING DIVISION DATE 12 -g -09 t -3 -09 s .6 -1 -Q9 1 -7 -38 2 -6 -fo . ] ARE I1NCR EQUIVALENTS 44 Ca ITt ass. sa i4tT loot. tit REVIN#01 Imo. $Y a »lip � Zlis of... 1�" !.>Ei, d: i Yi'11ES STSTIrS...VOWEL 1, WA/ O.S.A. tips vii . - .. iislii! l�PESAV AO SU ON U mu) seem. s scsitgAss:strtit swap ea P117 4 3A' fZ EC ;ible :t'iA 17lllEttQ: Ng iti """°: 911E Blume* 166913] SR1D .1aIE pl D!TE11.:8 (C•3 D-t) al ART REVISED TO REFLECT. t`v 9: E$,S310113 ROODS t8T84D1 ` t8- 43.15419:: WAS. 1384:: Lai- $1.:383 SAS - 397..1872723 (C -33 EL :SD•4P8.. i ES O TABLE (888651 O. 0.5.23 .SERSET.8Ei8ATS:1191143EIt 1641021 Mbo z us ?LW PLO, *Ja 130 ADV:1657 A RECEIVED SEP 2 4 2010 PERMITCENTER d31N3O1IWJ3d. °M t ? d3S a3AI23 6 I 5 SUGGE$TED BATTERY NEATER f CHARGER CORM I T . LOCATION I OPT !ONAL3 .SU ESTED BLOCK HEATER CONDIt I T LOCATION I OP7 I OVAL 3 CONDO t T : ENTRY. AREA FOR '.GENERATOR- LOAD. LEADS -IBOT'41' EI+LTRY 3 .CIRCUIT .. BREAKER :OPTION, REMOTE CONNECETI.ON:.TO' TRANSFER .SWITCH AND REMOTE ANNUWC I ATOR . SI TESTED .LOCATION FOR FUEL INLET FLEXIBLE FUEL LINE; 1 IN PPT (RALE) REVIEWEi FOR CODE COMPLIANCE er 1 Zi J - City of Tukwila BUILDING DlVISIflij BAT'S E R T RACK LOCAT I O 2.98 III -11 MODEL ALTERNATOR WEIGHT tWE-T 50 4PT 835 KG 1i 1841 LBSI 50 ' 4P$. . SS5 KO 11881 L BS 1 S0. 4A.I G 89$:' KG $$a LEIS I. 4P8.:.. 855: KG.:. t 18B 1:.I:BS I S0 4010 . B98 I(8....L ISSIt L�#Si . 64 4Y9 1009 RG I ifx4:. LOS T :1 As ,_ — Aar � A :� AIM —m��— - �� �..r � • VMS _ MEM 0 �_� � . ism • ._ - a MOM XIMX_XER m !a�� • M W VOW — ._.ice , sm�,amn . .',. we� � � • a'maw ® rte l a� mra waA'mm lam MN 'WNW 'eawa'�r ® M SEW am a—[ mtiw Voss mom r-u.- Ma.r ,� m.a logn • tiurrc MI O MB Va -� n-w �s mow MEM NM MOW drusissm moms Ammil f FUEL INLET DALE as : OS E . ems: tit raw srOR:K1t atria ' �fyEL 8,Y' - IE N IE' WI tart ;.fl., .:... E$ 4 -8 -4 !i' VIEWS C.,;'. 50 MODEL, .4PTt4P8l4Q1O 00. MODEL 43Z /4PB/4�Q:0. RECOHKECTABLE b 600V ALTERNATOR 5.0 8 5.7 LITER GM x009. EMISSIONS XEIF. [pi tt -Zt MISEV WE HATS. 11P0 iTE0 18110717 !► Eiy: E. 0. :.111 't ;. tC -21 .'SOtAPt 1t E1i O:Cl11NlT''E8881�3j • NOTES: 1. IF IBC CERTIFICATION 13 APPLICABLE OR .REWIRED SEE SEISMC ADV FOR IHSTALLAT1ON INSTRUCTIONS. x. 0114ENSIORS IfR E l ARE ENGLISH STANDARD EON.IYALENTS. { ..' Leal. silvan new Man 1�f tt:, NM in CO 11.1M1F1401k& �+bRER 5!SS.E $1,... !O�ti.ER* * 630s. It S.R. 6�1N1 i 0* ertii EP3.'IMC {fR CO CM ling Waif flb�. Ih .Rl� R�6 DT 3 1 . 111111111111111111 MODEL ALTERNATOR WEIGHT tWE-T 50 4PT 835 KG 1i 1841 LBSI 50 ' 4P$. . SS5 KO 11881 L BS 1 S0. 4A.I G 89$:' KG $$a LEIS I. 4P8.:.. 855: KG.:. t 18B 1:.I:BS I S0 4010 . B98 I(8....L ISSIt L�#Si . 64 4Y9 1009 RG I ifx4:. LOS T :1 As ,_ — Aar � A :� AIM —m��— - �� �..r � • VMS _ MEM 0 �_� � . ism • ._ - a MOM XIMX_XER m !a�� • M W VOW — ._.ice , sm�,amn . .',. we� � � • a'maw ® rte l a� mra waA'mm lam MN 'WNW 'eawa'�r ® M SEW am a—[ mtiw Voss mom r-u.- Ma.r ,� m.a logn • tiurrc MI O MB Va -� n-w �s mow MEM NM MOW drusissm moms Ammil f FUEL INLET DALE as : OS E . ems: tit raw srOR:K1t atria ' �fyEL 8,Y' - IE N IE' WI tart ;.fl., .:... E$ 4 -8 -4 !i' VIEWS C.,;'. 50 MODEL, .4PTt4P8l4Q1O 00. MODEL 43Z /4PB/4�Q:0. RECOHKECTABLE b 600V ALTERNATOR 5.0 8 5.7 LITER GM x009. EMISSIONS XEIF. [pi tt -Zt MISEV WE HATS. 11P0 iTE0 18110717 !► Eiy: E. 0. :.111 't ;. tC -21 .'SOtAPt 1t E1i O:Cl11NlT''E8881�3j • NOTES: 1. IF IBC CERTIFICATION 13 APPLICABLE OR .REWIRED SEE SEISMC ADV FOR IHSTALLAT1ON INSTRUCTIONS. x. 0114ENSIORS IfR E l ARE ENGLISH STANDARD EON.IYALENTS. { ..' Leal. silvan new Man 1�f tt:, NM in CO 11.1M1F1401k& �+bRER 5!SS.E $1,... !O�ti.ER* * 630s. It S.R. 6�1N1 i 0* ertii EP3.'IMC {fR CO CM ling Waif flb�. Ih .Rl� R�6 DT 3 1 6 5 SUGGESTED • BATTERY NEATER ! CHARGER CONDU.I T 1.0C AT ION (OPT IONAL4 SUGGESTED BLOCK HEATER CONDUIT LOCAT ION to IONAL3 CONDU I T ENTRY AREA FOR •GENERATOR LOAD LEADS (BOTTOM ENTRY ) C.I RCU I.T .. BREAKER :OPTION REMOTE CONNECTION TO TRANSFER .SWITCH AND REMOTE ANNUNC I ATOR. SUGGESTED LOCAT ION FOR FUEL 1N1-ET FLEXIBLE FUEL LINE: I III MIT (MALE ) BATTERY 1t4C* LOCATIO 5 [ 4 zp8 iiti.71 IOCAMON REVIEK/ 0 FOR-- -- ODE COMPLIANCE A p@r fl l/ eij 1 - 2010 City o of Tukwila BUILDING DIVISION MODEL ALTERNATOR WEIGHT tWET) 50 835 ' KG : 11841 ` LOS) 50 • 4P8 855 :' KG. 1188 I LEIS 1 50. 40.10 80$:.: KG i 1 980 LOS 1. Go `: .:.. 4P8.:. : " 85 S. KG 1 1881... LBS 1 • I( L. 1 60 4010 . 898.KG. 1:1980 LOST. 60 1009 KG 12224 LEIS) FUEL INLET I d NPT (MALE (NAT :..GAS OR I.P. GAS) MwM A.K — fAP: - w aaae� aIm spiel — - — . �. — - -» yam - -1 — .m imam �..»w ,LEI , — ,ao, �, mama MAR #�.A�..oa. .� asau swam :- ..ew' 7 FUEL INLET EX ED APR 0 0 2012 NOTES: 1. IF IBC CERTIFICATION IS APPLICABLE OR .REQUIRED .SEE SE ISMC ADY FOR I II STALL AT I ON INSTRUCT IONS . 2. DIMENSIONS IN E.3 ARE ENGLISH STANDARD EOrU.I:VALENTS. 3. i - ASTER ISKDENOTES 864 134.01 SKID WI DTH. • • I- list S0 MODEL. .4P7 /4P8 /4010 60. MODEL :4S /4P8l;4010 Rr CONNECTABLE . 8 600V..ALTE.R$ATOR 5.0 I S. 7 LITER GM 2000 . EM I SS IONS A -0 400 .4 -47 -10 VUUE: e tG- 0, IVA IGSIT&.•• t D*1'(*:: ISO I0 000E0 :CHMT 160613):::. ::.:;. 1201A lti v1tv. *NEf.° X6113 t 11111t.EN# :: 141figit. • 3t3eu. {{.s.R. . SWOPwt.i D: �r D &pis. IKON DT oR e*c met* co :liir�tDTl `s�tE:::RE3ENve0.. 2•2 •0$ M1O 30 RECEIVED SEP 24X010 PERMIT CENTER D c 50 MODEL, 4P7/4P3/4010 60 MODEL 4$7108/4010 RECONNECTABLE 8600Y ALTERNATOR 5.0 & 5.7 LITER GM 2009 tMISS1014$ Ai 7-02 .Ai217.110 EX APR 0 9 202 • . • 0111•VPIPOSI :P I .itifIN014 INA HLV Lqv ctia rUiri CODE COMPBANCE bIttri nOICFn _ City ot Tukwila BUILDING DIVISION LLU - UZI V...1 I:131EL :11806113;.- . '1 'OW026120272 :13 4 LT:41L-4 C.-T.4 YAK „ calliffie;,C•:11112.1. Usu B . . k:Or $E Lit. . Tait A*417iTiktiL :iS twit? 0. IRCIMIT:A119.01111T OI t usfo EIGEPT 14_1 • Alt :11.t1IFTS 'Or VIESOWII .011 lirriatelt :1111IMITte -4440 M RLCEIVED SEP 2 4 2010 PERMIT CENTER